Service Manual Sy365(b)h-9 2014-04-16.pdf
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Crawler Hydraulic Excavator Shop Manual SY365(B)H-9
Crawler Hydraulic Excavator
SY365H-9 SY365BH-9
SANY HEAVY MACHINERY LIMITED 318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P.R. of China 201413
Tel: (86) 21 5700 8518 Service hotline: (86) 4006 098 318 E-mail: [email protected] Documentation No.: B06T03ENAN1-SY365(B)H-9
Shop Manual
SY365(B)H-9 Crawler Hydraulic Excavator
SY365(B)H-9 Crawler Hydraulic Excavator Shop Manual
WARNING ● Read and follow the safety precautions and instructions in this manual and on the machine decals. Failure to do can cause serious injury, death or property damage. Keep this manual with the machine for reading and future reference. Shop Manual - April 2014
SY365(B)H-9 Crawler Hydraulic Excavator
Sany Group Sany Heavy Machinery Limited 318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P. R. of China 201413 http://www.sanygroup.com Tel: 0086-21-57008518 Fax: 0086-21-58596210 Service hotline: 0086-21-58592902 Complaint hotline: 0086-21-58590631 E-mail: [email protected]
© 2012 by Sany Group. All right reserved. No part of this publication may be reproduced, used, distributed or disclosed except during normal operation of the machine as described herein. All information included within this publication was accurate at the time of publication. Product improvements ,revisions, etc., may result in differences between your machine and what is presented here. Sany Group assumes no liability. For more information, Contact Sany Group. Shop Manual - April 2014
Table of Contents
SY365(B)H-9 Crawler Hydraulic Excavator
Table of Contents 1 Introduction 1.1 How to Read the Manual ......................................................................................... 1-3 1.1.1 Shop manual organization ............................................................................. 1-3 1.1.2 Revision and distribution ................................................................................ 1-4 1.1.3 Symbols ......................................................................................................... 1-5 1.1.4 Units ............................................................................................................... 1-5 1.2 Technical Terms ....................................................................................................... 1-6 1.2.1 Standard size and tolerance .......................................................................... 1-6 1.2.2 Standard clearance and value ....................................................................... 1-7 1.2.3 Standard interference .................................................................................... 1-7 1.2.4 Repair limit and allowable value .................................................................... 1-8 1.2.5 Clearance limit ............................................................................................... 1-8 1.2.6 Interference limit ............................................................................................ 1-8 1.3 Handling Electrical and Hydraulic Components....................................................... 1-9 1.3.1 Points to remember when handling electric components .............................. 1-9 1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9 1.3.1.2 Main failures occurring in wiring harness ............................................ 1-10 1.3.1.3 Removing, installing, and drying connectors and wiring harnesses ... 1-12 1.3.1.4 Handling the integrated control monitor .............................................. 1-16 1.3.1.5 Electric circuits troubleshooting precautions ....................................... 1-17 1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18 1.3.2.1 Be careful of the operating environment ............................................. 1-18 1.3.2.2 Disassembly and maintenance work in the field ................................. 1-18 1.3.2.3 Sealing openings ................................................................................ 1-18 1.3.2.4 Do not let any dirt or dust get in during refilling operations ................. 1-19 1.3.2.5 Change hydraulic oil when the temperature is high ............................ 1-19 1.3.2.6 Flushing operations............................................................................. 1-19 1.3.2.7 Cleaning operations ............................................................................ 1-20 1.4 Hose Connector ..................................................................................................... 1-20 1.4.1 Type of hose connector................................................................................ 1-21 1.4.2 Hose connector tightening torque table ....................................................... 1-21 1.4.3 Connection of O-rings .................................................................................. 1-22 1.5 Table of Standard Tightening Torques .................................................................. 1-23 Shop Manual - April 2014
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Table of Contents
SY365(B)H-9 Crawler Hydraulic Excavator
1.6 Type of Bolts .......................................................................................................... 1-24 1.7 Tightening Sequence ............................................................................................. 1-24 1.8 Maintenance of Half Flanges ................................................................................. 1-25 1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25 1.8.2 Temperature ................................................................................................. 1-31
2 Shop Safety 2.1 Hazard Alert Information .......................................................................................... 2-3 2.2 General Shop Safety ............................................................................................... 2-5 2.2.1 Rules and shop behavior ............................................................................... 2-6 2.2.2 Housekeeping ................................................................................................ 2-6 2.2.3 Shop Liquids Storage..................................................................................... 2-7 2.2.4 Cleaning the Parts ......................................................................................... 2-7 2.2.5 Cleaning the Machine .................................................................................... 2-8 2.2.6 Appropriate Working Apparel ......................................................................... 2-8 2.2.7 Personal Protective Equipment...................................................................... 2-8 2.2.8 Using the Correct Tools.................................................................................. 2-9 2.2.9 Fire Extinguisher and Emergency Exits ......................................................... 2-9 2.2.10 Electrical Dangers ...................................................................................... 2-10 2.2.11 Hoisting a Load .......................................................................................... 2-10 2.3 Before Repair..........................................................................................................2-11 2.3.1 Safe Work Preparations ................................................................................2-11 2.3.2 Preparing yourself ........................................................................................ 2-12 2.3.3 Lockout/Tagout............................................................................................. 2-13 2.3.4 Two people when engine running ................................................................ 2-15 2.3.5 Safety Partners ............................................................................................ 2-15 2.4 Repair Precautions ................................................................................................ 2-16 2.4.1 Running the Machine ................................................................................... 2-16 2.4.2 Mounting and Dismounting .......................................................................... 2-17 2.4.3 Removing Attachments ................................................................................ 2-18 2.4.4 Jacking Up the Machine............................................................................... 2-18 2.4.5 Adding Fluids to a System ........................................................................... 2-18 2.4.6 Aligning Parts or Components ..................................................................... 2-19 2.4.7 Driving Pins .................................................................................................. 2-19 2.4.8 When compressed air is used...................................................................... 2-19 2.4.9 Welding operation ........................................................................................ 2-20 II
Shop Manual - April 2014
Table of Contents
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.10 Track Recoil Springs .................................................................................. 2-20 2.4.11 High-Pressure Fluid Lines .......................................................................... 2-21 2.4.12 Air-conditioning system maintenance ........................................................ 2-22 2.4.13 High voltage precautions ........................................................................... 2-22 2.4.14 Disconnecting the System Power .............................................................. 2-23 2.4.15 Accumulator ............................................................................................... 2-23 2.4.17 Battery Hazards ......................................................................................... 2-24 2.4.18 Jump-Start Safety ...................................................................................... 2-25 2.4.19 Avoiding fire and explosion ........................................................................ 2-26 2.4.20 Chemical hazard ........................................................................................ 2-27 2.4.21 Material Safety Data Sheets (MSDS) ........................................................ 2-27 2.4.22 Proper disposal of wastes .......................................................................... 2-28 2.5 Other Precautions .................................................................................................. 2-29 2.5.1 Sling work and giving signals ....................................................................... 2-29 2.5.2 Using mobile crane ...................................................................................... 2-31 2.5.3 Using overhead hoist crane ......................................................................... 2-31 2.5.4 Selecting wire ropes..................................................................................... 2-33
3 Specifications 3.1 Specific Dimension .................................................................................................. 1-3 3.1.1 Dimension ...................................................................................................... 1-3 3.1.2 Working ranges .............................................................................................. 1-4 3.2 Technical Specifications........................................................................................... 1-5 3.3 Weight Table ............................................................................................................ 1-7 3.4 Engine oil, Fuel and Coolant.................................................................................... 1-8 3.5 Engine Performance Curves.................................................................................... 1-9
4 Structure and Functions 4.1 Engine and Cooling System ................................................................................... 4-5 4.1.1 Engine-related parts....................................................................................... 4-5 4.1.2 Radiator and intercooler................................................................................. 4-6 4.2 Power Train.............................................................................................................. 4-7 4.2.1 Overview ........................................................................................................ 4-7 4.2.2 Travel reducer AS ......................................................................................... 4-8 4.2.3 Swing reducer mechanism........................................................................... 4-10 4.2.4 Swing bearing .............................................................................................. 4-12 Shop Manual - April 2014
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SY365(B)H-9 Crawler Hydraulic Excavator
4.3 Undercarriage Travel System ............................................................................... 4-14 4.3.1 Track frame and tensioning mechanism ...................................................... 4-14 4.3.2 Idler .............................................................................................................. 4-16 4.3.3 Carrier roller ................................................................................................. 4-18 4.3.4 Track roller ................................................................................................... 4-19 4.3.5 Track ........................................................................................................... 4-20 4.3.6 Tri-grouser track shoe .................................................................................. 4-23 4.4 Hydraulic System, Part 1 ....................................................................................... 4-24 4.4.1 Deployment of hydraulic parts ..................................................................... 4-24 4.4.2 Hydraulic tank and filter ............................................................................... 4-26 4.4.3 Hydraulic pump ............................................................................................ 4-28 4.4.3.1 Outline................................................................................................. 4-29 4.4.3.2 Function .............................................................................................. 4-31 4.4.3.3 Structure ............................................................................................. 4-31 4.4.3.4 Operating principle .............................................................................. 4-32 4.4.3.5 Oil delivery control .............................................................................. 4-33 4.4.4 Pilot pump .................................................................................................... 4-34 4.4.5 Regulator .................................................................................................... 4-35 4.5 Hydraulic system, Part 2 ........................................................................................ 4-48 4.5.1 Main control valve ........................................................................................ 4-48 4.5.1.1 Overview ............................................................................................ 4-48 4.5.1.2 Main valve structure ............................................................................ 4-50 4.5.2 Hydraulic circuit (With bucket confluence function) .............................................. 4-56 4.6 Hydraulic System, Part 3 ....................................................................................... 4-79 4.6.1 Swing motor ................................................................................................. 4-79 4.6.2 Swing holding brake..................................................................................... 4-81 4.6.3 Relief valve section ...................................................................................... 4-82 4.6.4 Anti-jerk valve............................................................................................... 4-84 4.6.4.1 Operation diagram .............................................................................. 4-84 4.6.4.2 Effect illustration.................................................................................. 4-84 4.6.5 Central Swivel Joint ..................................................................................... 4-86 4.6.6 Travel motor ................................................................................................. 4-87 4.6.7 Reducer ....................................................................................................... 4-89 4.6.8 Travel motor (Nabtesco) .............................................................................. 4-91 4.6.9 Operating principle of the basic components ............................................... 4-93 4.6.9.1 Double-balanced valve ....................................................................... 4-93 IV
Shop Manual - April 2014
Table of Contents
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.9.2 Operation of parking brake ................................................................. 4-98 4.6.9.3 Operation of braking valve .................................................................. 4-99 4.6.10 Control system ......................................................................................... 4-108 4.6.11 Manual pilot valve .....................................................................................4-110 4.6.12 Travel pilot valve .......................................................................................4-114 4.6.12.1 Operating principle ...........................................................................4-116 4.6.13 Solenoid valve...........................................................................................4-118 4.6.14 PPC accumulator ......................................................................................4-119 4.6.15 Pilot oil filter.............................................................................................. 4-121 4.6.16 Hydraulic cylinders ................................................................................... 4-122 4.6.16.2 Lubrication at every 100 service hours ........................................... 4-123 4.6.16.1 Lubrication at every 500 service hours ........................................... 4-123 4.7 Work Equipment .................................................................................................. 4-124 4.7.1 Component dimensions ............................................................................. 4-124 4.7.2 Arm dimensions ......................................................................................... 4-126 4.7.2.1 Bucket dimensions ............................................................................ 4-128 4.8 Operator Station and Its Attachments .................................................................. 4-130 4.8.1 Air conditioner lines .................................................................................... 4-130 4.8.1.1 Layout of A/C components ................................................................ 4-132 4.8.1.2 A/C control panel............................................................................... 4-133 4.8.1.3 Diagram of electrical circuit ............................................................... 4-134 4.8.1.4 Operating principle ............................................................................ 4-136 4.8.1.5 Compressor ...................................................................................... 4-137 4.8.1.6 Clutch ................................................................................................ 4-139 4.8.1.7 Condenser ........................................................................................ 4-140 4.8.1.8 Expansion valve ................................................................................ 4-141 4.8.1.9 Evaporator ........................................................................................ 4-141 4.8.1.10 Dehydrator ..................................................................................... 4-142 4.8.1.11 Pressure switch .............................................................................. 4-143 4.8.1.12 Fresh air sensor .............................................................................. 4-144 4.8.2 Refrigerant ................................................................................................. 4-145 4.8.2.1 Compressor oil .................................................................................. 4-163 4.9 Engine Control ..................................................................................................... 4-164 4.9.1 System operation ....................................................................................... 4-165 4.9.1.1 Engine starting .................................................................................. 4-165 4.9.1.2 Engine speed control ........................................................................ 4-165 Shop Manual - April 2014
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SY365(B)H-9 Crawler Hydraulic Excavator
4.9.1.3 Engine shutdown .............................................................................. 4-165 4.9.2 System components .................................................................................. 4-166 4.9.2.1 Fuel control dial................................................................................. 4-166 4.9.2.2 Controller .......................................................................................... 4-168 4.10 Electrical Control System................................................................................... 4-170 4.10.1 Control function ........................................................................................ 4-170 4.10.2 Diagram of machine control system......................................................... 4-171 4.10.3 Engine-pump combination control ........................................................... 4-173 4.10.4 Pump control function .............................................................................. 4-177 4.10.4.1 Constant power control ................................................................... 4-180 4.10.4.2 ESS control ..................................................................................... 4-180 4.10.5 Valve control function ............................................................................... 4-181 4.10.6 Dual travel speed control ......................................................................... 4-183 4.10.7 Engine preheat/overheat alarm ............................................................... 4-185 4.10.8 Auto deceleration/acceleration control ..................................................... 4-187 4.10.9 Engine speed calibration function ............................................................ 4-188 4.10.10 System parts and components .............................................................. 4-190 4.11 Monitoring System ............................................................................................. 4-195 4.11.1 Monitor ..................................................................................................... 4-196 4.11.2 Monitor panel ........................................................................................... 4-197 4.11.2.1 Alert and signal indicators .............................................................. 4-197 4.11.2.2 Operation keys ................................................................................ 4-199 4.11.3 Monitor display and operation .................................................................. 4-201 4.11.3.1 Default page .................................................................................... 4-201 4.11.3.2 Password entry to system information ............................................ 4-202 4.11.3.3 Main menu ...................................................................................... 4-202 4.11.3.4 Engine & throttle signals ................................................................. 4-203 4.11.3.5 Pilot pressure signals ...................................................................... 4-203 4.11.3.6 Main pump & main valve signals..................................................... 4-204 4.11.3.7 Failure codes................................................................................... 4-204 4.11.3.8 Throttle help information ................................................................. 4-205 4.11.3.9 Language selection ......................................................................... 4-205 4.11.3.10 System clock setup ....................................................................... 4-206 4.11.3.11 GPS information ............................................................................ 4-207 4.11.3.12 System setup ................................................................................ 4-208 4.11.3.13 Machine configuration ................................................................... 4-208 VI
Shop Manual - April 2014
Table of Contents
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.14 4.11.3.15 4.11.3.16 4.11.3.17 4.11.3.18 4.11.3.19
Service hour setup ....................................................................... 4-209 Machine configuration setup ......................................................... 4-210 Hydraulic oil temperature ...............................................................4-211 Screen brightness setup ................................................................4-211 System lockout (level 1) ................................................................ 4-212 System lockout (level 2) ................................................................ 4-212
5 Table of Standard Values 5.1 Standard Values for Engine-Related Parts .............................................................. 5-3 5.2 Standard Values for Chassis-Related Parts ............................................................ 5-4
6 Testing and adjusting 6.1 Engine Speed - Test and Adjust............................................................................... 6-3 6.2 Exhaust Gas Color - Test ......................................................................................... 6-5 6.3 Valve Clearance - Adjust.......................................................................................... 6-7 6.3.1 Testing............................................................................................................ 6-8 6.3.2 Adjusting ........................................................................................................ 6-9 6.4 Compression force - Test ....................................................................................... 6-10 6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13 6.5.1 Testing.......................................................................................................... 6-14 6.5.2 Adjusting ...................................................................................................... 6-18 6.6 A/C Compressor Belt Tension - Test and Adjust .................................................... 6-19 6.6.1 Testing ......................................................................................................... 6-19 6.6.2 Adjusting ...................................................................................................... 6-19 6.7 Swing Bearing Clearance - Test ............................................................................ 6-20 6.8 Track Tensioner - Test and Adjust .......................................................................... 6-21 6.8.1 Testing.......................................................................................................... 6-21 6.8.2 Adjusting ...................................................................................................... 6-22 6.9 Oil in Hydraulic Circuits - Test and Adjust .............................................................. 6-23 6.9.1 Testing.......................................................................................................... 6-23 6.9.2 Adjusting ...................................................................................................... 6-25 6.10 Control Oil Circuit Pressure - Test and Adjust...................................................... 6-28 6.10.1 Testing........................................................................................................ 6-28 6.10.2 Adjusting .................................................................................................... 6-28 6.11 Solenoid Valve Output Pressure - Test ................................................................ 6-29 6.12 Pilot Valve Output Pressure - Test ....................................................................... 6-31 Shop Manual - April 2014
VII
Table of Contents
6.13 6.14 6.15 6.16 6.17
SY365(B)H-9 Crawler Hydraulic Excavator
Work Equipment and Swing Pilot Valves - Adjust ................................................ 6-33 Hydraulic Drift of Work Equipment - Test ............................................................. 6-34 Remaining Pressure in Hydraulic Lines - Relieve................................................ 6-36 Oil Leakage Amount - Test................................................................................... 6-37 Air in Each Component - Purge ........................................................................... 6-41
7 Troubleshooting 7.1 Checks before Troubleshooting ............................................................................... 7-5 7.2 Failure Symptoms and Troubleshooting Codes ....................................................... 7-6 7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-9 7.3.1 Connector location layout ............................................................................ 7-13 7.3.2 Diagram of system electrical elements ........................................................ 7-18 7.3.3 Diagram of electrical control system ........................................................... 7-20 7.3.4 SWP connectors .......................................................................................... 7-22 7.3.5 A/AMP connectors ....................................................................................... 7-23 7.3.6 DT connectors.............................................................................................. 7-24 7.4 Troubleshooting with an Event Code ..................................................................... 7-25 7.5 Troubleshooting Electrical System (E-Mode)......................................................... 7-49 7.6 Troubleshooting Hydraulic and Mechanical Systems (H-mode) ............................ 7-81
8 Disassembly and Assembly 8.1 How to Read This Manual ....................................................................................... 8-5 8.1.1 Removing and installing an assembly............................................................ 8-5 8.2 Operating Precautions ............................................................................................. 8-6 8.3 Start Motor AS ........................................................................................................ 8-9 8.3.1 Removal ......................................................................................................... 8-9 8.3.2 Installation ...................................................................................................... 8-9 8.4 Fuel Injection Pump AS ........................................................................................ 8-10 8.4.1 Removal ....................................................................................................... 8-10 8.4.2 Installation .................................................................................................... 8-12 8.5 Engine Front Oil Seal ............................................................................................ 8-13 8.5.1 Removal ....................................................................................................... 8-13 8.5.2 Installation .................................................................................................... 8-13 8.6 Engine Rear Oil Seal ............................................................................................ 8-14 8.6.1 Removal ....................................................................................................... 8-14 8.6.2 Installation .................................................................................................... 8-14 VIII
Shop Manual - April 2014
Table of Contents
SY365(B)H-9 Crawler Hydraulic Excavator
8.7 Cylinder Head AS .................................................................................................. 8-15 8.7.1 Removal ....................................................................................................... 8-15 8.7.2 Installation .................................................................................................... 8-19 8.8 Radiator AS ........................................................................................................... 8-20 8.8.1 Removal ....................................................................................................... 8-20 8.8.2 Installation .................................................................................................... 8-23 8.9 Engine and Hydraulic Pump AS ............................................................................ 8-24 8.9.1 Removal ....................................................................................................... 8-24 8.9.2 Installation .................................................................................................... 8-30 8.10 Final Drive AS ..................................................................................................... 8-31 8.10.1 Removal ..................................................................................................... 8-31 8.10.2 Installation .................................................................................................. 8-32 8.11 Final Drive AS ...................................................................................................... 8-33 8.11.1 Disassembly ............................................................................................... 8-33 8.11.2 Assembly .................................................................................................... 8-36 8.12 Swing Motor and Swing Drive AS ....................................................................... 8-42 8.12.1 Removal ..................................................................................................... 8-42 8.12.2 Installation .................................................................................................. 8-43 8.13 Swing Motor and Swing Drive AS ....................................................................... 8-44 8.13.1 Disassembly............................................................................................... 8-44 8.13.2 Assembly.................................................................................................... 8-49 8.14 Idler AS ............................................................................................................... 8-54 8.14.1 Disassembly............................................................................................... 8-54 8.14.2 Assembly.................................................................................................... 8-55 8.15 Sprocket .............................................................................................................. 8-58 8.15.1 Removal ..................................................................................................... 8-58 8.15.2 Installation .................................................................................................. 8-58 8.16 Track AS ............................................................................................................. 8-59 8.16.1 Removal ..................................................................................................... 8-59 8.16.2 Installation .................................................................................................. 8-60 8.17 Swing Bearing AS ............................................................................................... 8-62 8.17.1 Removal ..................................................................................................... 8-62 8.17.2 Installation .................................................................................................. 8-63 8.18 Swing frame AS .................................................................................................. 8-64 8.18.1 Removal ..................................................................................................... 8-64 8.18.2 Installation .................................................................................................. 8-66 Shop Manual - April 2014
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SY365(B)H-9 Crawler Hydraulic Excavator
8.19 Swivel Joint AS .................................................................................................... 8-67 8.19.1 Removal ..................................................................................................... 8-67 8.19.2 Installation .................................................................................................. 8-69 8.20 Central Swivel Joint AS ....................................................................................... 8-70 8.20.1 Disassembly............................................................................................... 8-70 8.20.2 Assembly.................................................................................................... 8-70 8.21 Hydraulic Tank AS ............................................................................................... 8-71 8.21.1 Removal ..................................................................................................... 8-71 8.21.2 Installation .................................................................................................. 8-73 8.22 Control Valve AS .................................................................................................. 8-74 8.22.1 Removal ..................................................................................................... 8-74 8.22.2 Installation .................................................................................................. 8-79 8.23 Hydraulic Pump AS ............................................................................................. 8-80 8.23.1 Removal ..................................................................................................... 8-80 8.23.2 Installation .................................................................................................. 8-83 8.24 Middle Oil Seal (Hydraulic Pump Input Shaft) ..................................................... 8-84 8.24.1 Removal ..................................................................................................... 8-84 8.24.2 Installation .................................................................................................. 8-84 8.25 Pilot Valve AS (Work Equipment) ....................................................................... 8-85 8.26 Travel Pilot Valve AS ........................................................................................... 8-86 8.27 Hydraulic Cylinder AS ......................................................................................... 8-87 8.27.1 Disassembly............................................................................................... 8-88 8.27.2 Assembly.................................................................................................... 8-92 8.28 Work Equipment AS ............................................................................................ 8-97 8.28.1 Removal ..................................................................................................... 8-97 8.28.2 Installation .................................................................................................. 8-99 8.29 Air Conditioner AS ............................................................................................. 8-100 8.29.1 Removal ................................................................................................... 8-100 8.29.2 Installation ................................................................................................ 8-103 8.30 Counterweight AS ............................................................................................. 8-104 8.30.1 Removal ................................................................................................... 8-104 8.30.2 Installation ................................................................................................ 8-105 8.31 Cab AS .............................................................................................................. 8-106 8.31.1 Removal ................................................................................................... 8-106 8.31.2 Installation ................................................................................................ 8-109 8.32 Cab Window Glass ............................................................................................8-110 X
Shop Manual - April 2014
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SY365(B)H-9 Crawler Hydraulic Excavator
8.32.1 Removal ....................................................................................................8-111 8.32.2 Installation .................................................................................................8-114 8.33 Front Window AS ............................................................................................... 8-126 8.33.1 Disassembly............................................................................................. 8-126 8.33.2 Assembly.................................................................................................. 8-129 8.34 Monitor - Remove and Install ............................................................................. 8-135 8.34.1 Removal ................................................................................................... 8-135 8.34.2 Installation ................................................................................................ 8-135 8.35 Controller AS ..................................................................................................... 8-136 8.35.1 Removal ................................................................................................... 8-136 8.35.2 Installation ................................................................................................ 8-136 8.36 Radio ................................................................................................................. 8-137 8.36.1 Structure .................................................................................................. 8-137 8.36.2 Removal and installation .......................................................................... 8-139 8.36.3 Connector model and wiring .................................................................... 8-140 8.37 Battery ............................................................................................................... 8-141 8.37.1 Structure .................................................................................................. 8-141 8.37.2 Removal and installation .......................................................................... 8-142 8.37.3 Replacement ............................................................................................ 8-143 8.38 Start Switch........................................................................................................ 8-144 8.38.1 Structure ................................................................................................. 8-144 8.38.2 Removal ................................................................................................... 8-145 8.38.3 Working principle ..................................................................................... 8-146 8.38.4 Wiring ....................................................................................................... 8-146 8.39 Fuse Box............................................................................................................ 8-147 8.40 Wiper ................................................................................................................. 8-148 8.40.1 Structure .................................................................................................. 8-148 8.40.2 Working principle ..................................................................................... 8-149 8.40.3 Removal ................................................................................................... 8-150 8.40.4 Installation ................................................................................................ 8-150 8.40.5 Angle adjustment of wiper arm................................................................. 8-151 8.41 Relays ................................................................................................................ 8-152 8.41.1 Engine relays ........................................................................................... 8-152 8.41.2 Other relays ............................................................................................. 8-153 8.41.3 Removal and installation .......................................................................... 8-154 8.41.4 Relay connector and wiring...................................................................... 8-154 Shop Manual - April 2014
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SY365(B)H-9 Crawler Hydraulic Excavator
8.42 Sensors.............................................................................................................. 8-155 8.43 Connector Terminals ......................................................................................... 8-157 8.43.1 Insertion ................................................................................................... 8-157 8.43.2 Removal ................................................................................................... 8-158
9 System Schematics 9.1 9.2 9.3 9.4 9.5 9.6
XII
Diagram of Hydraulic Lines...................................................................................... 9-3 Electrical diagram of chassis ................................................................................... 9-4 Electrical diagram of control switches...................................................................... 9-5 Electrical diagram of operator station ...................................................................... 9-6 Electrical diagram of air conditioner......................................................................... 9-7 Electrical diagram of monitor ................................................................................... 9-8
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Introduction 1 Introduction
1.1 How to Read the Manual ......................................................................................... 1-3 1.1.1 Shop manual organization ............................................................................. 1-3 1.1.2 Revision and distribution ................................................................................ 1-4 1.1.3 Symbols ......................................................................................................... 1-5 1.1.4 Units ............................................................................................................... 1-5 1.2 Technical Terms ....................................................................................................... 1-6 1.2.1 Standard size and tolerance .......................................................................... 1-6 1.2.2 Standard clearance and value ....................................................................... 1-7 1.2.3 Standard interference .................................................................................... 1-7 1.2.4 Repair limit and allowable value .................................................................... 1-8 1.2.5 Clearance limit ............................................................................................... 1-8 1.2.6 Interference limit ............................................................................................ 1-8 1.3 Handling Electrical and Hydraulic Components....................................................... 1-9 1.3.1 Points to remember when handling electric components .............................. 1-9 1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9 1.3.1.2 Main failures occurring in wiring harness ............................................ 1-10 1.3.1.3 Removing, installing, and drying connectors and wiring harnesses ... 1-12 1.3.1.4 Handling the integrated control monitor .............................................. 1-16 1.3.1.5 Electric circuits troubleshooting precautions ....................................... 1-17 1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18 1.3.2.1 Be careful of the operating environment ............................................. 1-18 1.3.2.2 Disassembly and maintenance work in the field ................................. 1-18 1.3.2.3 Sealing openings ................................................................................ 1-18 1.3.2.4 Do not let any dirt or dust get in during refilling operations ................. 1-19 1.3.2.5 Change hydraulic oil when the temperature is high ............................ 1-19 司
公
销 营
Shop Manual - April 2014
1-1
Introduction
1.4
1.3.2.6 Flushing operations............................................................................. 1-19 1.3.2.7 Cleaning operations ............................................................................ 1-20 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 Table of Standard Tightening Torques .................................................................. 1-23 Type of Bolts .......................................................................................................... 1-24 Tightening Sequence ............................................................................................. 1-24 Maintenance of Half Flanges ................................................................................. 1-25 1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25 1.8.2 Temperature ................................................................................................. 1-31
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1.5 1.6 1.7 1.8
SY365(B)H-9 Crawler Hydraulic Excavator
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1 INTRODUCTION 1.1 How to Read the Manual ● Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult Sany distributors. ● Materials and specifications are subject to change without notice.
1.1.1 Shop manual organization
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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. Introduction
This section provides an overview of what is covered in the rest of this manual and how to use this manual,.
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Shop Safety
This section covers basic shop safety information relating to this equipment. It also describes what the hazard alerts mean that are used throughout the manual. Specifications
Technical specification of work equipment and optional parts are given in this section. Structure and functions
This section explains the structure and function of each component. It helps the reader to get a better understanding of the machine structure, and also serves as a reference for troubleshooting.
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SY365(B)H-9 Crawler Hydraulic Excavator
Standard Values This section explains the standard values for a new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. Testing and adjusting
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This section details the inspection before and after repair work as well as the adjustment during inspection and repair work. Troubleshooting table that involves “Fault”and “Cause”are also included in this section. Troubleshooting
This section explains the way to detect faulty parts and the method to repair them. This section is divided into the following parts: Electrical system, Engine, Hydraulic and mechanical system and Monitoring system.
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Disassembly and assembly
This section explains the procedures as well as precautions for removing, installing, disassembling and assembling of each component. Engine
This section provides information the cooling system, lubricating system, electrical system and alternator in addition to disassembly and reassembly of the engine. System Schematics
This section provides hydraulic circuit diagrams and electrical circuit diagrams.
1.1.2 Revision and distribution Any complements, revisions, or other change of notices will be sent to Sany distributors. Get the most up-to-date information before you start any work.
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1.1.3 Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Remarks
Safety
Special safety precautions are necessary when performing work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for tightening torque during assembly.
Coat
Places to be coated with adhesives, etc. during assembly.
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★
Item
Oil, Coolant
Places where oil, etc. must be added, and capacity. 司
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Drain
Places where oil, etc. must be drained, and quantity to be drained.
1.1.4 Units
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 { }.
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1.2 Technical Terms The maintenance standard values necessary for judgment of products and parts are described by the following terms.
1.2.1 Standard size and tolerance ● To be accurate, the finishing size of parts is a little different from one to another.
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● To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. ● The above size set temporarily is called the "standard size" and the range of difference from the standard size is called the "tolerance".
● The tolerance with the symbols of + or – is indicated on the right side of the standard size.
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Example
Standard size 120
Tolerance –0.022 –0.126
Std.size F 60
★ The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)
Tolerance of hole (upper):+0.046
Std.clearance (max.):0.122 Std.clearance (min.):0.030 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. ● Indication of size of rotating shaft and hole and relationship drawing of them.
ZX215-1000003
Fig. 1-1
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SY365(B)H-9 Crawler Hydraulic Excavator
Example Standard size φ60
Tolerance Shaft -0.030
Hole +0.046
-0.076
0
1.2.2 Standard clearance and value
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● The clearance made when new parts are assembled is called the "standard clearance", which is indicated by the range from the minimum clearance to the maximum clearance.
● When some parts are repaired, the clearance is generally adjusted to the standard clearance.
● A value of performance and function of new products or equivalent is called the "standard value", which is indicated by a range or a target value.
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● When some parts are repaired, the value of performance/function is set to the standard value.
1.2.3 Standard interference
● 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 difference (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.
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1.2.4 Repair limit and allowable value ● The size of a part changes due to wear and deformation while it is used. The limit of changed size is called the "repair limit". ● If a part is worn to the repair limit must be replaced or repaired.
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● The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the "allowable value". ● If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
1.2.5 Clearance limit
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● Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the "clearance limit". ● If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
1.2.6 Interference limit
● The allowable maximum interference between 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 exceeds the interference limit, they must be replaced or repaired.
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1.3 Handling Electrical and Hydraulic Components
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To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be carried out. This section deals particularly with correct repair 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 equipment" (particularly gear oil and hydraulic oil).
1.3.1 Points to remember when handling electric components 1.3.1.1 Handling wiring harnesses and connectors
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Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection 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.
ZX215-1000004
Fig. 1-2
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Introduction
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1.3.1.2 Main failures occurring in wiring harness 1. Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely 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.
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Improper insertion
ZX215-1000005
Fig. 1-3
2. Defective crimping or soldering of connectors
The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
Crimped portion
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ZX215-1000006
Fig. 1-4
3. Disconnections in wiring
If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
ZX215-1000007
Fig. 1-5
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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 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-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
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ZX215-1000008
Fig. 1-6
5. Oil or dirt stuck to connector
If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so 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 compressed air and spray it with a contact restorer.
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★ When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins.
ZX215-1000009
Fig. 1-7
★ 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.
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1.3.1.3 Removing, installing, and drying connectors and wiring harnesses 1. Disconnecting connectors A. Hold the connectors when disconnecting. Press lightly when removing
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 stopper, press down the stopper with your thumb and pull the connectors apart.
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Lock stopper
ZX215-1000010
Fig. 1-8
★ Never pull with one hand. B. When removing from clips
● Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
Both stoppers
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ZX215-1000011
Fig. 1-9
● When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. ★ If the connector is twisted up and down or to the left or right, the housing may break.
ZX215-1000012
Fig. 1-10
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C. Action to take after removing connectors 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 cover the connector.
ZX215-1000013
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Fig. 1-11
2. Connecting connectors
A. Check the connector visually
Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins.
Clicks into position
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Check that there is no damage or breakage to the outside of the connector.
ZX215-1000022
Fig. 1-12
★ 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 wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. ★ If there is any damage or breakage, replace the connector.
B. Fix the connector securely. Align the position of the connector cor-
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Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
rectly, and then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. C. Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
ZX215-1000014
Fig. 1-13
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★ If the connector cannot be corrected easily, remove the clamp and adjust the position. ● If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps. 3. Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty wire connectors have 2 latches respectively, push them in until they click 2 times. ● Male connector: 1
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ZX215-1000015
Fig. 1-14
● Female connector: 2
● Normal locking state (Horizontal): a, b, d
2
a
1
c
● Incomplete locking state (Diagonal): c
b
d ZX215-1000016
Fig. 1-15
1-14
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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. A. Disconnect the connector and wipe off the water with a dry cloth.
ZX215-1000009
★ If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
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Fig. 1-16
B. Dry the connector with a dryer.
If water gets inside the connector, use a dryer to dry the connector.
★ Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
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ZX215-1000017
Fig. 1-17
C. Carry out a continuity test on the connector.
After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. ★ After completely drying the connector, blow it with contact restorer and reassemble.
T adapter
ZX215-1000018
Fig. 1-18
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1.3.1.4 Handling the integrated control monitor 1. The integrated control monitor contains a microcomputer, an electronic control circuits, an LCD monitor and GPS positioning circuit. They control all of the electronic circuits on the machine, so be extremely careful when handling the integrated control monitor. 2. Do not place objects on the integrated control monitor.
ZX135-1000001
3. Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand.
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Fig. 1-19
4. Do not leave it where it may be exposed to rain.
Tool Box
5. Do not place the integrated control monitor on oil, water, or soil, or in any hot place, even for a short time. 6. Precautions for arc welding
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When welding on the controller, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
ZX215-1000020
Fig. 1-20
ZX215-1000021
Fig. 1-21
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1.3.1.5 Electric circuits troubleshooting precautions 1. Always turn the power OFF before disconnecting 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.
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3. Always connect any disconnected connectors before going on to the next step. ★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester.
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★ If there is any change, there is probably defective contact in that circuit.
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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.
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1.3.2.1 Be careful of the operating environment Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.
1.3.2.2 Disassembly and maintenance work in the field
If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dust-proof workshop, and the performance should be checked with special test equipment.
ZX215-1000023
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Fig. 1-22
1.3.2.3 Sealing openings
After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
ZX215-1000024
Fig. 1-23 1-18
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1.3.2.4 Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
ZX215-1000025
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Fig. 1-24
1.3.2.5 Change hydraulic oil when the temperature is high
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
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1.3.2.6 Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing 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.
Flushing oil
ZX215-1000026
Fig. 1-25
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1.3.2.7 Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running 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 it is an extremely effective device.
ZX215-1000027
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Fig. 1-26
1.4 Hose Connector
Hose connector is used to connect hoses with a small diameter. The metal sealing surface (4) of the joint (1) must be in close contact with the metal sealing surface (5) of the hose (2) to seal pressurized oil.
NOTICE
1
3
5
2
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● Do not over-tighten the nut (3). Excessive force applied on the metal sealing surface (4) and (5) may cause the joint (1) to break. Be sure to tighten nut (3) according to technical specifications.
Connector
ZX215-1000028
Fig. 1-27
● Scratches or other damages on sealing surface (4) and (5) may cause leaks at the joint. Be extremely careful not to damage the sealing surfaces during connecting and disconnecting work.
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1.4.1 Type of hose connector 24° 24°
Male
Female
ZX215-1000029
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Fig. 1-28
1.4.2 Hose connector tightening torque table
Type
Wrench size mm
Wrench size mm
Tightening torque
Connecting nut
Hose joint
N·m(kgf·m,Ibf·ft)
19
19
59(6,44)
22
22
98(10,72)
27
118(12,87)
36
36
235(24,173)
41
41
295(30,218)
50
50
490(50,361)
60
60
670(68,494)
70
70
980(100,723)
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)
27
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24° Male
24° Female
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.
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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 oil.
7
6
9
NOTICE ● Replace o-rings (6) with new ones when re-connecting hoses.
8
● Before tightening nut (9), make sure the o-ring (6) has been placed into the oring seat (8).Displacement of the o-ring may have it damaged and cause leaks.
10
Hose connector
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ZX215-1000030
Fig. 1-29
● Be careful not to damage the o-ring seat (8) or the sealing surface (10). Damaged o-ring (6) may cause oil leakage.
● If oil leakage due to loosened nut (9) is detected, do not try to stop the leakage by tightening nut (9). Instead, replace o-ring (6) with a new one and make sure it is well positioned, and tighten nut (9).
1-22
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Wrench size mm
Wrench size mm
Tightening torque
Connecting nut
Hose joint
N·m (kgf·m,Ibf·ft)
19
17
44(4.5,32)
22
19
59(6,44)
27
22
118(12,87)
36
30, 32
235(24,173)
41
36
295(30,218)
50
46
490(50,361)
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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 diameter
Bolt grade
Wrench Hex wrench size size
M6
10.9
10
M8
10.9
M10
Hexagonal bolt
Hexagonal socket head bolt
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
4
13.2
1.37
9.74
13.2
1.37
9.74
13
6
31
3.16
22.87
31
3.16
22.87
10.9
17
8
66
6.73
48.7
66
6.73
48.7
M12
10.9
19
10
113
11.53
83.39
113
11.53
83.39
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
10.9
27
14
382
38.98
281.9
382
38.98
281.9
M20
10.9
30
17
549
56.02
405.16
549
56.02
405.16
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
In Ma t rk er n et a in ti o g n De al pt .
N·m
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M12
12.9
19
8
137
13.98
101.1
137
13.98
101.1
M16
12.9
24
14
339
34.6
250.18
339
34.6
250.18
M20
12.9
30
17
664
67.75
490
664
67.75
490
NOTICE
The following items apply to fine thread and coarse thread.
● Apply grease (zinc white B dissolved in spindle oil) onto the nuts and bolts to reduce the friction coefficient. Thrust bolts do not require greasing. ● Torque tolerance is ±10%.
● Always use bolts of correct length. The tip of bolts with excessive length may contact the bottom of the bolt hole, resulting in under-tightening. Bolts with inadequate length may result in insufficient fastening. ● The torque values listed in the table are intended for general application. If different torque values are specified for a special purpose, the torque values in this table are not applicable any more. ● Make sure the threads are free of dirt or rusts before installation of nuts and bolts.
Shop Manual - April 2014
1-23
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.6 Type of Bolts Tighten nuts and bolts properly to specified torque values. The type and grade of bolts are illustrated on the right.
Hex bolt
8.8
Use correct bolts and tighten them properly when assembling machines or components.
Socket head hex bolt
12.9
10.9
ZX215-1000031
In Ma t rk er n et a in ti o g n De al pt .
Fig. 1-30
1.7 Tightening Sequence
When two or more bolts are being tightened, follow the tightening sequence shown on the right to ensure even tightening.
Cross tightening
Diagonal tightening 1
1
3
6
3
4
5
4
CAUTION
2
● Always use suitable tools for specific work. Use of improper tools and methods may cause a hazardous situation.
● Use tools of correct sizes when loosening or tightening the nuts or bolts. Otherwise, the tools may slide and cause personal injury.
2
Central and diagonal tightening
司
公
销 营
12
9
4
1
6
7
14
13
8
5
2
3
10
11
ZX215-1000032
Fig. 1-31
ZX215-1000033
Fig. 1-32
1-24
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.8 Maintenance of Half Flanges 1. Clean the sealing surface of the flange and check it carefully. Scratches and coarseness 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 the O-rings are not damaged. Do not file the surface of the O-ring. Apply grease onto the O-ring to locate it.
ZX215-1000034
In Ma t rk er n et a in ti o g n De al pt .
Fig. 1-33
3. Tighten the half flanges carefully. Locate the opening at the center so that it is perpendicular to the oil opening. Tighten the bolt manually to maintain the location of the components.
Improper
司
公
销 营
ZX215-1000035
Fig. 1-34
1.8.1 Table of tightening torques for half flange bolts
★ Unless specified otherwise, tighten the half flange bolts to the torques below. Thread diameter of bolt
Width across flats
Tightening torque
mm 10
mm 14
Nm 59~74
kgm 6.0~7.5
12
17
98~123
10.0~12.5
16
22
235~285
23.5~29.5
Shop Manual - April 2014
1-25
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
Conversion Table Method of using conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches Convert 55 mm into inches Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A).
In Ma t rk er n et a in ti o g n De al pt .
Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. Convert 550 mm into inches
The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. Carry out the same procedure as above to convert 55 mm to 2.165 inches. 司
公
销 营
The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
1-26
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
Millimeters to Inches 1mm=0.03937in
(B) 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
50
1.969
2.008
2.047
2.087
2.126
(C) 2.165
2.205
2.244
2.283
2.323
In Ma t rk er n et a in ti o g n De al pt .
(A)
0
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
Millimeters to Inches
司
公
销 营
1mm=0.03937in
0
1
2
3
4
5
6
7
8
9
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.535
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
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
0 10 20 30 40
50 60
Shop Manual - April 2014
1-27
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
Kilogram to Pound 1kg=2.2046 lb 1
2
3
4
5
6
7
8
9
0
0
2.20
4.41
6.61
90.39
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
112.43
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
134.48
55.12
57.32
59.52
61.73
63.93
30
66.14
68.34
70.55
72.75
156.53
77.16
79.37
81.57
83.77
85.98
40
88.18
90.39
92.59
94.80
178.57
99.21
101.41
103.62
105.82
108.03
50
110.23
112.43
114.64
116.84
200.62
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
222.66
143.30
145.50
147.71
149.91
152.12
154.32
156.53
158.73
160.94
244.71
165.35
167.55
169.75
171.96
174.16
176.37
178.57
180.78
182.98
266.76
187.39
189.60
191.80
194.00
196.21
198.41
200.62
202.82
205.03
288.80
209.44
211.64
213.85
216.05
218.26
60
In Ma t rk er n et a in ti o g n De al pt .
0
15.852
16.116
16.380
16.645
16.909
17.173
17.437
17.701
17.966
18.230
70
18.494
18.758
19.022
19.287
19.551
19.815
20.079
20.343
20.608
20.872
80
21.136
21.400
21.664
21.929
22.193
22.457
22.721
22.985
23.250
23.514
90
23.778
24.042
24.306
24.571
24.835
25.099
25.363
25.627
25.892
26.156
70 80 90
Liters to U.S. Gallons
司
公
销 营
1 L=0.2642 U.S.Gal
0 10 20 30 40
50
1-28
0
1
2
3
4
5
6
7
8
9
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.114
2.378
2.642
2.906
3.170
3.435
3.699
3.963
4.227
4.491
4.756
5.020
5.284
5.548
5.812
6.077
6.341
6.605
6.869
7.133
7.398
7.662
7.926
8.190
8.454
8.719
8.983
9.247
9.511
9.775
10.040
10.304
10.568
10.832
11.096
11.361
11.625
11.889
12.153
12.417
12.682
12.946
13.210
13.474
13.738
14.003
14.267
14.531
14.795
15.059
15.324
15.588
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
Liters to U.K. Gallons 1 L=0.21997 U.K.Gal 1
2
3
4
5
6
7
8
9
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.739
3.959
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.699
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.779
50
10.999
11.218
11.438
11.658
11.878
12.098
12.318
12.538
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
17.598
17.818
18.038
18.258
18.477
18.697
18.917
19.137
19.357
19.577
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
70 80 90
In Ma t rk er n et a in ti o g n De al pt .
0 0
kgm to ft.lb
1 kgm=7.233 ft.lb
0
1
2
3
4
5
6
7
8
9
司
公
销 营
0 72.3 144.7 217.0 289.3
7.2 79.6 151.9 224.2 296.6
14.5 86.8 159.1 231.5 303.8
21.7 94.0 166.4 238.7 311.0
28.9 101.3 173.6 245.9 318.3
36.2 108.5 180.8 253.2 325.5
43.4 115.7 188.1 260.4 332.7
50.6 123.0 195.3 267.6 340.0
57.9 130.2 202.5 274.9 347.2
65.1 137.4 209.8 282.1 354.4
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.4 520.8 593.1 665.4
383.3 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.1 542.5 614.8 687.1
405.0 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
419.5 491.8 564.2 636.5 708.8
426.7 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 795.6 868.0 940.3 1012.6
730.5 802.9 875.2 947.5 1019.9
737.8 810.1 882.4 954.8 1027.1
745.0 817.3 889.7 962.0 1034.3
752.2 824.6 896.9 969.2 1041.6
759.5 831.8 904.1 976.5 1048.8
766.7 839.0 911.4 983.7 1056.0
773.9 846.3 918.6 990.9 1063.3
781.2 853.5 925.8 998.2 1070.5
788.4 860.7 933.1 1005.4 1077.7
150 160 170 180 190
1085.0 1157.3 1229.6 1301.9 1374.3
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.2 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
0 10 20 30 40 50 60 70 80 90
Shop Manual - April 2014
1-29
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
kg/cm2 to lb/in2
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.3
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.0
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
In Ma t rk er n et a in ti o g n De al pt .
1 kg/cm2=14.2233 lb/in2
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
996
1010
1024
1038
1053
1067
1081
1095
1109
1124
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
2133
2148
2162
2176
2190
2205
2219
2233
2247
2262
2276
2290
2304
2318
2333
2347
2361
2375
2390
2404
2418
2432
2446
2461
2475
2489
2503
2518
2532
2546
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
2702
2717
2731
2745
2759
2774
2788
2802
2816
2830
2845
2859
2873
2887
2902
2916
2930
2944
2958
2973
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3342
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
70 80 90 100 110 120 130 140 150 160 170 180 190 200 210
1-30
司
公
销 营
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.8.2 Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
℃
In Ma t rk er n et a in ti o g n De al pt .
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
-40.0 -37.2 -34.4 -31.7 -28.9 -28.3 -27.8 -27.2 -26.7 -26.1 -25.6 -25.0 -24.4 -23.9 -23.3 -22.8 -22.2 -21.7 -21.1 -20.6 -20.0 -19.4 -18.9 -18.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2
-40 -35 -30 -25 -20 -2 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10
℉
℃
-40.0 -31.0 -22.0 -13.0 -4.0 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0
-11.7 -11.1 -10.6 -10.0 -9.4 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0.0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
℉
℃
51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0
7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7
司
公
销 营
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
Shop Manual - April 2014
℉
℃
114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0
27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.8 65.6 68.3 71.1 73.9 76.7 79.4
℉ 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175
177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
1-31
Introduction
BL In Ma t ArkNer n etK a in ti Pg Aona DG l ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
1-32
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Shop Safety 2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3 2.2 General Shop Safety ............................................................................................... 2-5 2.2.1 Rules and shop behavior ............................................................................... 2-6 2.2.2 Housekeeping ................................................................................................ 2-6 2.2.3 Shop Liquids Storage..................................................................................... 2-7 2.2.4 Cleaning the Parts ......................................................................................... 2-7 2.2.5 Cleaning the Machine .................................................................................... 2-8 2.2.6 Appropriate Working Apparel ......................................................................... 2-8 2.2.7 Personal Protective Equipment...................................................................... 2-8 2.2.8 Using the Correct Tools.................................................................................. 2-9 2.2.9 Fire Extinguisher and Emergency Exits ......................................................... 2-9 2.2.10 Electrical Dangers ...................................................................................... 2-10 2.2.11 Hoisting a Load .......................................................................................... 2-10 2.3 Before Repair..........................................................................................................2-11 2.3.1 Safe Work Preparations ................................................................................2-11 2.3.2 Preparing yourself ........................................................................................ 2-12 2.3.3 Lockout/Tagout............................................................................................. 2-13 2.3.4 Two people when engine running ................................................................ 2-15 2.3.5 Safety Partners ............................................................................................ 2-15 2.4 Repair Precautions ................................................................................................ 2-16 2.4.1 Running the Machine ................................................................................... 2-16 2.4.2 Mounting and Dismounting .......................................................................... 2-17 2.4.3 Removing Attachments ................................................................................ 2-18 2.4.4 Jacking Up the Machine............................................................................... 2-18 2.4.5 Adding Fluids to a System ........................................................................... 2-18 司
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SY365(B)H-9 Crawler Hydraulic Excavator
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2.4.6 Aligning Parts or Components ..................................................................... 2-19 2.4.7 Driving Pins .................................................................................................. 2-19 2.4.8 When compressed air is used...................................................................... 2-19 2.4.9 Welding operation ........................................................................................ 2-20 2.4.10 Track Recoil Springs .................................................................................. 2-20 2.4.11 High-Pressure Fluid Lines .......................................................................... 2-21 2.4.12 Air-conditioning system maintenance ........................................................ 2-22 2.4.13 High voltage precautions ........................................................................... 2-22 2.4.14 Disconnecting the System Power .............................................................. 2-23 2.4.15 Accumulator ............................................................................................... 2-23 2.4.17 Battery Hazards ......................................................................................... 2-24 2.4.18 Jump-Start Safety ...................................................................................... 2-25 2.4.19 Avoiding fire and explosion ........................................................................ 2-26 2.4.20 Chemical hazard ........................................................................................ 2-27 2.4.21 Material Safety Data Sheets (MSDS) ........................................................ 2-27 2.4.22 Proper disposal of wastes .......................................................................... 2-28 2.5 Other Precautions .................................................................................................. 2-29 2.5.1 Sling work and giving signals ....................................................................... 2-29 2.5.2 Using mobile crane ...................................................................................... 2-31 2.5.3 Using overhead hoist crane ......................................................................... 2-31 2.5.4 Selecting wire ropes..................................................................................... 2-33 司
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2 SHOP SAFETY 2.1 Hazard Alert Information Most accidents are usually caused by the failure to follow fundamental repair procedures and safety rules for the system under repair. To avoid accidents it is important to read and understand all information outlined in this manual before performing repairs on the machine system.
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The following (ANSI/ISO) signal words are used to inform you that there is a potentially hazardous situation that may lead to damage, personal injury or even death. In this manual, on the machine, part or component decals and different signal words are used to express the potential level of a hazard.
DANGER
WARNING
● Indicates an imminent hazard which WILL result in serious injury or death if message is ignored.
CAUTION
● Indicates a potentially hazardous situation which COULD result in serious injury or death if message is ignored.
NOTICE
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● Indicates a potentially hazardous situation which COULD RESULT IN MINOR OR MAJOR INJURY if message is ignored.
● Indicates THE MACHINE MAY BE DAMAGED if improperly operated or maintained.
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.
Besides the above signals words, the following words are also used to remind you of rules to be followed or to provide you with very useful information. Note: It is followed by measures that must be taken to prevent reduction of machine service life. Remark: It is followed by very useful information.
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WARNING ● Improper repair procedures on this machine can be hazardous and could result in serious injury or even death. ● All personnel involved with the repair of this machine must read this manual thoroughly before performing any procedures on this equipment. ● Some actions involved in the operation or repair of this machine could cause a serious accident if they are not performed in the manner described in this manual.
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● All precautions outlined in this manual apply only to intended repair procedures of the machine or system. If you perform any repairs not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual. ● SANY delivers machines that comply with all applicable regulations and standards of the country to which the machines have been shipped. If this machine has been purchased in another 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 applicable standards and regulations of your country, contact your SANY representative before performing repairs on this machine. 司
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Shop Safety
SY365(B)H-9 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.
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Always keep in mind, shop safety is NOT something to be studied at the start of a project and then forgotten; most accidents are caused by carelessness, being in a hurry or by simply disregarding safety rules. Remember this, if you are DILIGENT and follow instructions outlined in this shop manual with care, repair operations can be safe and enjoyable. Safe work practices, should become a force of habit.
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WARNING
● Mistakes in operation are extremely hazardous. Read the Safety, Operation & Maintenance Manual that came with the machine carefully before operating the machine. Failure to follow this alert could result in serious injury or death.
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SY365(B)H-9 Crawler Hydraulic Excavator
2.2.1 Rules and shop behavior ● Study all shop rules relating to the procedure carefully and constantly apply them. When in doubt about any task, get help! DO NOT take chances.
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● Know your job. It is foolish, and often disastrous, to make repairs to a machine without first receiving proper instructions. Always use the shop manual when performing any repair tasks. Get additional help if you are NOT sure what must be done or how a task should be performed. ● The shop is a place to work, not play. It is NOT a place for “horseplay”. A “joker” in a repair shop is a “walking hazard” to everyone. Daydreaming or socializing on the job also increases your chances of injury. ● If you must smoke, smoke only in the area provided for smoking. Never smoke while on the shop floor or work area.
Fig. 2-2
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2.2.2 Housekeeping
● Oils, grease, fuel, antifreeze or any fluid spills should be mopped up immediately. These items pose a serious slip hazard. Regardless of who was responsible for the spill, it is your job as a shop employee to secure and clean up the spill area. ● Keep the shop clean. Scrap or old parts should be disposed of properly. Never allow 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.
WX235R-1200001
Fig. 2-1
● Always keep in mind, proper house cleaning is vital for a safe and pleasant work environment.
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2.2.3 Shop Liquids Storage ● Liquids, cleaning solvents or machine fluids 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.
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● Never leave open containers of liquids sitting around. These could spill or catch fire. Always read the container label for information on storage and handling of the liquids.
WX235R-1200002
Fig. 2-3
● Never store liquids in containers that are not properly labeled for that liquid. Confusion could result in equipment damage, fire or an unexpected explosion. ● Never smoke or bring open flames around liquids, doing so could result in an unexpected fire or explosion.
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● Never handle liquids without using personal protective equipment. Treat all liquids with caution.
2.2.4 Cleaning the Parts
Never use gasoline, diesel fuel or similar flammable liquids to clean parts. Always use approved non-flammable solvents to clean parts. Failure to do so could result in explosion or fire.
WX235R-1200003
Fig. 2-4
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2.2.5 Cleaning the Machine ● Always use high-pressure hot water and mild, nonflammable grease-cutting soaps or cleaning agents to clean the machine parts. Never use flammable or caustic cleaning agents. ● Never use high-pressure steam cleaners to clean the machine. Steam cleaners will damage the paint, hoses or electrical system. ● Never pressure-wash or flood the inside of an operator cab. This will damage sensitive electrical components.
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WX235R-1200007
Fig. 2-5
2.2.6 Appropriate Working Apparel
Improper or loose clothing, casual dress clothing, 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.
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WX235R-1200005
Fig. 2-6
2.2.7 Personal Protective Equipment
If your shop specifies the use of safety equipment, 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 without the proper personnel protective equipment even for a moment. Always keep personnel protective equipment in good condition and replace them as required.
CZ335-1102002
Fig. 2-7 2-8
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.2.8 Using the Correct Tools ● Always use the proper authorized tools for the job. Using tools that are not authorized, incorrect for the job, defective or damaged could cause serious injury. ● Keep all tools in good condition, learn the correct way to use them. ● Before starting the work, thoroughly check the tools, machine, forklift, crane, service car, etc. ● Keep your tools clean, and when the job is complete, take inventory of the tools you were using to be sure no tools were left in the machine.
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ZX215-1000033
Fig. 2-8
● 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 carry out the work.
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2.2.9 Fire Extinguisher and Emergency Exits
● It is important to know where all emergency exits and fire extinguishing equipment are located if a fire should occur in the shop.
● Before preparing for work, take time and walk around the shop to make a mental note of where all exits and fire equipment are located. If you are performing repairs in the field, always have a fire extinguisher handy and within reach.
● If you do not know how to use a fire extinguisher contact someone who can instruct you in the proper use of this equipment.
WX235R-1200006
Fig. 2-9
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2.2.10 Electrical Dangers ● When testing electrical circuits, always be aware of what you will be checking in these systems. High voltage or high amp circuits could damage your equipment or cause a spark, explosion or possible fire. ● Before performing any repairs or testing on an electrical system be sure of the system voltage dangers. Always check the circuit to be sure it is off before performing any repairs.
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● When working around flammable liquids or explosive systems, use only approved antiexplosion proof work lamps. Non-approved work lamps can cause an explosion or fire.
Fig. 2-10
2.2.11 Hoisting a Load
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If you will be lifting parts or components that weigh more than 35 lbs (16 kg), it is important to follow some basic rules.
● Always use the appropriate lifting equipment such as hoist, crane, forklift etc. to handle a loads if possible. ● Be sure the lifting equipment is in good condition and rated for the load you are 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.
2-10
Fig. 2-11
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.3 Before Repair 2.3.1 Safe Work Preparations Before starting any repairs, be sure the machine is sitting on a level stable surface.
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Lower all the work equipment to a safe and stable position on the ground. Turn the engine OFF and neutralize the work equipment controls by rotating them to the left and right (joystick control) or moving them back and forth (lever control). This function will relieve system pressure. Block the tracks (if equipped) or wheels (if equipped) with chocks to prevent the machine from moving. If equipped, set the hydraulic lock lever in the LOCKED position. If equipped, set the parking brake in the PARK position. Be sure all personnel and equipment is clear of your work area and you can be seen by all working personnel especially if performing repairs in the field.
Fig. 2-12
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SY365(B)H-9 Crawler Hydraulic Excavator
2.3.2 Preparing yourself Only approved personnel can maintain or repair the machine. An observer may be assigned if necessary. ● Wear protective clothing and shoes necessary for the job. ● Wear rubber apron and rubber gloves when handling corrosive materials. Wear heavy gloves when handling wooden materials, wire ropes or sharp-edged metals.
CZ335-1102069
Fig. 2-13
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● Wear a face shield when removing spring or elastic parts, or adding acid to battery. Wear safety hat and goggles when you weld or cut with a torch. ● Never carry out grinding, flame cutting or welding without an aspirator and ventilation equipment. If you have to weld on the machine, refer to related instructions and understand the correct operating procedure.
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CZ335-1102070
Fig. 2-14
2-12
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.3.3 Lockout/Tagout
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Due to the size and complexity of this machine, 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 energy, and to ensure that the machine is“locked out and tagged out” before anyone performs repairs on the machine. Sequence of procedures
Only authorized employees performing repairs on the machine shall perform Lockout/Tagout in accordance with this procedure listed below.
If the employee performing repairs to the machine is issued a lock and key, the employee shall not share the lock or key with other employees until all repair procedures are complete and the machine is ready to put back into service.
DA
NG
ER
DO OP NO ER T AT E
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The following steps shall be performed in the sequence listed when the equipment is to be either locked-out or tagged-out for repair.
Locking out of service
1. Notify all employees who may be potentially affected by the repair process on the machine.
2. Secure the machine in a safe position. If equipped, set the parking brake or hydraulic lock lever in the PARK or LOCKED position.
Fig. 2-15
3. Identify, remove or disconnect all power
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SY365(B)H-9 Crawler Hydraulic Excavator
or energy sources and be sure to install a Lockout/Tagout device on them. If the machine is equipped with a Maintenance Alert Tag, attach this tag to the machine controls.
DANGER
4. Be sure all employees involved in the repairs have installed there lock on the power source before performing any repairs. Once an employee has completed there repair procedure, they must remove there lock and not access the machine in any manor.
DO NOT OPERATE When this is not being used, keep it in the storage compartment.
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Fig. 2-16
Returning to service
1. The authorized person who performed the Lock out/Tagout procedure shall check the area around the machine to ensure that no one is exposed to any hazard before startup.
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.
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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 machine will be back in service. 4. Remove the Lockout/Tagout equipment and any additional alert equipment and reenergize the machine for return to service.
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SY365(B)H-9 Crawler Hydraulic Excavator
2.3.4 Two people when engine running In order to prevent injury, do not perform the service while the engine is running. If the service 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 operation seat and be ready to turn off the engine at any time. All the operators must keep in touch with each other.
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● Set the safety lock control lever to the lock position.
● Do not touch any control lever. If some control lever must be operated, send signal to other people and warn them to transfer to safe place quickly. ● Do not drop or insert the tools and other objects into the fan or fan belt, or the parts will be broken or thrown out.
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2.3.5 Safety Partners
No one should be allowed to perform work operations in any shop alone. It should be a general shop safety rule for a minimum of two people in the shop area at all times when work procedures are performed. A person alone in the shop might not be able to get emergency help in the event of a shop accident.
When working together always maintain clear contact with each other at all times to avoid the occurrence of unexpected incidents. When carrying out any operation with two or more workers, always agree on the operating procedures and signals before starting.
Fig. 2-17
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2.4 Repair Precautions 2.4.1 Running the Machine Run the machine during repair procedures ONLY if directed to do so in this shop manual. If the machine must be run when making repairs, it is important to follow some basic safety rules. ● Always be aware of rotating components.
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● 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 repairs on the machine at all times.
CZ335-1102077
Fig. 2-18
● If equipped, all lock levers must be in the LOCK position or the parking brake must be in the PARK position. ● The person in the cab must never touch any controls. If a control lever must be operated, always maintain a clear view to the person doing the repair and signal them when you are about to move the control lever.
● Be aware of hot surfaces. During running operations, most surfaces will be hot, and some surfaces will be extremely hot. If necessary, use personnel protective equipment when working around high temperature surfaces.
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CC13031805
Fig. 2-19
● Keep in mind that during running operations, hydraulic systems, cooling systems and fuel systems will be under extremely high pressure and at high temperatures. ● Always use caution when working on or near these systems.
CZ335-1102012
Fig. 2-20 2-16
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.2 Mounting and Dismounting It is important to follow these procedures when mounting or dismounting the equipment: ● Use all hand-holds and step plates on your equipment. ● Never jump off or onto the equipment. ● Wipe off any oil, grease, or mud from your shoes, rails, steps or platforms before getting on the equipment; always keep these areas clean and in good condition.
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● Never get on or off moving equipment. These actions may lead to serious injury. Always bring the equipment to a full stop and turn the engine OFF.
● When getting on or off the equipment, always face the equipment and maintain a three-point contact (both feet and one hand or one foot and both hands) with the handrails, steps and platforms to ensure that you support yourself correctly.
Fig. 2-21
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● Never climb on areas of the machine that are not designated walk areas.
● Never climb on or off the machine with tools, parts or similar objects in your hands. ● Never use machine controls or non-specified points on the equipment to get on or off the machine. ● Use all hand-holds when on the machine.
Fig. 2-22
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2.4.3 Removing Attachments ● If you will be removing large heavy attachments 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 storing is sitting stable on a stable surface and clear of all walkways or fire exits.
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WX235R-1200009
Fig. 2-23
2.4.4 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 machine or a hydraulic jack to support the machine during repairs.
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● Always lower the work equipment to the ground and check the stability of the machine before going under the machine.
CZ335-1102078
Fig. 2-24
2.4.5 Adding Fluids to a System
If it should be necessary to add fluids to a system during running operations, always be aware that these systems may be hot and under high pressure. Before adding fluids, shut the machine down and allow the systems to cool down to outdoor ambient temperatures before removing any caps. Failure to do so may result in serious burns or a sudden loss of fluid.
Fig. 2-25
2-18
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SY365(B)H-9 Crawler Hydraulic Excavator
2.4.6 Aligning Parts or Components ● Be careful when installing or aligning parts or components. ● Avoid using your fingers or hands to position holes or part mating surfaces, serious injury could result if your hand or fingers should get ought between the surfaces.
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● Always use tools to align a part or component to avoid any finger or hand injuries.
WX235R-1200012
Fig. 2-26
2.4.7 Driving Pins
When using a hammer to drive pins, metal particles may fly off. This may lead to serious eye injuries. Always do the following: ● Always wear a face shield or goggles when striking a metal object with a metal hammer.
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● Before performing any of these procedures, 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. Damage to the component may result. Always use a soft or non-ferrous hammer to drive a component or a pin.
CZ335-1102069
Fig. 2-27
2.4.8 When compressed air is used When compressed air is used for cleaning, flying particles may cause personal injury. In this case, wear goggles, dust-preventive mask, gloves and other protective gear.
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2.4.9 Welding operation There is possibility of fire or electrocution during welding. Therefore, welding must be performed by qualified personnel with suitable equipment. Never allow other people to do the welding.
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CZ335-1102070
Fig. 2-28
2.4.10 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.
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Be careful when removing or installing tracks on track-type machines. When removing the master track link the track system may separate suddenly and cause possible injury.
Always stand clear of the track travel path when separating the master link section of the track.
2-20
Fig. 2-29
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.11 High-Pressure Fluid Lines Always keep in mind that these systems are under high pressure. When inspecting or replacing piping or hoses, always check to be sure the pressure in the system has been relieved before proceeding. Working on a system still under pressure could lead to serious injury, always do as follows:
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● If you will be removing a line or component with fluid in the system, always cap and seal the opening to avoid leakage or system 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 cardboard when checking for leaks from small holes.
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● If high pressure fluids should penetrate your skin or get into your eyes, seek medical attention immediately.
CZ335-1102082
Fig. 2-30
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2.4.12 Air-conditioning system maintenance WARNING ● Refrigerant R134 a is a harmless gas under room temperature. It will change into highly toxic gas when burning. ● Refrigerant getting into eyes may cause blindness. It may cause frostbite if splashed on your skin.
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● Keep fire source away when servicing airconditioning system. ● In maintenance of air-conditioning system, observe the instruction on the refrigerant cylinder and use it correctly. The type of refrigerant is R134a. Use of other refrigerants may damage the air-conditioning system. ● Obey local material disposal regulations. Never discharge refrigerant directly into the air.
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CZ335-1102083
Fig. 2-31
2.4.13 High voltage precautions
You must understand the elements before testing electric circuit. High voltage or current could lead to machine damage, spark, explosion or fire.
You must know the voltage before repairing or testing electrical system. Always check the circuit and make sure it is disconnected before doing repair job. Only explosion-proof light can be used when you work near flammable fluids or explosive system. Unapproved illumination equipment could lead to explosion or fire.
2-22
CZ335-1102084
Fig. 2-32
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SY365(B)H-9 Crawler Hydraulic Excavator
2.4.14 Disconnecting the System Power Before starting any repair operations, remove the battery leads from the battery or set the main disconnect on the machine in the OFF position. For the location of the machine main electrical disconnect switch, refer to the machines Safety, Operation & Maintenance Manual for location and procedures.
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If the battery must be disconnected, remove the negative (-) terminal clamp first then remove the positive (+) clamp last.
Fig. 2-33
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.
2.4.15 Accumulator
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If the machine is equipped with an accumulator 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. ● Never strike the accumulator.
● Use only nitrogen gas to charge the accumulator. Unapproved gases could be explosive.
CZ335-1102085
Fig. 2-34
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SY365(B)H-9 Crawler Hydraulic Excavator
2.4.17 Battery Hazards Working around batteries always poses a hazard, especially if the battery has been in service 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 equipment when working around batteries. ● Battery gasses are extremely explosive. When opening a battery compartment, always allow ample time for the gasses to escape before servicing the battery.
In Ma t rk er n et a in ti o g n De al pt .
CZ335-1102061
Fig. 2-35
● When working with batteries, always work in a well ventilated area.
● If the battery is corroded, flush the area with a baking soda and warm water mix.
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CZ335-1102062
Fig. 2-36
● If battery acid should get on your skin or in your eyes, flush the area immediately with fresh water and seek medical attention.
CZ335-1102083
Fig. 2-37
2-24
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.18 Jump-Start Safety CAUTION ● Never use a welder or a machine with a higher voltage system to jump-start the machine. Doing so may damage the machine’s electrical system or cause an unexpected explosion or fire resulting in minor or major injury.
In Ma t rk er n et a in ti o g n De al pt .
When using jumper cables to start the machine, connect the positive (+) jumper first, then the negative (-) jumper to a remote location on the chassis away from the battery.
Fig. 2-38
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Shop Manual - April 2014
2-25
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.19 Avoiding fire and explosion WARNING
In Ma t rk er n et a in ti o g n De al pt .
● Never smoke when handling the fuel or maintaining the fuel system. The gases in empty fuel tank can cause explosion easily. Never carry out flame-cutting or welding operation on fuel pipe, fuel tank or fuel vessels, which can lead to fire, explosion, injury or death.
● Then engine must be shut down and electrical equipment must be switched off when refueling the tank. Be extremely careful when adding fuel to a hot engine. No sparks shall occur around the grounding nozzle. ● Handle all solvents and dry chemicals in a place with good ventilation according to the steps indicated on vessel.
● Clean the machine of all dust and residuals. Never place greasy rag or other flammable materials on machine.
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CZ335-1102014
Fig. 2-39
● When cleaning the parts and components, use nonflammable solvents instead of gasoline, diesel oil or other flammable fluids. ● Store flammable liquids and materials in suitable vessels as required by safety laws and regulations.
● Check fire extinguishers, fire-fighting system and fire detectors (if equipment) and make sure they are ready for use.
2-26
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.20 Chemical hazard
In Ma t rk er n et a in ti o g n De al pt .
Exposure to hazardous chemicals pose a serious danger if released or mishandled. Handling hazardous materials often releases substances that could pose a hazard. Temporary implication or possible residual injury may result unless proper precautions are observed while working with these materials. All workers involved in handling hazardous materials should use approved personal protective equipment and follow all environmental safety regulations.
2.4.21 Material Safety Data Sheets (MSDS)
Material Safety Data Sheet (MSDS) information relating to the materials the workers could be exposed to.
● MSDS data sheets provide both workers and emergency personnel with the proper procedures for handling or working with a particular substance. Information includes physical data, health effects, first aid, reactivity, storage, disposal and protective equipment required.
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● Be sure all personnel involved are familiar with all MSDS-related information as it relates to the hazardous materials they could be exposed to. Keep MSDS data sheets handy in site of all employees and emergency personnel where they can be easily accessed.
Fig. 2-40
● Never handle hazardous materials without the proper MSDS information. Always verify the data on the MSDS sheet before handling any hazardous materials.
Shop Manual - April 2014
2-27
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.22 Proper disposal of wastes Improper disposal of wastes harms the environment and ecology. Consult local environmental protection department or Sany distributors for methods of recycling and waste disposal. ● Potential harmful substances used in Sany products include hydraulic oil, fuel, cooling liquid, refrigerant, filter and batteries etc.. ● Use leak-proof vessels to hold discharged fluids. Never use food or beverage containers.
CZ335-1102086
In Ma t rk er n et a in ti o g n De al pt .
Fig. 2-41
● Never dump waste fluids directly to the ground, sewage or water source.
● Leaking of refrigerant from air conditioner can spoil the atmosphere of the globe. Related laws and regulations must be followed to recover or regenerate the refrigerant.
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CZ335-1102087
Fig. 2-42
2-28
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.5 Other Precautions 2.5.1 Sling work and giving signals
Load capacity kN(kg)
1. Only one appointed worker is allowed to give signals and co-workers must communicate with each other frequently. The appointed signal person must give specified signals clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The signal person must always stand in front of the load and guide the operator safely.
19.6 2000 19.6 2000
kN kg 18.6 1900
16.7 1700
13.7 1400
9.8 1000
9.8 1000
In Ma t rk er n et a in ti o g n De al pt .
● Do not stand under the load.
30
60
90
120
4.9 500
150
Hanging angle (Deg.)
● Do not step on the load.
2. Check the slings before starting sling work.
ZX215-1000001
Fig. 2-43
3. Always wear gloves during sling work. (Wear leather gloves, if available.) 4. Measure the weight of the load by the eye and check its center of gravity.
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5. Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 销 营
6. Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.
7. Limit the hanging angle to 60º, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120 ° . If the 2 ropes sling a 19.6 kN {2,000 kg} load
Shop Manual - April 2014
2-29
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
at a lifting angle of 150 ° , each of them is subjected to a force as large as 39.2 kN {4,000 kg}. 8. When installing wire ropes to an angular load, apply softeners to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9. Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 100%
88%
79%
71%
In Ma t rk er n et a in ti o g n De al pt .
10. Apply wire ropes to the middle portion of the hook.
● Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
ZX215-1000002
Fig. 2-44
11. Do not use twisted or kinked wire ropes.
12. When lifting up a load, observe the following.
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● Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. ● After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and softener. ● If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. ● Do not lift up the load slantingly. 13. When lifting down a load, observe the following.
● When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. ● Check that the load is stable, and then remove the sling. 2-30
41%
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
● Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
2.5.2 Using mobile crane CAUTION
In Ma t rk er n et a in ti o g n De al pt .
● Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
2.5.3 Using overhead hoist crane
1. Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety.
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2. Observe the signals for sling work. 3. Operate the hoist at a safe place.
4. Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail 5. Do not sling a load slantingly. Do not move the crane while the slung load is swinging.
6. Do not raise or lower a load while the crane is moving longitudinally or laterally. 7. Do not drag a sling.
8. When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9. Consider the travel route in advance and lift up a load to a safe height. 10. Place the control switch on a position where it will not be an obstacle to work and passage.
Shop Manual - April 2014
2-31
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
11. After operating the hoist, do not swing the control switch. 12. Remember the position of the main switch so that you can turn off the power immediately in an emergency. 13. If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state.
In Ma t rk er n et a in ti o g n De al pt .
14. If you find an obstacle around the hoist, stop the operation.
15. After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
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Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.5.4 Selecting wire ropes Select adequate ropes according to the weight of parts to be hoisted. See the table below. Wire Rope (Standard Z or S type of strand, ungalvanized) Nominal Diameter
Allowable Load
kN
t
10
9.8
1.0
11.5
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
18
35.5
3.6
20
43.1
4.4
22.4
54.9
5.6
30
98.1
10.0
176.5
18.0
50
274.6
28.0
60
392.2
40.0
In Ma t rk er n et a in ti o g n De al pt .
mm
40
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CAUTION
● The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
Shop Manual - April 2014
2-33
Shop Safety
BLM In t aAr e kNe rn a tKi t i nP o gA n al DG ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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Shop Manual - April 2014
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Specifications 3 Specifications
3.1 Specific Dimension .................................................................................................. 1-3 3.1.1 Dimension ...................................................................................................... 1-3 3.1.2 Working ranges .............................................................................................. 1-4 3.2 Technical Specifications........................................................................................... 1-5 3.3 Weight Table ............................................................................................................ 1-7 3.4 Engine oil, Fuel and Coolant.................................................................................... 1-8 3.5 Engine Performance Curves.................................................................................... 1-9 司
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Shop Manual - April 2014
3-1
Specifications
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
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3-2
Shop Manual - April 2014
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
3 SPECIFICATIONS 3.1 Specific Dimension 3.1.1 Dimension
A D
I
C
In Ma t rk er n et a in ti o g n De al pt .
E
G B
H
L
F
J K
Fig. 3-1
CZ425-1103002
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Item
Unit
SY365H-9
SY365BH-9
Shipping length
mm
11,360
11,380
Overall width
mm
3,190
3,190
Shipping height
mm
3,550
3,640
Top width
mm
3,150
3,150
Overall height (to cab top)
mm
3,320
3,320
Standard width of track shoe
mm
600
600
Gauge
mm
2,590
2,590
Min. ground clearance
mm
550
550
Tail swing radius
mm
3,380
3,380
J
Track grounding length
mm
4,140
4,140
K
Track length
mm
5,065
5,065
L
Upper-structure ground clearance
mm
1,250
1,250
A B C D E F G H I
Shop Manual - April 2014
1-3
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
3.1.2 Working ranges
a
In Ma t rk er n et a in ti o g n De al pt .
f
g
b
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d
c
e
CZ425-1103004
Fig. 3-2
1-4
Shop Manual - April 2014
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
Unit
SY365H-9
SY365BH-9
a
Max. cutting height
mm
9,900
9,850
b
Max. dumping height
mm
6,930
6,815
c
Max. digging depth
mm
7,040
6,750
d
Max. vertical wall depth
mm
5,180
4,870
e
Max. digging reach
mm
10,610
10,405
f
Min. swing radius
mm
4,330
4,300
g
Max. height at min. swing radius
mm
8,600
8,720
In Ma t rk er n et a in ti o g n De al pt .
Item
3.2 Technical Specifications Item
Unit
SY365H-9
SY365BH-9
Bucket capacity
m3
1.6（Rockwork）
1.8（Earthwork）
Operating weight
kg
35,000
35,000
Max bucket digging force
KN
235
235
Max arm-in force
KN
180
206
Swing speed
rpm
9.5
9.5
Travel speed (high/low)
km/h
5.5/3.5
5.5/3.5
Degree
35
35
KPa
63
63
Gradeability
Specific ground pressures
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Shop Manual - April 2014
1-5
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
Machine Model
SY365H-9
SY365BH-9
In Ma t rk er n et a in ti o g n De al pt .
Performance
ISUZU AA-6HK1XQP-01 6 cylinders, 4 cycles, water cooling, in-line, and direct injection Type No. Of cylinder-bore × 6-Φ115mm×125mm mm 7.8 stroke L Total displacement Rated power kW/rpm 190.5/ 2000 Max. torque N·m/rpm 873 / 1700 Max. speed at zero load rpm 2200±25 1000±25 Min. speed at zero load rpm 237 Min. fuel consumption g/kWh Start motor 24V/5kW 24V/50A Alternator Carrier roller (each side) 2
Track shoe (each side)
49
Type KAWASAKI (two variable swash plate plunger pumps, constant Max main pump delivery power control and proportional solenoid valve) L/min 2×158 Main safety valve presMpa 34.3 sure
Type X No. Control method
Hydraulic motor
Hydraulic pump
9
Control valve
Track roller (each side)
Hydraulic cylinder
Hydraulic system
Undercarriage
Engine
Model
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KMX32NA/P45001×1 Hydraulic type
Angle type variable plunger motor A6VE107HZ3/63WVZL22XB-S Planetary gear reducer F80/121/OM/MB (Including brake valve and parking brake)×2 Angle type plunger motor - planetary gear reducer (upright) M5×180CHB-10A-3NA/265 - RG20D25G2-140 (Swing stop controller)×1 Boom Arm Bucket Boom Arm Bucket
Travel motor
Swing motor
Type Cylinder inner diameter Piston rod diameter Stroke
Reciprocal plunger mm mm mm
140 100 1420
170 120 1748
Hydraulic tank Hydraulic oil filter element Hydraulic oil cooler 1-6
140 100 1135
Reciprocal plunger 140 100 1480
Closed type Tank return side Air-cooling type Shop Manual - April 2014
160 110 1685
140 100 1748
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
3.3 Weight Table Unit: kg SY365H-9
SY365BH-9
Engine
720
720
Radiator assembly Hydraulic tank assembly (excluding hydraulic oil) Fuel tank assembly (excluding fuel)
118
118
234
234
235
235
Swing platform
3040
3040
Operator station
150
150
In Ma t rk er n et a in ti o g n De al pt .
Machine Model
Operator seat & console
76
76
Counterweight
6800
6800
Hydraulic pump
186
186
Main control valve
380
380
Swing reducer assembly
422
422
Travel reducer assembly
389×2
389×2
45
45
4612 544 175×2 190×2 35×4 44×18
4612 544 175×2 190×2 35×4 44×18
2574
2574
Arm assembly
1165
1200
Bucket assembly
1620
1582
264×2
264×2
Arm cylinder assembly
484
484
Bucket cylinder assembly
150
150
Connecting rod
114
105
35×2
40×2
Swivel joint Track frame Swing bearing Idler Tensioning device Carrier roller Track roller Boom assembly
Boom cylinder assembly
Rocker arm
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Note: The weight table is only used as a reference for handling the components or transporting the machine.
Shop Manual - April 2014
1-7
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
3.4 Engine oil, Fuel and Coolant Reservoir
Liquid type
-22 -30
-4 -20
14 -10
Ambient temperature 32 50 68 0 10 20
86 30
104 40
SAE 30 SAE 10W Engine oil pan SAE 10W-30
Engine oil
In Ma t rk er n et a in ti o g n De al pt .
SAE 15W-40 Carrier roller Idler Track roller Swing drive Final drive
SAE 30
Gear oil
SAE 10W
SAE 10W-30
Engine oil
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SAE 15W-40
Hydraulic system
HDZ32 low temp, wear-resistant
Hydraulic oil
HDZ46 wear-resistant
HDZ68 wear-resistant
GB252 super 0#
Fuel tank
GB252 super -20#
Diesel oil
GB252 super -35#
Grease fitting
Grease
Cooling system
Coolant
NLGI No.2 TEEC-L35 antifreeze
Note: 1) Sany recommends using API CF-4 or above, not lower than API CD. 2) Sany recommends using gear oil GL-5. 3) To ensure oil quality, always buy genuine oil from Sany or your Sany distributor. 1-8
Shop Manual - April 2014
122 ℉ 50℃
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
3.5 Engine Performance Curves AA-6HK1XQP-01 Test condition: 1. Temperature 298K, one standard atmospheric pressure. 2. Maximum output power: 183.9KW (with fan); 190.5KW (without fan) Max torque
1050
872.8 or more Ｎｍ/approx.1700 min-1 (872.8～/approx.1700 min -1)
In Ma t rk er n et a in ti o g n De al pt .
950 850 750 650
Max output power
183.9±2.9 kW/2000 min-1 (181.0～186.8kW/2000min-1 )
200
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150
100
50
Max speed without load
2275±25 min-1 -1 (2250～2300min )
0
Rate of fuel consumption (Max output power)
280
236.6 g/kWh or less （～236.6 g/kWh)
260 240 220 200 180
800
1000
1200
1400
1600
1800
2000
2200
2400 W36531305
Fig. 3-3 Shop Manual - April 2014
1-9
Specifications
BLM In t aAr e kNe rn a tKi t i nP o gA n al DG ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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1-10
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Structure and Functions
In Ma t rk er n et a in ti o g n De al pt .
2
4 Structure and Functions
4.1 Engine and Cooling System ................................................................................... 4-5 4.1.1 Engine-related parts....................................................................................... 4-5 4.1.2 Radiator and intercooler................................................................................. 4-6 4.2 Power Train.............................................................................................................. 4-7 4.2.1 Overview ........................................................................................................ 4-7 4.2.2 Travel reducer AS ......................................................................................... 4-8 4.2.3 Swing reducer mechanism........................................................................... 4-10 4.2.4 Swing bearing .............................................................................................. 4-12 4.3 Undercarriage Travel System ............................................................................... 4-14 4.3.1 Track frame and tensioning mechanism ...................................................... 4-14 4.3.2 Idler .............................................................................................................. 4-16 4.3.3 Carrier roller ................................................................................................. 4-18 4.3.4 Track roller ................................................................................................... 4-19 4.3.5 Track ........................................................................................................... 4-20 4.3.6 Tri-grouser track shoe .................................................................................. 4-23 4.4 Hydraulic System, Part 1 ....................................................................................... 4-24 4.4.1 Deployment of hydraulic parts ..................................................................... 4-24 4.4.2 Hydraulic tank and filter ............................................................................... 4-26 4.4.3 Hydraulic pump ............................................................................................ 4-28 4.4.3.1 Outline................................................................................................. 4-29 4.4.3.2 Function .............................................................................................. 4-31 4.4.3.3 Structure ............................................................................................. 4-31 4.4.3.4 Operating principle .............................................................................. 4-32 司
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Shop Manual - April 2014
4-1
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
4.4.3.5 Oil delivery control .............................................................................. 4-33 4.4.4 Pilot pump .................................................................................................... 4-34 4.4.5 Regulator .................................................................................................... 4-35 4.5 Hydraulic system, Part 2 ........................................................................................ 4-48 4.5.1 Main control valve ........................................................................................ 4-48 4.5.1.1 Overview ............................................................................................ 4-48 4.5.1.2 Main valve structure ............................................................................ 4-50 4.5.2 Hydraulic circuit (With bucket confluence function) .............................................. 4-56 4.6 Hydraulic System, Part 3 ....................................................................................... 4-79 4.6.1 Swing motor ................................................................................................. 4-79 4.6.2 Swing holding brake..................................................................................... 4-81 4.6.3 Relief valve section ...................................................................................... 4-82 4.6.4 Anti-jerk valve............................................................................................... 4-84 4.6.4.1 Operation diagram .............................................................................. 4-84 4.6.4.2 Effect illustration.................................................................................. 4-84 4.6.5 Central Swivel Joint ..................................................................................... 4-86 4.6.6 Travel motor ................................................................................................. 4-87 4.6.7 Reducer ....................................................................................................... 4-89 4.6.8 Travel motor (Nabtesco) .............................................................................. 4-91 4.6.9 Operating principle of the basic components ............................................... 4-93 4.6.9.1 Double-balanced valve ....................................................................... 4-93 4.6.9.2 Operation of parking brake ................................................................. 4-98 4.6.9.3 Operation of braking valve .................................................................. 4-99 4.6.10 Control system ......................................................................................... 4-108 4.6.11 Manual pilot valve .....................................................................................4-110 4.6.12 Travel pilot valve .......................................................................................4-114 4.6.12.1 Operating principle ...........................................................................4-116 4.6.13 Solenoid valve...........................................................................................4-118 4.6.14 PPC accumulator ......................................................................................4-119 4.6.15 Pilot oil filter.............................................................................................. 4-121 4.6.16 Hydraulic cylinders ................................................................................... 4-122 4.6.16.2 Lubrication at every 100 service hours ........................................... 4-123 4.6.16.1 Lubrication at every 500 service hours ........................................... 4-123 4.7 Work Equipment .................................................................................................. 4-124 4.7.1 Component dimensions ............................................................................. 4-124 4.7.2 Arm dimensions ......................................................................................... 4-126 司
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4-2
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
4.7.2.1 Bucket dimensions ............................................................................ 4-128 4.8 Operator Station and Its Attachments .................................................................. 4-130 4.8.1 Air conditioner lines .................................................................................... 4-130 4.8.1.1 Layout of A/C components ................................................................ 4-132 4.8.1.2 A/C control panel............................................................................... 4-133 4.8.1.3 Diagram of electrical circuit ............................................................... 4-134 4.8.1.4 Operating principle ............................................................................ 4-136 4.8.1.5 Compressor ...................................................................................... 4-137 4.8.1.6 Clutch ................................................................................................ 4-139 4.8.1.7 Condenser ........................................................................................ 4-140 4.8.1.8 Expansion valve ................................................................................ 4-141 4.8.1.9 Evaporator ........................................................................................ 4-141 4.8.1.10 Dehydrator ..................................................................................... 4-142 4.8.1.11 Pressure switch .............................................................................. 4-143 4.8.1.12 Fresh air sensor .............................................................................. 4-144 4.8.2 Refrigerant ................................................................................................. 4-145 4.8.2.1 Compressor oil .................................................................................. 4-163 4.9 Engine Control ..................................................................................................... 4-164 4.9.1 System operation ....................................................................................... 4-165 4.9.1.1 Engine starting .................................................................................. 4-165 4.9.1.2 Engine speed control ........................................................................ 4-165 4.9.1.3 Engine shutdown .............................................................................. 4-165 4.9.2 System components .................................................................................. 4-166 4.9.2.1 Fuel control dial................................................................................. 4-166 4.9.2.2 Controller .......................................................................................... 4-168 4.10 Electrical Control System................................................................................... 4-170 4.10.1 Control function ........................................................................................ 4-170 4.10.2 Diagram of machine control system......................................................... 4-171 4.10.3 Engine-pump combination control ........................................................... 4-173 4.10.4 Pump control function .............................................................................. 4-177 4.10.4.1 Constant power control ................................................................... 4-180 4.10.4.2 ESS control ..................................................................................... 4-180 4.10.5 Valve control function ............................................................................... 4-181 4.10.6 Dual travel speed control ......................................................................... 4-183 4.10.7 Engine preheat/overheat alarm ............................................................... 4-185 4.10.8 Auto deceleration/acceleration control ..................................................... 4-187 司
公
销 营
Shop Manual - April 2014
4-3
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
4.10.9 Engine speed calibration function ............................................................ 4-188 4.10.10 System parts and components .............................................................. 4-190 4.11 Monitoring System ............................................................................................. 4-195 4.11.1 Monitor ..................................................................................................... 4-196 4.11.2 Monitor panel ........................................................................................... 4-197 4.11.2.1 Alert and signal indicators .............................................................. 4-197 4.11.2.2 Operation keys ................................................................................ 4-199 4.11.3 Monitor display and operation .................................................................. 4-201 4.11.3.1 Default page .................................................................................... 4-201 4.11.3.2 Password entry to system information ............................................ 4-202 4.11.3.3 Main menu ...................................................................................... 4-202 4.11.3.4 Engine & throttle signals ................................................................. 4-203 4.11.3.5 Pilot pressure signals ...................................................................... 4-203 4.11.3.6 Main pump & main valve signals..................................................... 4-204 4.11.3.7 Failure codes................................................................................... 4-204 4.11.3.8 Throttle help information ................................................................. 4-205 4.11.3.9 Language selection ......................................................................... 4-205 4.11.3.10 System clock setup ....................................................................... 4-206 4.11.3.11 GPS information ............................................................................ 4-207 4.11.3.12 System setup ................................................................................ 4-208 4.11.3.13 Machine configuration ................................................................... 4-208 4.11.3.14 Service hour setup ....................................................................... 4-209 4.11.3.15 Machine configuration setup ......................................................... 4-210 4.11.3.16 Hydraulic oil temperature ...............................................................4-211 4.11.3.17 Screen brightness setup ................................................................4-211 4.11.3.18 System lockout (level 1) ................................................................ 4-212 4.11.3.19 System lockout (level 2) ................................................................ 4-212 司
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销 营
4-4
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4 STRUCTURE AND FUNCTIONS 4.1 Engine and Cooling System 4.1.1 Engine-related parts
1
M6
2
M6
In Ma t rk er n et a in ti o g n De al pt .
Ⅱ
俁 2
Ⅰ
4
3
I
4
司
公
销 营
Ⅱ
Coupling installation
5
6
4×M18×60-10.9
Tightening torque 320N•m
2×M16
Tightening torque 120N•m
AA-6HK1XQA
7
W365413091
Fig. 4-1 (1) (2) (3) (4) (5) (6) (7)
Air cleaner Muffler AS Air cleaner Damper Flywheel Coupling Plunger pump
Specification Engine oil capacity: 35 L
Shop Manual - April 2014
4-5
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.1.2 Radiator and intercooler 3 4
1
In Ma t rk er n et a in ti o g n De al pt .
5
2
6
7
司
公
销 营
W365413092
Fig. 4-2 (1) (2) (3) (4) (5) (6) (7)
4-6
Coolant tank Water inlet pipe Water outlet pipe Air intercooler Condenser Oil radiator Water radiator
Specification
Radiator AS: H1260×460×1100-S105Y100Z30 Aluminum ribbon-tublar radiator
Tank capacity: 8.4 L
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.2 Power Train 4.2.1 Overview 2
1
In Ma t rk er n et a in ti o g n De al pt .
3
4
5
6
司
公
销 营
7
8
9
10
ZX365-1304003
Fig. 4-3 (1) (2) (3) (4) (5)
Swing motor (M5×180CHB-10A-3NA/265) Swing reducer (RG20D25G2-140) Swing bearing Idler Swivel joint
(6) Accumulator (7) Main control valve (KMX32NA/P45001) (8) Travel reducer (F80/121/OM/MB) (9) Plunger pump (K5V160DTH1×4R-9T06-V) (10) Engine (AA-6HK1XQP-01)
Shop Manual - April 2014
4-7
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.2.2 Travel reducer AS
7
6
In Ma t rk er n et a in ti o g n De al pt .
10
司
公
销 营
1
9
8
2
3
4
5
11
12°
12
Fig. 4-4 4-8
Shop Manual - April 2014
ZX335-1002050
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
(1) (2) (3) (4) (5) (6)
Gear hub No.1 planetary gear No.1 planetary carrier pin No.1 sun gear No.1 planetary carrier No.2 planetary gear
(7) No.2 planetary carrier pin (8) No.2 sun gear (9) No.2 planetary carrier (10) Motor (11) Check port (12) Filler/drain port
Check item
13
Clearance between No.2 planetary gear and gear hub
14 15 16
Criteria 0.100 ～ 0.356
Remedy 1.10
In Ma t rk er n et a in ti o g n De al pt .
No.
Clearance between No.1 planetary gear and gear hub
0.133 ～ 0.386
1.00
Clearance between No.1 sun gear and No.1 planetary gear
0.05 ～ 0.286
1.10
Clearance between No.2 sun gear and No.2 planetary gear
0.076 ～ 0.304
1.00
Replace
司
公
销 营
Shop Manual - April 2014
4-9
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.2.3 Swing reducer mechanism
9
19
In Ma t rk er n et a in ti o g n De al pt .
20
21
8
24
22 10
6
23 11 12
司
公
销 营
5
26
7
4
13
14
3 2
15
1
17 16 18 28 ZX335-1002004
Fig. 4-5
4-10
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
(1) Plug (2) Oil seal (3) Self-aligning bearing (4) Gear ring (teeth: 66) (5) No.2 planetary carrier (6) No.1 planetary carrier (7) No.2 sun gear (teeth: 18) (8) No.1 sun gear (teeth: 15) (9) Swing motor (10) No.1 planetary gear (teeth: 25)
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)
No.2 planetary gear GP No.2 planetary gear (teeth: 23) Spring pin Screw plug Grease fitting Self-aligning bearing Bearing seal Pinion gear Dipstick Oil-filling tube
In Ma t rk er n et a in ti o g n De al pt .
Specification
Reduction ratio: 25.2
No. 21 22 23 24 25 26 27 28
Check Item
Criteria
Clearance between swing motor shaft and No.1 sun gear
Clearance between No.1 sun gear and No.1 planetary gear Clearance between No.1 planetary gear and gear ring Clearance between No.1 planetary carrier and No.2 sun gear Clearance between No.2 sun gear and No.2 planetary gear Clearance between No.2 planetary gear and gear ring Clearance between No.2 planetary carrier and swing pinion gear Clearance between swing pinion gear and swing bearing
Standard clearance
Clearance limit
0.18- 0.28
—
0.16- 0.50
1.00
0.18- 0.59
1.10
0.39- 0.71
1.20
0.16- 0.50
0.90
0.18- 0.59
1.00
0.07- 0.23
—
0.22- 1.32
2.00
司
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销 营
Shop Manual - April 2014
Remedy Replace
Replace
4-11
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.2.4 Swing bearing b ●
●
●
a
A
In Ma t rk er n et a in ti o g n De al pt .
A
1
2
司
公
销 营
927±103 Nm
927±103Nm
A-A
ZX335-1002005
Fig. 4-6 (1) Inner race (teeth: 78) (2) Steel ball (3) Outer race
Specification Reduction ratio: 78/11= 7 Grease volume filled: 27±1 Kg
a. Location S (soft zone of inner race) b. Location S (soft zone of outer race)
4-12
3
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Check Item
Remedy
Standard clearance
Clearance limit
0.5-1.6
3.2
Replace
In Ma t rk er n et a in ti o g n De al pt .
Bearing axial clearance (Mounted on chassis)
Criteria
司
公
销 营
Shop Manual - April 2014
4-13
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.3 Undercarriage Travel System 4.3.1 Track frame and tensioning mechanism 2
3
4
In Ma t rk er n et a in ti o g n De al pt .
1
11
9
8
7
6
5
Ɣ
10
12
司
X
公
销 营
X
ZX365-1304006
Fig. 4-7 (1) (2) (3) (4) (5) (6) (7) (8) (9)
Idler Track frame Carrier roller Sprocket Track roller Track Long guard Short guard Guide seat
4-14
● Dimension and number of track rollers may vary depending on the machine model, but their basic structures are the same. ● Number of track rollers on one side: 9
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Unit: mm No.
Check Item
10
Vertical width of idler guide
11
Standard
Horizontal width of idler guide
Standard size Track frame
123
Idler support
120
Track frame
266
Idler support
261
Remedy Tolerance
Standard size
+3 — -1 ±0.5 — +4 — -1 0 — -0.5 Repair limit
Free length × Outer diameter
Installation length
Installation load
Free length
Installation load
1225x 262
655
{21280kg} 208.5KN
795
—
In Ma t rk er n et a in ti o g n De al pt .
12
Repair limit
Tension spring
Standard track shoe
Build-up welding or replace
Replace
司
公
销 营
Model
SY365H-9/SY365BH-9
Item Shoe width (mm)
Link pitch (mm) Number of track shoes on one side
600
216 49
Shop Manual - April 2014
4-15
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.3.2 Idler
5 6 4 3 7
8
In Ma t rk er n et a in ti o g n De al pt .
9
157~255 Nm
1
2
司
公
销 营
ZX215-1002010
Fig. 4-8
4-16
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Unit: mm No.
Check item
1
Protrusion outer dia.
2
Criteria
Remedy
Standard size
Repair limit
635
—
Tread outer dia.
590
578
3
Tread thickness
30
24
4
Tread difference
22.5
26
5
Overall width
190
—
6
Tread width
44
—
8
9
Clearance between shaft and bushing
Shaft
φ80
—
Hole
Standard clearance
Clearance limit
—
—
—
In Ma t rk er n et a in ti o g n De al pt .
7
Tolerance
Standard size
Build-up welding or replace
Interference between idler and bushing
Clearance between bushing and support (Sum of clearances at both sides)
Tolerance
Standard size
Shaft
Hole
Standard interference
Interference limit
φ86
—
—
—
—
Standard clearance 司
Replace bushing
Clearance limit
公
销 营
0.5-1.0
Shop Manual - April 2014
—
4-17
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.3.3 Carrier roller
5
3
In Ma t rk er n et a in ti o g n De al pt .
8
4
6
7
2
1
司
公
销 营
ZX215-1002011
Fig. 4-9 No.
Check item
Criteria
Remedy
Standard size
Repair limit
190
—
Tread outer dia.
150
136
3
Tread width
57
—
4
Tread thickness
39
32
5
Flange width
16
—
6
Clearance between shaft and bushing
Standard size
Shaft
65
—
Interference between carrier roller and bushing
Standard size
1
Flange outer dia.
2
7
8 4-18
Carrier roller axial clearance
72
Tolerance Hole
Standard clearance
Clearance limit
—
—
—
Standard interference
Interference limit
—
—
Tolerance Shaft Hole —
—
Standard clearance
Clearance limit
0.44-0.76
—
Shop Manual - April 2014
Unit: mm
Replace
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.3.4 Track roller 10
3
9
2
1
In Ma t rk er n et a in ti o g n De al pt .
8
549±59 Nm
5
7
6
4
司
ZX215-1002012
公
销 营
Fig. 4-10 No. 1 2 3 4 5 6 7 8
Check item
Criteria
Standard clearance
Repair limit
216
—
Tread outer dia.
180
168
Tread thickness
51.5
40.5
Overall width
250
—
Tread width
50.5
—
Flange width
27
—
Inner width
95
Flange outer dia.
Clearance between shaft and bushing
Standard size
Tolerance Shaft Hole
70
—
—
Tolerance Shaft Hole
Standard clearance
Clearance limit
—
—
Standard interference
Interference limit
—
—
9
Interference between track roller and bushing
Standard size
Standard clearance
Clearance limit
10
Clearance between bushing and collar (Sum of clearances on both sides)
0.5 - 1.0
—
77
—
—
Shop Manual - April 2014
Unit: mm Remedy
Build-up welding or replace
Replace bushing
Replace
4-19
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.3.5 Track
1
In Ma t rk er n et a in ti o g n De al pt .
4
20
22
8
16
24
司
公
销 营
12
13
5
11
21
25
23
7
10
6 15
18
2
17
Fig. 4-11
4-20
3
9
Shop Manual - April 2014
19
14
ZX215-1002013
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Unit: mm No. 1
Check item
Criteria
Link pitch Bushing outer diameter
3
Bushing metal thickness
4
Link height
5
Link metal thickness (bushing pressfitting portion)
6 7 8 9
10 11
Standard size
Repair limit
216
219
Standard size
Reverse
66.9
60.23
11.1
—
Standard size
Repair limit
116
104.4
30.65
22.5
Reverse or replace
Repair or replace
In Ma t rk er n et a in ti o g n De al pt .
2
Remedy
12
178.4
Shoe bolt pitch
140.4 76.2
Link
Inside width
102
Overall width
23.2
Tread width
21.3
Pin protrusion
4.2
Adjust or replace
司
公
销 营
13 14 15 16 17 18 19
Bushing protrusion Overall length of pin Overall length of bushing Spacer thickness Press-fitting force
5.3
242
158.9 —
Bushing
88.2 -245 kN{9-25 ton}
Regular pin Master pin
127.4 -274.4 kN{13-28 ton} 78.4 -147 kN{8-15 ton}
Shop Manual - April 2014
—
4-21
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Unit: mm No.
Check item a. Regular link
20
Shoe bolt b. Master link
Interference between bushing and link
Remedy
Tightening torque(Nm{kgm}) Retightening angle (deg) 1100±55 Tri-grouser 120±10 track shoe {112.2±5.6} Tightening Lower torque torque limit Retightening angle (deg) (Nm) (Nm{kgm}) — — —
Retighten
Tolerance
Standard size
Shaft Hole +0.46 +0.074 +0.41 0 +0.19 –0.188 +0.09 –0.20 Tolerance Shaft Hole +0.19 +1.35 +0.09 +0.85
66.5
22
23
Interference between pin and link Clearance between pin and bushing
44.6
Standard size 44.6
司
公
销 营
4-22
Standard interference
In Ma t rk er n et a in ti o g n De al pt .
21
Criteria
Shop Manual - April 2014
0.36-0.464
0.285-0.485
Standard clearance 0.18-0.83
Adjust or replace
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.3.6 Tri-grouser track shoe
5
1
6
7
8
4
2
In Ma t rk er n et a in ti o g n De al pt .
3
ZX215-1002014
Fig. 4-12
No. 1 2 3 4 5 6 7 8
Check item
Height
司
公
销 营
Criteria
Standard size
Repair limit
30
20
Thickness
Unit: mm Remedy
11
29
Length of base
24
Build-up welding or replace
22
Length at tip
16 22
Thickness
Standard size
Repair limit
41
31
Shop Manual - April 2014
4-23
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4 Hydraulic System, Part 1 2
4.4.1 Deployment of hydraulic parts (1) Bucket cylinder (2) Arm cylinder (3) Boom cylinder (4) Hydraulic tank (5) Hydraulic oil filter (6) Main control valve
In Ma t rk er n et a in ti o g n De al pt .
(7) Main pump (8) Radiator
(9) Accumulator
(10) Left travel motor
(11) Right travel motor
1
(12) Swing motor
(13) Hydraulic lockout control (14) Left pilot valve
司
公
销 营
(15) Central swivel joint (16) Right pilot valve
(17) Travel pilot valve
(18) Solenoid valve AS
18A. Hi/Lo travel speed shift solenoid valve
18B. Negative flow solenoid valve (front pump)
ZX335-1002007
Fig. 4-13
18C. Negative flow solenoid valve (rear pump) 18D. Pilot lockout solenoid valve
4-24
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4
5
6
8
7
In Ma t rk er n et a in ti o g n De al pt .
3
司
公
销 营
A
10 11 12 13 14 16
17
9
18F18E
A 18D 18C 18B 18A
15 18 W365-1304008
Fig. 4-14 Shop Manual - April 2014
4-25
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.2 Hydraulic tank and filter 1
2
B
In Ma t rk er n et a in ti o g n De al pt .
6<++&
B
B-B
4
3
5
6
7
司
公
销 营
W365-1304009
Fig. 4-15
4-26
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
(1) Hydraulic tank (2) Level gauge (3) Filter element (oil drain) (4) Filler cap (5) Breather valve (6) Filter element (oil suction) (7) Filter element (oil return) Specification
In Ma t rk er n et a in ti o g n De al pt .
Tank capacity: 340 L Breather valve
Filter fineness: 10μm
Ambient temp: -30℃ -100℃
Pressure setting: Air inlet side → 0.005 MPa
Air outlet side → 0.05 MPa
司
公
销 营
Shop Manual - April 2014
4-27
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.3 Hydraulic pump Type: K5V160DTH1×4R-9T06-V B1
a5(16N·m)
a2(36N·m)
In Ma t rk er n et a in ti o g n De al pt .
a1(36N·m)
1
2
Dr1(170N·m)
B3
Dr4(170N·m)
司
公
销 营
PH1
5
4
A2
A3
Dr2(170N·m)
PH2
Psv2
A1
a3(36N·m)
Dr4(170N·m)
Psv1
3 a4(36N·m)
Fig. 4-16 4-28
Shop Manual - April 2014
ZX335-1002010
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.3.1 Outline ● This pump consists of 2 variable swash plate plunger pumps, 2 adjustors, and 1 pilot gear pump. a1: Main pressure detection port (front pump) a2: Main pressure detection port (rear pump) a3: Regulator pressure detection port (front pump) a4: Regulator control pressure detection port (rear pump)
In Ma t rk er n et a in ti o g n De al pt .
a5: Delivery pressure detection port (pilot gear pump)
PH1: Pressure sensor mounting port (front pump) PH2: Pressure sensor mounting port (rear pump) A1: Oil delivery port (front pump) A2: Oil delivery port (rear pump)
司
公
销 营
A3: Oil delivery port (pilot gear pump)
Psv1: Regulator control port (front pump) Psv2: Regulator control port (rear pump) Dr1: Drain plug (front pump) Dr2: Drain plug (rear pump) Dr4: Oil drain port
B1: Oil suction port (pump)
B3: Oil suction port (pilot gear pump) (1) 1: Front pump (2) 2: Rear pump (3) 3: Pilot gear pump (4) 4: Regulator (front pump) (5) 5: Regulator (rear pump)
Shop Manual - April 2014
4-29
Structure and Functions
2
3
13
SY365(B)H-9 Crawler Hydraulic Excavator
6
7
14
8
9
16
10
1
In Ma t rk er n et a in ti o g n De al pt .
15
4
5
12
11
ZX215-1002019
Fig. 4-17
司
公
销 营
(1) (2) (3) (4) (5) (6) (7) (8)
Front shaft Min. delivery adjusting screw Front casing Swash plate Slipper Plunger Cylinder block Oil distributor
4-30
(9) End cap (10) Rear shaft (11) Rear casing (12) Gear pump (13) Piston (14) Max. delivery adjusting screw (15) Gear pump shaft (16) Driving pin
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
1
6
13
7
8
In Ma t rk er n et a in ti o g n De al pt .
B
18
4
A
5
18
17
ZX215-1002020
Fig. 4-18
司
公
4.4.3.2 Function
销 营
● The torque of the engine is transmitted to the pump shaft (1), and drives cylinder block (7) to rotate. At the same time, nine plungers (6) slide along the oil distributor (8). Plunger (6) moves back and forth inside cylinder block (7) and pressurized oil is sucked in and discharged alternatively.
● Swash plate (4) has flat surface (A), and slipper (5) is always pressed against this surface while sliding in a circular movement.
● It is possible to change the displacement by changing the swash plate angle.
● Plunger (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
4.4.3.3 Structure
● Cylinder block (7) is supported to shaft (1) by spline (17).
● Shaft (1) is supported by front and rear bearings (18). ● Tip of plunger (6) is shaped as a concave ball and slipper (5) is caulked to it to form one unit. ● Plunger (6) and slipper (5) constitute the spherical bearing.
● Swash plate (4) conducts high pressure oil to cylinder surface (B), and forms a static pressure bearing when it slides.
● Cylinder block (7) seals the pressurized oil to oil distributor (8) and carries out relative rotation. ● This surface is designed so that the oil pressure balance is maintained at a suitable level. ● The oil inside the respective cylinder chambers of cylinder block (7) is sucked in and delivered through oil distributor (8).
Shop Manual - April 2014
4-31
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.3.4 Operating principle ● Cylinder block (7) rotates together with shaft (1), and slipper (5) slides on flat surface (A).
1
4
7
5 A
● When this happens, swash plate (4) moves along cylindrical surface (B), so angle (a) between central line (X) of swash plate (4) and the axial direction of cylinder block (7) changes.
a X B
● (a) stands for the angle of the swash plate.
ZX215-1002021
Fig. 4-19
In Ma t rk er n et a in ti o g n De al pt .
● With central line (X) of swash plate (4) at a swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to slipper (5).
4
A
● In this way, plunger (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). ● A single plunger sucks and discharges the oil by the amount (F) – (E).
6
5
F
a
X
E ZX215-1002022
司
公
销 营
7
Fig. 4-20
● As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged.
● On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is sucked in. ● As central line (X) of swash plate (4) overlaps the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7)becomes 0.
F
● Suction and discharging of pressurized oil is not carried out in this state. Namely pumping action is not performed. (In reality, however, the swash plate angle is not set to 0)
E 4
Fig. 4-21
4-32
Shop Manual - April 2014
7
ZX215-1002023
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.3.5 Oil delivery control
13
16
F
● If swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and pump delivery (Q) increases. ● Piston (13) is used for changing swash plate angle (a). ● Piston (13) makes linear reciprocal movement under the control of the regulator.
a
● This linear motion is transmitted to swash plate (4) via drive pin (16). The sliding of the swash plate changes the swash plate angle and changes the displacement of the main pump.
E
In Ma t rk er n et a in ti o g n De al pt .
4
ZX215-1002024
Fig. 4-22
司
公
销 营
Shop Manual - April 2014
4-33
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.4 Pilot pump 435
433
710
700
354
351
434 310
355
311 312
In Ma t rk er n et a in ti o g n De al pt .
732
309
307
308
434
850
466
725
435
361
353
ZX215-1002025
Fig. 4-23
司
公
销 营
307: Valve stem 308: Valve base 309: Retainer 310: Spring 311: Adjusting screw 312: Nut 351: Body 353: Gear shaft 354: Gear shaft 355: Filter element
361: Body 433: Screw 434: Screw 435: screw 466: Plug 700: Washer 710: O-ring 725: O-ring 732: O-ring 850: Washer
Function The engine drives the main pump shaft and the pilot pump shaft through the gearbox. The pilot pump is operated through gear engagement.
4-34
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.5 Regulator 755
541
545 543
ൟো TYPE ᑣ߫ো SERIAL NUMBER
Pm E-E
E
铭牌 DETAIL OF STAMP FOR TYPE AND SERIAL NUMBER
601
E 642
753
467,727
F
B
496
757 413 438
656
F向
In Ma t rk er n et a in ti o g n De al pt .
D-D
418
079
439
646
438
D
司
公
销 营
D
B
722
543
755 545
755 438 466
541
724
C向
897
876
874
A
412 612
730
643
708
725
644
645
924 728
801
B-B
A-A
734 755 653 655 858 641
654 836 651 652
601
624
615 814
614
629
630 628 802
C
613 A
611 875
627 631
753
898
756
732
763
733 622
621
623
625
626
887 W365P130701
Fig. 4-24 Shop Manual - April 2014
4-35
Structure and Functions
Part name
Material
Quantity
Part code
Remark
—
Regulator
Alloy steel
1
412
Screw, socket head
Alloy steel
2
60150559
JIS B1176 M8-50
413
Screw, socket head
Alloy steel
2
60150560
JIS B1176 M8-70
418
Screw, socket head
Alloy steel
2
60150556
JIS B1176 M5-12
438
Screw, socket head
Alloy steel
10
60150557
JIS B1176 M6-20
439
Screw, socket head
Rolled steel
3
60150558
JIS B1176 M6-35
466
Plug
Rolled steel
1
60008724
G1/4
467
Plug
Carbon steel
1
60008507
G3/8×M8
496
Plug
Alloy steel
15
60008728
497
Plug
Alloy steel
4
Seat
Alloy steel
2
60008884
Stopper 1
Alloy steel
2
60008885
Steel ball
Bearing steel
2
Housing
Cast iron
1
60197213
Feedback rod block
Alloy steel
1
60075481
Lever（1）
Alloy steel
1
60008532
Lever（2）
Alloy steel
1
60008522
Pivot pin Compensation piston In-cavity piston
Carbon steel
1
60008533
Carbon steel
1
60008534
Alloy steel
1
60008535
Piston shell
Cast iron
1
60008536
Compensation piece
Alloy steel
1
60008524
Spring seat（C）
Alloy steel
1
60008494
Outer spring
Spring steel
1
Inner spring
Spring steel
1
60075415
Adjusting ring（C） Carbon steel
1
60008526
Adjusting bolt（C） Carbon steel Aluminum alCover（C） loy Locknut Rolled steel
1
60008497
1
60008529
1
60008537
1
60150553
543 545 601 611 612 613 614 615 621 622 623 624 625 626 627 628 629 630
In Ma t rk er n et a in ti o g n De al pt .
No.
541
631
PF sleeve
641
Guide cover
642
司
公
销 营
1
60008510
Valve stem
Cast iron Aluminum alloy Carbon steel
1
B229900001021
643
Guid piston
Alloy steel
1
60008520
644
Spring seat（Q）
Alloy steel
1
60008495
1
60197211
645 4-36
SY365(B)H-9 Crawler Hydraulic Excavator
Adjusting ring（Q） Carbon steel
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
No.
Part name
Material
Quantity
Part code
Remark
646
Guide spring
Spring steel
1
651
Sleeve
Alloy steel
1
60008503
652
Spool
Alloy steel
1
60008538
653
Spring seat
Carbon steel
1
60008539
654
Reset spring
Spring steel
1
60008541
655
Adjusting spring
Spring steel
1
60008540
656
Cover plate
Cast iron
1
60008548
708
O-ring seal
NBR
1
60008694
JISB 2401
722
O-ring seal
NBR
3
60008707
JISB 2401
724
O-ring seal
NBR
8
725
O-ring seal
NBR
1
60008696
JISB 2401
727
O-ring seal
NBR
1
60008700
JISB 2401
728
O-ring seal
NBR
1
60008702
JISB 2401
730
O-ring seal
NBR
1
60008704
JISB 2401
732
O-ring seal
NBR
1
60008701
JISB 2401
733
O-ring seal
NBR
1
60221603
JISB 2401
734
O-ring seal
NBR
1
60008692
JISB 2401
753
O-ring seal
NBR
2
60008709
JISB 2401
755
O-ring seal
NBR
5
60008697
JISB 2401
756
O-ring seal
NBR
1
60008706
JISB 2401
757
O-ring seal
NBR
1
60008698
JISB 2401
763
O-ring seal
NBR
1
60039416
JISB 2401
801
Nut, hexagon
Rolled steel
2
60150561
JIS B1181 RN-M8
802
Nut, hexagon
Rolled steel
1
60008506
M10
814
Collar
Tool steel
1
60009938
JIS B 2B04 SR-10
836
Collar
Tool steel
1
60008748
858
Collar
Tool steel
2
60009937
JIS B 2B04 RR-15
874
Pin
Bearing steel
1
60008734
Φ4×11.7L
875
Pin
Bearing steel
2
60008733
Φ4×8L
876
Pin
Bearing steel
2
60008735
Φ5×8L
887
Pin
Carbon steel
1
60008546
897
Pin
Bearing steel
1
60008736
Φ5×19L
898
Pin
Bearing steel
1
60150562
Φ8.5×10L
924
Screw, socket head Pressure-reducing solenoid valve
Alloy steel
1
60008743
1
60125194
2
60117792
In Ma t rk er n et a in ti o g n De al pt .
JISB 2401
079
041
Check valve block
司
公
销 营
Shop Manual - April 2014
4-37
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Operating principle ● The regulator controls the flow of the main pup through various pressure signal commands, keeping the pump’s driving power lower than the engine power
Psv
1
A
2
● Pump 1 and pump 2 are each equipped with a regulator. Primary components of the regulator are electromagnetic proportional pressure-reducing valve (1), electrohydraulic converter valve (2), variable power regulator (3), positive flow regulator (4), servo piston (5) and servo directional valve (6). The regulator opens or closes the oil passage of servo piston (5) according to various pressure signal commands, change the inclination of swash plate, and control the flow of pump as a result.
6
P2
5 3
a3
In Ma t rk er n et a in ti o g n De al pt . 4
B
W365P130702
Fig. 4-25
Components of control mechanism
Electric current flow control: when normal
司
公
销 营
By changing the value I of command current flowing to the electromagnetic proportional pressure reducing valve, the inclination angle (output flow) of pump can be controlled freely. This is a regulator featured with positive flow control (forward control), in which the output flow Q increases with the value I of command current. With such a device, when you input a current necessary for flow required by corresponding operation, the pump only delivers a flow as desired and no power will be wasted. Power control (+ power shift): For emergency (with rod pulled out)
● In case of emergency, the power shift command pressure Pf is used to change the value of power setting. The power shift command pressure (secondary pressure P2 of electromagnetic proportional pressure reducing valve) is introduced via in-pump passage to the power control component of each regulator and shifted to respective similar power setting value. ● When power shifting is being performed, the rising of self-pump output pressure Pd1 automatically reduces the inclination (output flow) of the pump. As a result, the input torque is limited under certain value. (In case of constant speed, the input power becomes constant too.) ●
When power control is exercised, regulator of each pump is controlled to the same inclination (output flow). Therefore, power control is performed irrelevant to the load of both pumps. Overload of prime mover is prevented as a result. In addition, the normal pressure for power shift is 0 MPa. So the power control is inactive in normal hours.
● With this mechanism, optimum power can be achieved in butting operation. Although the regulator has the two control mechanisms described above, each control in joint action can put small inclination (flow) command to priority via mechanical calculation. 4-38
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Regulator adjustment ● Adjusting the adjusting screws (953, 954) at the pump body side can obtain the minimum flow and the maximum flow. Power control characteristics can be changed by adjusting the screw (C) (628) and the wheel (C) (627) of this adjustor. The flow control characteristics can be achieved by adjusting the socket-headed setscrew (924).
806
532
548 531
808
954
In Ma t rk er n et a in ti o g n De al pt .
953
司
公
销 营
ZX335-1002014
Fig. 4-26
531: Inclination pin 532: Servo piston
548: Feedback pin 806: Retaining nut 808: Retaining nut
953: Adjusting screw (min. flow)
954: Adjusting screw (max. flow)
Shop Manual - April 2014
4-39
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Output flow Q
Maximum flow adjustment (pump body side) ● Loosen the hex nut (808). Tighten (or loosen) socket-headed setscrew (954). No control characteristics except the maximum flow changes.
Command current I
In Ma t rk er n et a in ti o g n De al pt .
W365P130703
Fig. 4-27
● Loosen the hex nut (806). Tighten (or loosen) the socket-headed setscrew (953). Though this action is the same as the adjustment of maximum flow and all the other control characteristics do not change, power required for maximum output pressure (at relief) is likely to increase if overtightened. Be careful in this case.
Output flow Q
Minimum flow adjustment (pump body side)
司
公
销 营
Command current I W365P130704
Fig. 4-28
Input power
Loosen the nut (630) and tighten or loosen the screw (C) (628) to perform adjustment. When screw (C) (628) is tightened, the control line, as shown in the right figure, moves rightward. The input power increases. Moreover, When the screw (C) (628) is turned by N turns, inner spring (626) also changes along with its setting. So turn the adjusting wheel (C) (627) in the opposite direction by N×A turns. (For value of A “Annexed Table: Regulator adjusting values” on page 4-47.)
Output flow Q
1) Adjustment of the outer spring
Output pressure (Pd1) W365P130705
Fig. 4-29 4-40
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
2) Adjustment of inner spring Output flow Q
After hex nut (802) is loosened, tighten (or loosen) the adjusting roller (C) (627) to carry out adjustment. When adjusting roller (C) (627) is being tightened, the flow (as shown) will increase and input power will also increase.
In Ma t rk er n et a in ti o g n De al pt .
Output pressure (Pd1) W365P130706
Fig. 4-30
Loosen the hex nut (801) and tighten (or loosen) the socket-headed setscrew (924) for adjustment. When the setscrew (924) is being tightened, The control lines will move rightward as shown by the illustration.
Output flow Q
Adjustment of flow control characteristics
司
公
销 营
Command current I W365P130707
Fig. 4-31
Flow control
As shown in the illustration on the right, the outflow of pump can be controlled indefinitely via feedback pressure value.
Pump displacement Q
Operating principle
Command current I W365P130708
Fig. 4-32 Shop Manual - April 2014
4-41
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Increasing the flow Port C1 connected with head end of servo piston
652 646 613
B 876
D
F 897
875 611
A
643 C
In Ma t rk er n et a in ti o g n De al pt .
When the negative feedback pressure Pi2 reduces, the pilot plunger (643) will move in direction A until a relative balance between P2 and the resilient force of the guide spring (646) is achieved. The movement of the pilot plunger is transmitted to lever (2) (613) via pin (875) and rotates towards the arrow direction with B as the pivot. The movement of lever (2) is transmitted to the feedback rod (611)via pin shaft (897) and rotates in the same direction of B with C as the pivot. Along with this, the spool (652) connected to the feedback rod moves towards direction D. The spool moving in direction D connects port C1 with the oil tank port, and the pressure inside the large diameter end of the servo piston is relieved. As a result, the output pressure Pd1 inside the small diameter end moves the servo piston (532) in direction E and flow is increased. Since the feedback rod is connected with the servo piston and the spool, movement of the servo piston in direction E makes the feedback rod rotate with F as the pivot. In this way, the spool is moved to the original position. Through this movement, the opening portion between the spool and the valve block is closed slowly. The servo piston stops moving when the opening portion is completely closed.
532
E
W365P130709
Fig. 4-33
Psv
A
司
公
销 营
Pz
P2
Pd1
a3
B
W365P130710
Fig. 4-34
4-42
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Decreasing the flow Port C1 connected with head end of servo piston
613
652
G
646 H 876
J
L
875
897
611 I
643
K
In Ma t rk er n et a in ti o g n De al pt .
When the negative feedback pressure Pi2 rises, the pilot plunger (643) will move in direction G until a relative balance between P2 and the resilient force of pilot spring (646) is achieved. The movement of pilot plunger is transmitted to the feedback rod (611) via pin (897) and rotates in the same direction as H with I as the pivot. Along with this, spool (652) connected to the feedback rod moves in direction J. If the spool moves in direction J, output pressure Pd1 enters the large diameter end of the servo piston through the spool and port C1. On the other hand, output pressure Pd1 enters the small diameter end of the servo piston. As a result of the area difference, the servo piston moves in direction K and the inclination is reduced, and the flow is also reduced. Since the feedback rod, the servo piston and the spool form a whole unit, when the servo piston is moving in direction K, the feedback rod rotates with L as the pivot. This makes the spool move to its original position. As a result, the opening portion between the spool and the valve block is slowly closed. The servo piston stops moving when the opening portion is completely closed.
532
W365P130711
Fig. 4-35
Psv
A
Pz
司
公
销 营
P2
Pd1
a3
B W365P130712
Fig. 4-36
Shop Manual - April 2014
4-43
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Power control (for emergency)
Output flow Q
● As shown in the illustration, when load pressure increases, pump inclination is reduced to prevent the overloading of the prime mover. ● The action of power control is the same as that of the flow control. The following is a brief description.
In Ma t rk er n et a in ti o g n De al pt .
Output pressure (Pd1) W365P130713
Fig. 4-37
司
公
销 营
4-44
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Action against overloading (For emergency)
897 R
625 876 N 612 626
Port C1 connected with head end of servo piston
652 6 P
875
M
623
621
611 O
In Ma t rk er n et a in ti o g n De al pt .
When the self pump output pressure Pd1 increases, the output pressure Pd1 is acted onto the ladder portion of the offset piston (621) , and as a result, the offset rod (623) moves in direction M until the output pressure Pd1 balances the elastic forces of outer spring (625) and inner spring (626). The movement of the offset rod is transmitted to the lever (1) (612) via pin (875) and rotate in the arrow direction with N as the pivot. Then, the movement of lever (1) is transmitted to feedback rod (611) via pin (897) and rotates in the same arrow direction as N with O as the pivot. Along with this, spool (652) which is connected to the feedback rod moves in direction P. If the spool moves in direction P, output pressure Pd1 enters the large diameter end of the servo piston through the spool and port C1. However, output pressure Pd1 enters the small diameter end of the servo piston, and as a result of the area difference, the servo piston moves in direction Q. The inclination is reduced as a result and the flow is also reduced. Since the feedback rod, the servo piston and the spool is a whole unit, when the servo piston is moving in direction Q, the feedback rod rotates with R as the pivot. This allows the spool to move to its original position. Through this movement, the opening portion between the spool and the valve block is slowly closed. The servo piston stops moving when the opening portion is completely closed.
Q
532
W365P130714
Fig. 4-38
Psv
A
司
公
销 营
P2
Pd1
a3
B W365P130715
Fig. 4-39
Shop Manual - April 2014
4-45
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Action of flow recovery (For emergency)
625 876 897 T 612 626 X
Port C1 connected with head end of servo piston
S
652
J 875 623
V 621
611 U
W
In Ma t rk er n et a in ti o g n De al pt .
When the self pump output pressure Pd1 drops, elastic force offset rod (623) of outer spring (625) and inner spring (626) moves in direction S to a point where the elastic force of the outer spring and the inner spring balances the output pressure Pd1. The movement of the offset rod (623) is transmitted to lever (1) (612) via pin (875) and rotates in the arrow direction with T as the pivot. Then, the movement of lever (1) is transmitted to feedback rod (611) via pin (897) and rotates in the same arrow direction as T with U as the pivot. Along with this, spool (652) which is connected to the feedback rod moves in direction V. If the spool is moving in direction V, port C1 is connected with the tank port, and the pressure inside the large diameter end of the servo piston is relieved as a result. Servo piston (532) moves in direction W through the output pressure Pd1 of the small diameter end. The flow is increased in this way. Since the feedback rod, the servo piston and the spool is a whole unit, if the servo piston is moving in direction W, the feedback rod will rotate with X as the pivot. This allows the spool to move to its original position. Through this movement, the opening portion between the spool and the valve block is slowly closed. The servo piston stops moving when the opening portion is completely closed.
532
W365P130716
Fig. 4-40
Psv
A
司
公
销 营
P2
Pd1
a3
B
W365P130717
Fig. 4-41
Prior mechanism of small inclination (small flow) command ● As described above, though the inclination command of delivery control and power control is transmitted to the feedback rod (611) and spool (652) via lever (2) (613) and the big diameter end of lever (1) (612) respectively, pin (φ5) on the big hole (φ9) , as a protrusive structure, only contacts with the rod and pin at the small inclination side. It does not contact with the rod φ9 and pin (897) on the large inclination side. Through this mechanical option, the inclination command of the delivery control and power control is placed in priority.
4-46
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Power shift control (power control reduction) Output flow Q
● As shown in the right diagram, the power of the pump can be set freely through power shift pressure Pf. ● If the power shift pressure Pf is increased, compensating rod (623) will be pushed to the right side via pin (898) and the offset piston (621). Through the same action as described in the power control overloading prevention, the power set value can be reduced by reducing pump inclination. On the contrary, the power set value can be increased by reducing the power shift pressure Pf.
In Ma t rk er n et a in ti o g n De al pt .
Output pressure (Pd1) ZX335-1002029
Fig. 4-42
● When the pump is under normal condition, the power shift pressure Pf is 0 MPa. In an emergency, the power shift pressure Pf is 4.9 MPa.
司
公
销 营
Annexed Table: Regulator adjusting values Model of regulator
KR3K-9T06-V
RPM (min-1)
2100
Adjusting screw (954) screw-in (rotation)
+1/4
Max flow regulation Min flow regulation
Adjustment of input horse power
Adjustment of outer spring
Adjustment of inner spring
Adjustment of flow control characteristics
Delivery change (l/min-1)
6
Adjusting screw (953) screw-in (rotation)
+1/4
Delivery change (l/min-1)
+4.8
Adjusting screw (928) screw-in (rotation) Compensation control initial pressure change (MPa) Input torque change (N·m)
+1/4
+50.8
A
1.87
Adjusting wheel (627) screw-in (rotation)
+1/4
Flow change (l/min-1)
+10
Input torque change (N·m)
+39
Adjusting screw (924) screw-in (rotation) Flow control initial current change (mA) (Secondary pressure of proportional valve) Delivery change (l/min-1)
Shop Manual - April 2014
+1.88
+1/4 Around 35mA （+0.18） -19.4
4-47
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.5 Hydraulic system, Part 2 4.5.1 Main control valve 4.5.1.1 Overview XBp2
XBa1 PaL,Dra CCk
(P3)
(PTb)
XBtr Px
XBtL
XBs
XAb1 BbR XBc BcR XAa2 BaR
Pns Dr4 XAb2 Dr2 (P4) (XBo) BoR Pna1,Dr3
In Ma t rk er n et a in ti o g n De al pt .
+
Dr3
Rs1
Pna1
CCo
Rs2
(R4)
XBp1
As Atr
CT2 CP2 Pns Btr
MR
Dr4 Bs
XAtr
ে㸠䍄
LCs
XAs CCb
ಲ䕀
XBb2
ࡼ㞖2
(XAo) (Ao) XBa1
OPTION
Dr3
Dra
᭫ᴚ1 PaL
ARC
HVa Aa (ROD) LCa Pra1
XAtr
司
公
销 营
XBa2
R1
Ba1 (HEAD)
Py
Bb (ROD)
XAs
BtL CP1 CT1 CMR1 CMR2 AtL
Ꮊ㸠䍄
LCb
PbL,Drb
ࡼ㞖1
LCk
(PTb) XBtr
XAc
N1
LCAP2
XAtL Ab (HEAD) XBb1 PAcs
䫆᭫
ࡼ㞖2
P1 CUT
XBp2
(PTa)
Ⳉ㒓㸠䍄
(PTb)
Pns XBtL Dr4 XBb2 AbR XAb1 (XAo) AoR XBc Dra Bc Dr3 (HEAD) Pna1 XAa2 PaL XBa1 AaR XBp1 (Ba2) (HEAD)
P2
XAa1
XBp1
XBp1
A向
Drb
XBs PbL LCb2 XBb1 XAb2 Hvb A AcR (Bo) (XBo) Dr1
LCo
(R2)
XAa1
(PTa)
XAtL
XBtr
XAa1
P2 CUT
Ac (ROD) XBa2 XBp2
LCAT2
N2
PG
R3
P2 Pns,Dr4
P1 PH
(PTa) XAtr W365V130701
Fig. 4-43 4-48
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
P1
: Pump port (P1 side)
PAcs : Pilot port, bucket (DIG) travel limit
P2
: Pump port (P2 side)
Pna1 : Pilot port, arm 1 logic control valve
Aa
: Rod end port, arm cylinder (OUT)
Pns
: Pilot port, swing logic control valve
Ba1
: Head end port, arm cylinder (IN)
PG
: Pilot pressure source port
(Ba2) : Head end port, arm cylinder (IN)
PH
: Pilot pressure source port
: Head end port, boom cylinder (UP)
Pz
: Pilot pressure for boosting main relief valve
Bb
: Rod end port, boom cylinder (DOWN)
PaL
: Pilot port, lock valve (arm rod end )
Ac
: Rod end port, bucket cylinder (DUMP)
PbL
: Pilot port, lock valve (boom head end)
Bc
: Head end port, bucket cylinder (DIG)
Px
: Signal port used for work equipment
Atr
: Motor port, right travel
Py
: Signal port used for travel
Btr
: Motor port, right travel
Drl
: Oil drain port
XAc
In Ma t rk er n et a in ti o g n De al pt .
Ab
: Pilot port, bucket (DUMP)
(P3)
XBc
: Pilot port, bucket (DIG)
(P4)
: Motor port, left travel
Dr2
: Oil drain port
: Motor port, left travel
Dr3
: Oil drain port
: Motor port, swing
Dr4
: Oil drain port
: Motor port, swing
Dra
: Oil drain port
: Pilot port, right travel
Drb
: Oil drain port
: Pilot port, right travel
R1
: Oil return port
(R2)
: Oil return port
R3
: Oil return port
: Pilot port, swing
Rs1
: Oil refi lling port
: Pilot port, swing
Rs2
: Oil refi lling port
XBb1 : Pilot port, boom 1 (DOWN)
(Ao)
: Backup port
XAb1 : Pilot port, boom 1 (UP)
(Bo)
: Backup port
XBb2 : Pilot port, boom confluence (DOWN)
(XAo) : (Backup pilot port)
XAb2 : Pilot port, boom confluence (UP)
(XBo) : (Backup pilot port)
XBa1 : Pilot port, arm 1 (IN)
(PTa)
XAa1 : Pilot port, arm 1 (OUT)
(PTb)
XBa2 : Pilot port, arm 2 (IN)
(N1)
XAa2 : Pilot port, arm 2 (OUT)
(N2)
AtL BtL As Bs XAtr XBtr
XAtL : Pilot port, left travel XBtL : Pilot port, left travel XAs XBs
司
公
销 营
XBp1 : Pilot port, bypass stop valve spool (P1 side)
(R4)
XBp2 : Pilot port, bypass stop valve spool (P2 side)
Shop Manual - April 2014
4-49
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.5.1.2 Main valve structure B
A
XBp2
XBa1
N Right travel Py
C
Pns
Left travel
252
D
PbL
N
Swing Drb
102
Boom 1 P
273×4
+ (P3)
CCk
(P4)
Boom 2
P
991 992×2
D
Dr4
AbR Hvb
Rs1
E
AoR
CCo
Backup
Bucket
In Ma t rk er n et a in ti o g n De al pt .
E
101
Pz
C
PaL,Dra
M
971×6
C
MR
Straight travel
Q
AcR
F
Dra
Dr1
211
Arm 1
Arm 2
PaL
G
AaR
P2 stop
XBp2
H
Q
Pna1
G
252 103
PG
J
XBtr
L-L
L
PG
Direction J
167 151 541 542 554
司
销 营
XAa1
XBp1
351 152 168 公
R3
M
H
A
971×6
(R4)
Arm regeneration stop
B
(PTb)
Rs2
F
Dr3
Dra
PaL
167 151
151 167
166 543 151 167
Q-Q
L
515 521 551
P2
CCk
561 169 153 CCo 551 561 521 515
P1
A
PH
167 151
PbL Drb
MR Pz (PTa)
XAtr N-N
M-M P-P
W365V130704
Fig. 4-44
4-50
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
351
168 169 153
152 PH
PG
P2
XBtr
XAtr 271×2
271×2 XBs
XAs 271×2
271×2 XAb2
XBb2
271×2
271×2
(XBo)
In Ma t rk er n et a in ti o g n De al pt .
(XAo)
341 168
271×2
XAa1
XBa1
271×2
271×2
(R2)
153
(P4) 169 A-A
Rs1
Rs2
司
公
销 营
R3
P1
271×2 (PTb)
271×2
271×2
271×2
(PTa)
XBtL
XAtL
271×2
271×2
XBb1
XAb1
271×2
271×2
XBc
271×2 XAa2
271×2
272×2
272×2
XBa2
XBp2
XBp1
162
162 561 551
561 551 163 B-B W365V130705
Fig. 4-45
Shop Manual - April 2014
4-51
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
153 169 201 336 332 372 337 332 261 601 308 512 522 552 562 512 522
Right travel
（Pta）
XAtr
MR Py
301 511
CMR2
Atr
CMR1
CT2 CP2
521 551 561 561 551 521 511
In Ma t rk er n et a in ti o g n De al pt .
552 562 561 551
Straight travel
201 336 332 373 337 332 261
CT1
Btr
521 511
Px
263 203 169 153
XBtr
(PTb)
263 203
Section C-C 司
公
销 营
201 336 332 373 337 332 261 301 166 165 163
511 521
Left travel
Swing
XAtL
XAs
201 336 332 371 337 332 261 305 162
166
AtL
As
LCs
CP1
551 561 165 161
263 203
Pns
Bs
BtL
166 XBtL Section D-D
XBs
256 254
263 203
W365V130705
Fig. 4-46 4-52
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
201 336 332 373 337 332 261
Boom 1
511 521
XBb2 AbR
307
Hvb
165 163
Ab CCb
LCb
Lcb2
551 561 561
In Ma t rk er n et a in ti o g n De al pt .
551
Boom 2
XBb1
553 561 523 513 303
201 336 332 371 337 332 602 261
551 521
561
Bb
511
Dr2
602
BbR
XAb1
263 203
XAb2
263 203
Section E-E
555 563 204 342 336 332 371 337 332 261 602 304
153 169 201 336 332 371 337 332 261
司
公
销 营
Bucket
Backup
XBa2
(XAo)
PAcs
XAc AcR
166
162 164 165 163 511 521 551 561 164 161
309 605
AoR
275×4
(Ao)
Ac
LCk
264 213 511 521
LCo
551 561 264 （Bo） 213
Bc
275×4
605
166
602 BcR
XBc
BoR (XBo)
263
Section F-F
203 169 153
263 203
W365V130706
Fig. 4-47 Shop Manual - April 2014
4-53
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
201 336 332 375 337 332 261 306
Arm 2
201 336 332 371 337 332 261
Arm 1 XBa1
XBa2
302
Dra
Dr1 511 521 561 551
167 151 561 553 Hv6 LCa
523 513 Pna1
In Ma t rk er n et a in ti o g n De al pt .
276×4 LCAT2 285 266 214 531 522 514 Ba2 153 169 275×4 214 264 602 263 203 152 168 202 333 331 324 323 334 331 262 551 561
Ba1
BaR
255 253
261
XAa2
205
XAa1
司
公
销 营
Section G-G
P2 stop
Arm regeneration stop
XBp2
257 602
AaR
169 153
Aa
CCk
(N2)
310 310
CCo
R1
(N1)
153 169 561 551 262 331 334 323 324 331 333 202
(R2) 267 XBp1 P1 stop
Section H-H
Fig. 4-48 4-54
215 277×4
Shop Manual - April 2014
W365V130707
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Torque （N.m）
Part name
Qty
101 102 103
Valve body A Valve body B Valve body C
1 1 1
151
Oil plug
6
13~17
308
152 153 161 162 163 164 165 166 167 168 169 201 202 203 204 205 211 213 214
Oil plug Oil plug O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal Spring cap Spring cap Spool cap Spring cap Spool cap Plate Flange Check valve plate Pipeless opening cover plate Pipeless opening cover plate Lock valve selector GP Logic valve component, arm 1 Logic valve component, swing Logic control valve Stop valve GP, arm regeneration O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal Bolt, socket head Bolt, socket head Bolt, socket head Bolt, socket head Bolt, socket head Bolt, socket head Travel spool Spool GP, arm 1 Spool GP, boom 1 Bucket spool
2 10 4 6 9 2 4 12 6 3 10 9 2 9 1 1 1 2 1
34~39 69~78
275 216 252 253 254 255 257 261 262 263 264 265 266 267 271 272 273 275 276 277 301 302 303 304
No.
Part name
Qty
305 306 307
1 1 1
309 310 323 324 331 332 333 334 336 337 341 342 351 371 372 375 511 512 513
Swing spool Spool, arm 2 Spool, boom 2 Spool AS, straight travel Backup Spool, bypass stop Spring Spring Spring seat Spring seat Bolt with washer Stopper Bolt with washer Stopper Oil plug Piston 节流塞（φ0.7） Spring Spring Spring Cone valve Cone valve Cone valve
1 2 2 2 4 20 2 2 10 10 1 1 3 8 1 1 10 2 2
1
514
Cone valve
1
1
515
Cone valve
2
521
Spring
12
1
522
Spring
3
1
523
Spring
2
2
司
公
销 营
9.8~14
2
52~62
531
Spring seat
1
1
120~140
541
Steel ball
1
542 543 551 552 553 554 555 561 562 563 601 602 605 971 991 992
Spring seat Spring Oil plug Oil plug Oil plug Oil plug Oil plug O-ring seal O-ring seal O-ring seal Main relief valve Port relief valve Port relief valve Bolt, socket head Nameplate Rivet
1 1 17 2 2 1 1 19 2 1 1 6 2 12 1 2
11 2 9 3 1 1 1 40 4 4 12 4 4 2 1 1 1
52~62 25~34 210~260 140~180 25~34 83~110
Shop Manual - April 2014
Torque （N.m）
1
In Ma t rk er n et a in ti o g n De al pt .
No.
16~18 37~41 34~39 7.8~9.8
370~410 230~260 370~410 25~29 220~260
120~140 120~140 120~140 390~470
4-55
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.5.2 Hydraulic circuit (With bucket confluence function)
Travel (R)
Straight travel
In Ma t rk er n et a in ti o g n De al pt .
Travel (L)
Swing
Boom 1
Boom 2
司
公
销 营
Bucket
Backup
Arm 2
Arm 1
Bypass stop
W365V130703
Fig. 4-49 4-56
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Operating principle 1) When spool is neutral position (Main circuit) ● When all spools are in neutral position, the working oil from (front) hydraulic pump enters the pump port P1, is guided to the main oil passage (1), and returns to the oil tank via the return ports R1 and R3 by passing through the neutral bypass (2) (function of neutral M-shaped spool) of each spool in straight travel (308), left travel (301), boom 1 (303), bucket (304) and arm 2 (306).
In Ma t rk er n et a in ti o g n De al pt .
● The working oil from (rear) hydraulic pump enters the pump port P2, is guided to the main oil passage (3), and returns to the oil tank via the return ports R1 and R3 by passing through the neutral bypass (4) (function of neutral M-shaped spool) of each spool in right travel (301), swing (305), boom 2 (307), backup (309) and arm 1 (302).
司
公
销 营
Shop Manual - April 2014
4-57
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
R3
(1)
P1
(2) (PTb)
(PTa)
XBtL
XAtL
XAb1
XBb1
In Ma t rk er n et a in ti o g n De al pt .
XBc
XAa2
XBa2
XBp1
XBp2
司
公
销 营
(p3)
PH
P2
PG
(3)
(4)
XAtr
XBtr
XAs
XBs
XBb2
XAb2
(XAo)
(XBo)
XBa1
(R2)
(p4)
Rs1
Fig. 4-50 4-58
Shop Manual - April 2014
Rs2
WJV3651305
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
2) Travel (Pilot circuit) ● When switched to left travel spool or right travel spool, the side oil passage closes and the pressure in port Py (travel signal port) rises. (Main circuit) ● When pressure is present in pilot port XBtL used for left travel spool (301), the neutral bypass (2) at the side of boom 1 closes. The working oil fed from (front) hydraulic pump is delivered through port BtL to the left travel motor.
In Ma t rk er n et a in ti o g n De al pt .
● Likewise, when pressure is present in pilot port XBtr used for right travel spool (301), the neutral bypass (2) at the side of arm 1 closes. The working oil fed from (rear) hydraulic pump is delivered through port Btr to the right travel motor. ● On the other hand, the oil returning from both the left and right travel motors via port AtL (Atr) passes the left (right) travel spool and goes back to the oil tank via return ports R1 and R3. ● When operating travel in the opposite side (pressurizing the pilot ports XAtr and XAtL), the above principle also applies.
司
公
销 营
XAtL
AtL
XBtL
BtL
Travel motor WJV3651306
Fig. 4-51
Shop Manual - April 2014
4-59
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3) Arm Arm-out operation (Pilot circuit) ● When switched to the arm 2 spool (302), the side oil passage closes and the pressure in port Px (work equipment signal port) rises. (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When performing the arm-out operation, the pilot oil is fed to port XAa1 and port XAa2. When pilot oil is delivered to the two sides of port XAa1 and port XAa2, arm 1 spool and arm 2 spool are switched to the left, as shown in Fig. 4-52. As a result, the working oil from port P2 is introduced into the neutral bypass (4) via the main passage (3). The neutral bypass is cut off by switching the arm 1 spool (302). Therefore, the working oil in the parallel passage pushes open the cone valve (253) of the logic valve, and enters the arm 1 spool (302) via the U passage. The oil from arm 1 spool (302) is then delivered to the rod end (R) of arm cylinder. ● On the other hand, the working oil coming from port P1 is guided to the neutral bypass (2) via the main oil passage (1). The neutral bypass is cut off by switching the arm 2 spool (306). Therefore, the working oil in the parallel passage pushes open the cone valve (514) of logic valve, and working oil from neutral bypass pushes open the cone valve (511) of the check valve and flows into the arm 2 spool (306) via the U passage. The oil then comes into confluence with oil from port Aa in the passage of neutral bypass (306) and is fed to the rod end (R) of the arm cylinder. 司
公
销 营
● Return oil from the arm cylinder head end (H) via port BaI flows respective tank circuits of arm 1 and arm 2, and returns to working oil tank via tank ports R1 and R3.
4-60
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
511
514
(Ba2)
LCAT2
BaR
Dr1 XBa2
In Ma t rk er n et a in ti o g n De al pt .
XAa2
XBa1
Dra
XAa1
司
公
销 营
LCa
Aa
Ba1
253
Pna1
R
H WJV3651307
Fig. 4-52
Shop Manual - April 2014
4-61
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Arm-in operation (Pilot circuit) ● When switched to the arm 1 spool (302), the side oil passage closes and the pressure in port Px (work equipment signal port) rises. Pressurized oil is fed to the port PaL at the same time. Relief signal is sent to the lock valve selector GP (252). (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When performing the arm-in operation, pilot oil is fed to ports XBa1 and XBa2. When pilot oil is delivered to the two sides of port XBa1 and port XBa2, arm 1 spool and arm 2 spool are switched to the right as shown in Fig. 4-53. As a result, working oil from P2 is guided to the neutral bypass (4) via the main passage (3). The neutral bypass is cut off by switching arm 1 spool (302). Therefore, the working oil in the parallel passage pushes open the cone valve (253) of the check valve and flows to the arm 1 spool (302) via the U passage. Then, it flows to the periphery of arm 1 spool (302) and is delivered to the arm cylinder head end (H) via port Ba. ● On the one hand, the working oil from port P1 is guided to the neutral bypass (2) via the main passage (1). The neutral bypass is cut off by switching the arm 2 spool (306). Therefore, the working oil in the parallel passage pushes open the cone valve (514) of the arm 2 check valve, and the working oil from neutral bypass pushes open the cone valve (511) of the check valve and flows to the arm 2 spool (306) via the U passage. Then, it comes into confluence with oil from port BaI in the internal passage of arm 2 spool (306). 司
公
销 营
● On the other hand, the oil returning from the arm cylinder rod end (R) and the working oil whose pressure rises due to the dead weight of arm goes back to the port Aa. The working oil returned to the port Aa flows into the valve spool via the holes (a) on the periphery of arm 1 spool (302), pushes open the cone valve (302-317) only under light load, and comes into confluence in the peripheral holes with oil from port BaI. ● If the pressure at the arm cylinder head end and in the U passage rises, arm regeneration check valve spool (257-103) switches to the left, as shown in Fig. 4-54, and closes due to the back pressure of the cone valve (302-317) in the spool. In this way, the arm regeneration function is deactivated and return oil from the arm cylinder rod end (R) flows to the spool via the hole (a) on the periphery of arm 1 spool (302). Then, it flows into arm regeneration stop valve (257) via hole (c) on the periphery of arm 1 spool (302), and returns to the working oil tank via tank ports R1 and R3.
4-62
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Light load
(Ba2) LCAT2
BaR
Dr1
XAa2
In Ma t rk er n et a in ti o g n De al pt .
XBa2
(302-317)
(a)
XBa1
XAa1
(b)
Dra
司
公
销 营
Aa
LCa
Ba1
Pna1
Arm dead weight
R
H WJV3651308
Fig. 4-53
Shop Manual - April 2014
4-63
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● When pressure in arm cylinder head end (H) rises
(Ba2) LCAT2
BaR
Dr1 XBa2
In Ma t rk er n et a in ti o g n De al pt .
XAa2
(a)
(302-317)
(c)
XBa1
XAa1
司
公
销 营
Dra
LCa
Aa
Ba1
Pna1
(257-103)
R
H WJV3651309
Fig. 4-54
4-64
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4) Boom Boom-up operation (Pilot circuit) ● When switched to the boom 1 spool (307), the side passage is closed and the pressure in port Px (work equipment signal port) rises. (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When boom-up operation is performed, the pilot oil is fed to port XAb1 and boom 1 spool (303) moves to the left as shown in Fig. 4-55. The working oil from port P1 is introduced to the neutral bypass (2) via the main passage (1). The neutral bypass is cut off by switching boom 1 spool (303). In this way, the working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows to the boom 1 spool (303) via the U passage. It then flows to the periphery of boom 1 spool (303) and is delivered to the boom cylinder head end (H) via port Ab. ● At the same time, the pilot oil is also fed to port XAb2 and boom 2 spool (307) moves to the left as shown in Fig. 4-55. The working oil from P2 flows the parallel passage. As the switching boom 2 spool (307) cuts off the neutral bypass, the working in the parallel passage flows into boom 2 spool (307) via the U passage. The oil then pushes open the cone valve (511) of the check valve, comes into confluence with the oil from port Ab, and is fed to the boom cylinder head end (H). (This is called the boom confluence function.) 司
公
销 营
● On the other hand, the oil flows to the periphery of boom 1 spool (303) via port Bb from oil return side of the boom cylinder rod end (R) and goes back to the working oil tank via the ports R1 and R3.
Shop Manual - April 2014
4-65
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
H
R
511
In Ma t rk er n et a in ti o g n De al pt .
513
LCb
Ab
Bb
BaR
司
公
销 营
XBb1
XBb2
XAb1
XAb2
Dr2
AbR
511
511
WJV3651310
Fig. 4-55
4-66
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Boom-down operation (Pilot circuit) ● When switched to the boom 1 spool (303), the side passage is closed and the pressure in port Px (work equipment signal port) rises. Pressurized oil is fed to the port PbL at the same time. Relief signal is sent to the lock valve selector GP (252). (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When boom-down operation is performed, the pilot oil is fed to port XBb1 and boom 1 spool (303) moves to the right as shown in Fig. 4-56. The working oil from port P1 is introduced to the neutral bypass (2) via the main passage (1). The neutral bypass is cut off by switching boom 1 spool (303). In this way, the working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows to the boom 1 spool (303) via the U passage. It then flows to the periphery of boom 1 spool (303) and is delivered to the boom cylinder rod end (R) via port Bb. ● On the other hand, the oil returning from the head end (H) of boom cylinder flows to the hole (a) and periphery of boom 1 spool (303). ● The pressure of return oil rises due to the dead weight of boom. To maintain sufficient pressure, with the help of the oil passage inside the spool, the cone valve (303-317) in spool is pushed to the right, as shown in Fig. 4-56, and the oil flows out of the spool. As the working oil for boom-down operation, the pressurized oil is again delivered to the boom cylinder rod end (R) (which is called boom regeneration function). The return oil entering the internal passage of spool via the hole (a) partially goes back to the oil tank via the hole (b). 司
公
销 营
H
R
513
511
LCb
Ab
Bb
BbR
XAb1
XBb1
(b)
(a)
(303-317)
WJV3651311
Fig. 4-56
Shop Manual - April 2014
4-67
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
5) Bucket Bucket-dig operation (Pilot circuit) ● When switched to the bucket spool (304), the side passage is closed and the pressure in port Px (work equipment signal port) rises. The pressure oil is fed to port XBp2 at the same time. (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When bucket-dig operation is performed, the pilot oil is fed to the port XBc and the bucket spool (304) moves to the left as shown in Fig. 4-57. The working oil from port P1 is guided to the neutral bypass (2) via main passage (1). As the neutral bypass is cut off by switching bucket spool (304), the working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows to the bucket spool (304) via the U passage. It then flows to the periphery of bucket spool (304) and is fed to the bucket cylinder head end (H) via port Bc. ● On the other hand, return oil from the bucket cylinder rod end (R) flows in via port Ac. It then goes back to the oil tank via the ports R1 and R3 from the periphery of spool. ● When boom-up and bucket-dig operations are performed at the same time, the pilot oil is led to the port PAcs. Therefore, the travel of bucket spool is not restricted to the end, but can be held in a position on the way. As a result, bucket cylinder passage is throttled and working oil flows to boom 1 spool (303) via bucket spool (304). In this way, boom-up operation have the priority. 司
公
销 营
H
R
511
AC
LCk
AcR
PAcs
Bc
BcR
XAc
XBc
Confluence
Fig. 4-57
4-68
Shop Manual - April 2014
WJV3651312
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Bucket-dump operation (Pilot circuit) ● When switched to the bucket spool (304), the side passage is closed and the pressure in port Px (work equipment signal port) rises. The pilot oil is also fed to the port XBp2 at the same time. (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When bucket-dump operation is performed, the pilot oil is fed to the port XAc and bucket spool (304) moves to the right as shown in Fig. 4-58. The working oil from port P1 is led to the neutral bypass (2) via the main passage (1). The neutral bypass is cut off by switching bucket spool (304). Therefore, the working oil in the parallel passage pushes open the cone valve (511) of the check valve and flows to the bucket spool (304) via the U passage. It then flows to the periphery of bucket spool (304) and is fed to the bucket cylinder rod end (R) via the port Ac. ● On the other hand, return oil from the bucket cylinder head end (H) enters via the port Bc, passes the spool periphery of spool, and goes back to working oil tank via the ports R1 and R2.
H
R
司
公
销 营
511
LCk
Ac
Bc
AcR
XAc
BcR
PAcs
Confluence
XBc
WJV3651313
Fig. 4-58 Bucket confluence ● When bucket-dig or -dump operation is performed, the pilot oil is fed to the port XBp2 and the neutral bypass stop valve spool (310) is switched. Working oil from port P2 is led to the neutral bypass (4) via the main passage (3). The neutral bypass is cut off by switching neutral bypass valve spool (310). Therefore, working oil pushes open the check valve (515) and comes into confluence with bucket spool (304) via the internal passage and the U passage. Shop Manual - April 2014
4-69
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
6) Swing When swing operation performed separately (Pilot circuit) ● When switched to the swing spool (305), the side passage is closed and the pressure in the port Px (work equipment signal port) rises. (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When swing is operated separately, the pilot oil is fed to the port XAs (or XBs) and swing spool (305) is switched. Working oil from port P2 is led to the neutral bypass (4) via the main passage (3). Neutral bypass is cut off by switching swing spool (305). Therefore, working oil in the parallel passage pushes open the logic cone valve (254-101) of the swing logic component and flows to the swing spool (305) via the U passage. It then flows to the periphery of swing spool (305) and is delivered to the swing motor via port As (or Bs). ● On the other hand, return oil from the swing motor flows in via port Bs (or port As). Then, it flows into tank ports R1 and R2 from the periphery of spool and goes back to the working oil tank. Swing motor 司
公
销 营
Pns
As
LCs
Bs
(254-101)
XAs
XBs
WJV3651314
Fig. 4-59
4-70
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
7) Priority function ● This function enables the working oil from port P to be sufficiently allocated to the work equipment under higher load in order to improve the operability when the arm-in operation is performed along with swinging operation. ● The following shows the priority of swinging operation relative to the arm-in operation. (Main circuit) ● When pressure oil is applied to the port Pna1 of the logic control valve (255), the piston (255356) and spool (253-107) move upward. The lifting distance of cone valve (253-101) is limited.
XBa1
In Ma t rk er n et a in ti o g n De al pt .
● In this way, the passage from the parallel passage to the U passage is throttle. As a result, oil from the arm 1 spool has the priority to go to the swing spool, giving the priority to the boomup operation.
XAa1
司
公
销 营
LCa
Aa
Ba1
(253-101)
(253-107)
Pna1
(255)
(255-356
WJV3651315
Fig. 4-60
Shop Manual - April 2014
4-71
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
8) Backup The backup spool is used to control attachment such as hydraulic shear. Backup operation (Pilot circuit) ● When switched to the backup spool (309), the side passage is closed and the pressure in port Px (work equipment signal port) rises. (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When the backup is operated, the pilot oil is fed to the port XAo (or XBo) and the backup spool (309) is switched. Working oil from port P2 is fed to the neutral bypass (4) via the main passage (3). Neutral bypass is cut off by switching backup spool (309). Therefore, working oil in the parallel passage pushes open the cone valve (511) of the check valve and flows to the backup spool (309) via the U passage. Then, it flows into the periphery of backup spool (309) and is supplied into the attachment via port Ao (or Bo). ● On the other hand, return oil from the attachment flows in via port Bo (or port Ao). Then, it flows into tank ports R1 and R2 from the spool periphery and returns to the working oil tank. R
H
司
公
销 营
511
Ao
LCo
Bo
BoR
XAo
XBo
Confluence
WJV3651316
Fig. 4-61 Backup confluence To achieve backup confluence, pilot oil is also fed to port XBp1 and the bypass stop valve spool (310) is switched. Working oil from port P1 is introduced into neutral bypass (2) via main passage (1). Neutral bypass is cut off by switching bypass valve spool (310). Therefore, working oil pushes open the cone valve (515) of check valve and comes into confluence with backup spool (309) via the internal passage and the U passage. 4-72
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
9) Straight travel When travel spool (301) is operated along with other spools at the same time. The following case shows when travel spool (301) and swing spool (305) are operated at the same time. (When pilot oil is delivered to the ports XAtL, XAtr and Xas) (Pilot circuit) ● Close the side passage of right/left travel spool (301) and the downstream side passage of swing spool (305). Pilot oil from port PG is fed to port PTa in order to switch the straight travel spool (308). (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When straight travel spool (308) is switched, the port P2 and the right/left travel spool (301) are interconnected through for priority. The port 1 and the parallel passage of swing - boom 2 - backup - arm 1 oil circuit / boom 1 - bucket/ - arm 2 circuit are interconnected through for priority. Therefore, the working oil from port P2 is mainly delivered to the ports Atl and Atr and distributed evenly to the two travel motors. ● On the other hand, the working oil from port P1 is delivered to the swing motor via port As. ● When oil pressure in the port P2 is lower than that in the port P1, the working oil form port P1 will be partially delivered to the port P2. In this way, sudden drop of travel speed can be prevented. 司
公
销 营
P1
R3
P2
(PTa)
XAtL
(PTb)
XBtL
WJV3651317
Fig. 4-62
Shop Manual - April 2014
4-73
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
10) Function of lockout valve The lockout valve selector module (252) is mounted between the arm cylinder rod end (R) and the arm 2 spool (302) and arm 2 spool (306). It is used to reduce the internal leakage of the spool due to cylinder pressure. Likewise, lockout valve selector module (252) is also mounted between the boom cylinder head end (H) and the arm 1 spool (303) and boom 2 spool (307) to reduce the internal leakage of he spool due to cylinder pressure. The figure below shows the case of boom cylinder head end (H). (Similar case applies to the arm cylinder rod end (R).) Spool in neutral position
In Ma t rk er n et a in ti o g n De al pt .
● When boom 1 spool (303) and boom 2 spool (307) are in a neutral position, the spool (252-511) inside the lockout valve selector module is pressed against the seat of the body (252-101) of the lockout valve selector module, as shown in Fig. 4-63, by the preload of spring (252-512). ● In this position, working oil in the boom cylinder head end (H) flows in via hole (a) and flows out from hole (b) through the periphery of the lockout valve selector module spool (252-511), pressing the cone valve (513) against the seat of the valve block via hole (b). By this means, oil leakage is reduced. (252-512)
司
公
销 营
(252-511)
Drb
(b)
(252-101)
(a)
PbL
513
Ab
LCb
Bb
(RH)
BbR
XBb1
XAb1
WJV3651318
Fig. 4-63
4-74
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Boom-down operation In boom-down operation the pilot oil is fed to the ports PbL, XBb1 and XBb2. Spool (252-511) inside the lockout valve selector module is pushed to the top by the pilot oil as shown in Fig. 4-64. Due to the movement of spool (252-511) inside the lockout valve selector module, hole (a) is cut off and working oil from boom cylinder head end (H) does not go to spring chamber (RH). In addition, oil in the spring chamber (RH) enters the oil leak circuit via the hole (b). In this way, the cone valve (513) is pushed open by the pressure in boom cylinder head end (H) and the function of the lockout valve selector module (252) is deactivated.
In Ma t rk er n et a in ti o g n De al pt .
(252-512)
Drb
(252-511)
(b)
(252-101)
(a)
511
513
PbL
司
公
销 营
Ab
LCb
Bb
(RH)
XBb1
BbR
XAb1
WJV3651319
Fig. 4-64 Boom-up operation In boom-up operation the pilot oil is fed to the ports XAb1 and XAb2. The cone valve (513) is pushed open by the oil from boom 1 spool (303) and boom 2 spool (307). The working oil goes to the port Ab as a result.
Shop Manual - April 2014
4-75
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
11) Function of main relief valve The main relief valve is mounted on the valve block A (101). It has the following functions: ● Working oil fulfils the cavity (a) through the hole in valve post housing (601-101) and valve post (601-511). The valve post (601-511) is therefore pressed against the housing (601-101). Reliable sealing has formed as a result. ● When pressure in passage (P) exceeds the preload of spring (601-521), the cone valve (611) opens. Therefore, the working oil passes through the gap between the housing (601-101) and valve pocket (601-102) from the periphery of cone valve (601-401) and goes to the low pressure passage (R).
In Ma t rk er n et a in ti o g n De al pt .
● Opening of cone valve (601-401) causes pressure drop in cavity (a). So the valve post (601511) is opened. In this way, working oil in passage (P) flows to the low pressure passage (R) directly. ● When pressure oil higher than 3MPa is fed to the port Pz, it pushes plunger (601-302) to the left. The preload of spring (601-512) increases as a result and pressure boosts at the moment.
(601-101)
(601-401)
(601-512)
(601-102)
司
公
销 营
P
R
(601-511)
(a)
(601-302)
Pz
WJV3651320
Fig. 4-65
4-76
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
12) Function of port relief valve The port relief valve, mounted between the oil tank port and low pressure passage, can prevent cavitation as an oil compensation check valve except working as a port relief valve. Functions of the valve are given below: Functioning as a relief valve ● Working oil fulfils into cavity (B) via the hole (A) on plunger (301). Valve post (511) is pressed against valve seat (541), and valve seat (541) is pressed onto the seat of the valve block, forming a reliable sealing. (B)
541
In Ma t rk er n et a in ti o g n De al pt .
(A)
P
R
司
公
销 营
301
511
WJV3651321
Fig. 4-66
● When pressure in passage (P) exceeds the preload of spring (621), cone valve (611) is pushed open. Therefore, working oil flows through hole (C) via the periphery of cone valve (611) and enters the low pressure passage (R).
(C)
P
R 611
621 WJV3651322
Fig. 4-67 Shop Manual - April 2014
4-77
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Opening of cone valve (611) causes pressure in cavity (B) to drop and valve post (511) is opened. In this way, working oil in passage (P) goes to the low pressure passage (R) directly.
(B)
In Ma t rk er n et a in ti o g n De al pt .
P
R
511
611
WJV3651323
Fig. 4-68
司
公
销 营
Functioning as oil complement check valve against cavitation
When negative pressure is formed in passage (P), working oil is fed from passage (R). When pressure in passage (R) exceeds the pressure in passage (P), valve seat (541) moves to the right direction. Therefore, working oil is delivered from passage (R) to passage (P) via the periphery of valve seat (541). Cavitation is prevented as a result.
P
R
541 WJV3651324
Fig. 4-69
4-78
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6 Hydraulic System, Part 3 4.6.1 Swing motor
In Ma t rk er n et a in ti o g n De al pt .
Type: M5X180CHB-10A-3NA/265
L
SH
PG
PB
B
IP
PA
A
司
公
销 营
M
1
DB
2
ZX215-1002081
Fig. 4-70
A: Main oil port B: Main oil port M: Makeup port PA: Pressure detection port PB: Pressure detection port DB: Lubricant port PG: Brake release port SH: Brake command port L: Level stick IP: Gear oil feed port (1) Safety valve (2) Anti-swing valve
Specifications
Model Theoretical displacement Safety valve press. setting Max swing speed Brake release pressure
Shop Manual - April 2014
M5X180CHB-10A-3NA/265 180.1 cm3/rev 26.0 MPa 1470 rpm 2.7-4.9 MPa
4-79
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
7
In Ma t rk er n et a in ti o g n De al pt .
6
A-A
A
8
9
5
A
司
公
销 营
4
10
11
3
12
2
13
1
ZX215-1002082
Fig. 4-71 (1) (2) (3) (4) (5) (6) (7)
Spacer Housing Disc Brake spring Shell Spring Check valve
4-80
(8) Oil distributor (9) Cylinder barrel (10) Brake piston (11) Plate (12) Piston (13) Drive shaft
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.2 Swing holding brake ● Port PG is directly connected with the pilot gear pump and it is always under a pressure of 3.9MPa.
M a
Pump
1 Main valve
7
PX
PG
In Ma t rk er n et a in ti o g n De al pt .
6
SH
5
ZX215-1002083
Fig. 4-72
● Port SH is in connection with port (PX) of the main control valve. In case of any operation (except travel) is performed by the main control valve, Port (PX) will be put under pressure. This pressure establishes connection between PG and chamber (a) below piston (7). The pressurized oil pushes the brake piston upward to compress spring (1) and separate disc (5) from plate (6). The brake is released. 司
公
销 营
M
a
Pump
1
Main valve
7
PX
PG
6
SH 5
ZX215-1002084
Fig. 4-73 ● Otherwise, without pressure acting upon the port (PX), the connection between (PG) and chamber (a) below piston (7) is blocked. Brake spring (1) pushes the brake piston to press disc (5) against plate (6). The brake is engaged. Shop Manual - April 2014
4-81
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.3 Relief valve section Structure ● The relief valve section consists of relief valves (1) and (2) and check valves (3) and (4). Function ● When the machine is in the swing holding mode, control valve (5) closes the motor outlet circuit, but the motor rotation is continued due to inertial force. The motor output is, therefore, abnormally increased, which could damage the motor.
In Ma t rk er n et a in ti o g n De al pt .
● In order to prevent the motor from being damaged, the relief valve relieves the abnormally high pressure oil to port (M) from the outlet side (high-pressure side) of the motor. Operating principle
From oil port M
1
1. When starting swing (suppose pressurized oil is delivered to port A)
2
● When the swing control lever is set to the right- swing, pressurized oil from the pump is delivered to port (A) via control valve (5).
● The pressure at port (A) rises, the starting torque is generated in the motor, and the motor starts to rotate.
司
公
销 营
3
● The pressurized oil from the outlet port of the motor passes from port (B) through the control valve (5) and returns to the tank.
C
A
B
5
Fig. 4-74
4-82
4
Shop Manual - April 2014
ZX215-1002085
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
2. When swing is stopped
From oil port M
1
● When the swing control lever is set neutral, the supply of pressurized oil from the pump to port (A) is stopped. ● The pressurized oil from the motor outlet can't return to the tank since the returning circuit to the tank is closed from control valve (5). Thus, the pressure on port (B) increases.
2
4
3
● Swing resistance is generated on the motor and hence the brake starts working.
C
In Ma t rk er n et a in ti o g n De al pt .
● Pressurized oil will be relieved when the pressure on port (B) rises to the set pressure of relief valve (2).
A
5
● A high braking torque acts on the motor, thereby stopping the motor. ● When relief valve (2) is being actuated, the relieved oil and the pressurized oil from port (M) are fed to port (B) via check valve (4).
B
ZX215-1002086
Fig. 4-75
司
公
销 营
● The above prevents the formation of cavitation on port (B).
Shop Manual - April 2014
4-83
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.4 Anti-jerk valve 4.6.4.1 Operation diagram A
T1
T2
B 2
3
Valve body Spool (side A) Spring (side A) Plug Spool (side B) Spring (side B) Plug
4
In Ma t rk er n et a in ti o g n De al pt .
1
(1) (2) (3) (4) (5) (6) (7)
7
6
5
Swing motor
B
T
A 司
公
销 营
Swing Control Valve
Fig. 4-76
ZX215-1002087
4.6.4.2 Effect illustration
: With antiswing valve
：Without antiswing valve
Reversing pressure
Pressure MA
Suppressing pressure
Reversing pressure
Pressure MB
First reversing Second reversing
Motor speed
Start
Brake
Reverse
Time
Fig. 4-77 4-84
Shop Manual - April 2014
ZX215-1002088
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Outline
A
● The inertia of the swing body, the counteraction and rigidity of the mechanical system, or the compressibility of the hydraulic oil can cause shaking of machine during swing operation. The anti-jerk valve is able to reduce such impact. It is effective in preventing collapsing of load when the swing is stopped and in reducing the cycle time (by better positioning performance and quicker movement for next operation).
T
c e
D4 a D3
D1 d 㔎ষ D2 % b f 7
In Ma t rk er n et a in ti o g n De al pt .
ZX215-1002089
Fig. 4-78
Operation
$
1. When braking pressure is generated at port (B)
● Pressure (MB) is conducted to chamber (d) via the notch. The pressure compresses spring (6) by use of the difference in areas of circles (D1 > D2) of spool (5) and moves the spring (6) to the left side. Port (B) and chamber (e) will be interconnected. Since pressure (A) is lower than the set pressure of spring (3), spool (2) does not move and the pressurized oil is stopped by spool (2). Thus the braking force is ensured.
T
F H
' D '
司
公
销 营
' G 㔎ষ '
%
E I
T
ZX215-1002090
Fig. 4-79
2. When motor is stopped
A
● The motor rotation is reversed by the closing pressure generated at port (B). (1st reversing) Reversing pressure is generated on port (A) under the above condition. Pressure (A) is conducted to chamber (a), and spool (2) moves spring (3) to the right side, and A and B is interconnected. At this time, b is interconnected with f via the orifice on spool (5), and reversing pressure on port A is bypassed to port T in order to prevent second reversing.
T
5 d
a 2
3
B b f T ZX215-1002091
Fig. 4-80 Shop Manual - April 2014
4-85
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.5 Central Swivel Joint 12 11
9 10 8
15
E
E 7
D
In Ma t rk er n et a in ti o g n De al pt .
D
C
C
B
B
6
A
A
5 4
司
公
3
销 营
2
13，14
1
W365R130401
Fig. 4-81 (1) (2) (3) (4) (5) (6) (7) (8)
Bolt O-ring Cap O-ring Washer Collar Rotary seal (CSI) Housing
4-86
(9) O-ring (10) Swivel shaft (11) Rotor (12) Plug (13) Bolt, socket-head (14) Flat washer (15) Dust boot
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.6 Travel motor Type: MAG-170VP-3800E View of motor before installation Motor positioning cut Φ200H7
Z Bre
X
Y
S
B
In Ma t rk er n et a in ti o g n De al pt .
T
Hexagon bolt 2-M20×40 Torque 358Nm
Bolt hole for motor installation 2-M20
Oil inlet of brake M12×1.5
Oil inlet of brake
Y向
Z向
X
B
Bre
A
MA
Direction B
司
公
销 营
Oil inlet, level M18×1.5
MB S
Drain port M18×1.5
W365T130401
Fig. 4-82
A, B: Working oil port T: Oil drain port
MA, MB: Test port S: Oil compensation port X: Control pressure port Bre: Oil port for releasing external brake
Shop Manual - April 2014
4-87
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Table 1 - Motor Specifications Unit
Specifications
Max input torque
N·m
546
Max input speed
r/min
4788
Max output torque
N·m
69309
Max output speed Basic braking torque (without back pressure) Starting pressure
r/min
37.7
N·m
730
bar
18
Max withstanding pressure
bar
50
In Ma t rk er n et a in ti o g n De al pt .
Item
Oil refilling capacity
L
8.5
Speed ratio
-
126.94
Weight
kg
400
Brake disc
Disc type brake
Lubricant oil
220（40℃）industrial application
司
公
销 营
4-88
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.7 Reducer Type: GFT80
15 3 20 5 21 6 19 48 47 8 12 13 14 13 18 11 16 53 55 59 54 58 89 91 93 66 90 94 67 92 200 199
In Ma t rk er n et a in ti o g n De al pt .
105
司
公
销 营
38 37 38 35 36 35
23 22 39 1 28 26 32 31 25 44 46 30 29 27 4 99 100 17 49 52 88 87
69 70 51 103 W365T130402
Fig. 4-83
Shop Manual - April 2014
4-89
Structure and Functions
No.
Code
SY365(B)H-9 Crawler Hydraulic Excavator
Description
Qty
No.
Code
Description
Qty
E001
R988011946
Support shaft
1
E048
R913006477
Bolt, hexagon
24
E003
R988012090
Drive shaft
1
E049
R988010958
Gear ring
1
E004
R988011553
Planetary carrier
1
E051
R988011457
End cover
1
E005
R988012073
Bearing seat
1
E052
R988011597
Sun gear
1
E006
R916452282
Collar
1
E053
R988011951
Planetary carrier
1
E008
R916452408
Collar
1
E054
R988011483
Planetary gear
3 3
Planetary gear
5
E055
R988012459
E012
R916411696
Cylidrical roller bearing
10
E058
2916650023
Collar
3
E013
R988012373
Collar
10
E059
R913003909
Collar
1
E014
R916452254
Collar
5
E066
R988012492
Ring
1
E015
R988013065
Float seal
1
E067
R913006441
Bolt, hexagon
12
E016
2916650025
Elastic collar
5
E069
R913003865
Plug
2
E017
R988011192
Sun gear
1
E070
R916462052
Washer
2
E018
R916452068
Elastic collar
1
E087
R988011630
Sun gear
1
E019
R988011289
Round nut
1
E088
R988012341
Collar
1
1
E089
R988011188
Planetary carrier
1
E090
R988011840
Planetary gear
3 3
E011
In Ma t rk er n et a in ti o g n De al pt .
R988011587
Cylindrical roller bearing
E020
R916412778
E021
R916412722
Tapered roller bearing Tapered roller bearing
1
司
公
销 营
E022
R988012516
O-ring
1
E091
R988012458
Cylindrical roller bearing
E023
R913006409
Bolt, hexagon
2
E092
R916452026
Collar
3
E025
R988011598
Piston
1
E093
R916462507
Collar
6
E026
R988012185
Collar
1
E094
R916452244
Collar
6
E027
R988012320
Collar
2
E099
R988012398
Deep-grooved ball bearing
1
E028
R916452300
Collar
1
E100
R916462138
Collar
1
6
E103
R988012357
Cylidrical roller
1
5
E105
R902165278
Motor
1
Friction disc, outside Friction disc, inside
E029
R988012929
E030
R988012931
E031
R916423354
Spring
18
E199
R988012436
Rivet
4
E032
R916423355
Spring
18
E200
R909830326
Nameplate
1
E035
R988012913
Collar
2
E036
R988012397
Spring sleeve
1
E037
R988012404
X -ring
1
E038
R988012914
X -ring
2
E039
R902602007
Plug
1
E044
2917890148
Pin
2
E046
R988012493
O-ring
1
E047
R988011215
Bearing seat
1
4-90
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.8 Travel motor (Nabtesco) Type: GM60VA
In Ma t rk er n et a in ti o g n De al pt .
Pi
Nabtesco
Dr
MA
Nabtesco
MB
A
B
26XM20
18XM24
司
公
销 营
FILL lEVEL
Filling port
DRAIN
Drain port
ZX305-1102601
Fig. 4-84
A: Main oil port B: Main oil port
Am: Pressure detection port Bm: Pressure detection port Pi: Two-speed pilot tubing port Dr: Oil drain port
Shop Manual - April 2014
4-91
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Unit
Specifications
Input flow
L/min
280
Relief valve pressure setting
Mpa
34.3
Motor displacement
2
cm /rev
290.7/170.1
Reduction ratio
—
40.67
Total displacement
2
cm /rev
—
Theoretical output torque
KN·m
64.3/37.6
Theoretical output speed
r·p·m
23.8/40.7
Braking torque
KN·m
1.17
Brake release pressure
Mpa
1.54
Auto switching pressure
Mpa
26.5
Operating temperature range
℃
-20~90
Total weight
kg
399
In Ma t rk er n et a in ti o g n De al pt .
Item
司
公
销 营
4-92
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.9 Operating principle of the basic components 4.6.9.1 Double-balanced valve Function: ● When external load makes the plunger motor tend to go faster than the rated rotating speed of feed flow (hereunder referred to pump effect), this valve controls motor speed and prevents over-speed of the motor in relation with the feed flow. ● The double-balanced valve and the relief valve constitute the braking circuit. The braking circuit applies braking force onto the swing of plunger motor and stops the motor gradually.
In Ma t rk er n et a in ti o g n De al pt .
● This valve can serve as a shuttle valve for high pressure selection to release the brake under its own pressure. ● The structure of a standard double-balanced valve is shown below. The following information describes the operating principle of a standard double-balanced valve. A. When stopped
● When the main valve is neutralized (motor stopped), port M1 and port M2 are shut off by spool (1) and check valve (2) since no pressure is generated at port P1 and port P2. The motor is not rotating. 司
公
销 营
8-1
8
8-2
Oil circuit B Oil circuit C2
Oil circuit C1
M2
M1
Orifice D3
Orifice D1
Damper chamber A2
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2 Spring chamber1 P2
P1
6-1
6-2
7-2
7-1
5-1
3
4-1
2-1
1
2-2
4-2
5-2
ZX215-1002094
Fig. 4-85 Shop Manual - April 2014
4-93
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
B. When motor is started
In Ma t rk er n et a in ti o g n De al pt .
● When the hydraulic oil from the main pump enters port P1 of the double-balanced valve, spring (3) is pushed to the left by check valve (2-1), opening circuit C1. The hydraulic oil enters the plunger motor via port M, trying to make the motor rotating. At the same time, return oil from the plunger motor enters the counterbalance valve via port M2, but it is stopped by check valve (2-2). The output pressure of the main pump increases as a result, and the hydraulic oil works on the inside of spring chamber (1) and damper chamber (A1) via orifice (4-1) and check valve (5-1). The force generated in this way pushes spring (7-2) on the other side and moves plunger (1) to the right. At this time, return oil from port M2 passes through circuit of the notch on the periphery of plunger (1), and through port P2 when pressure is generated at port M2, and enters the tank via the main valve finally. The motor starts rotating at this time.
8-1
8
8-2
Oil circuit B
司
公
Oil circuit C2
销 营
Oil circuit C1
M1
M2
Orifice D3
Orifice D1
Damper chamber A2
Damper chamberA1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
P2
P1
6-2
6-1
7-2
7-1
5-1
3
4-1
2-1
1
Fig. 4-86
4-94
Shop Manual - April 2014
2-2
4-2
5-2
ZX215-1002095
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
C. Counterbalance function
In Ma t rk er n et a in ti o g n De al pt .
● When the engine runs at an excessively high speed because of external force applied on it, the motor may lose control. At this time, port P1 serves as the inlet side, and the pressure drops. Pressure in spring chamber (1) and damper chamber A1 also drop. As a result, plunger (1) moves to the left under the force of spring (7-2), closing circuit B. Circuit at the suction side is also closed at the same time when the circuit at return side is closed. When circuit B is closed, pressure at port P1 rises due to hydraulic oil from the main pump, moving plunger (1) to the right again. In this way, when external load generates pump effect, slight movement of plunger (1) keep circuit B open. The rotation speed of the motor keeps in line with fuel supply of the main pump, and the motor will not lose control because of the vacuum in the hydraulic system.
司
公
销 营
Shop Manual - April 2014
4-95
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
D. Braking of motor ● The double-balanced valve and the relief valve forms the braking circuit. ● When the main valve is in neutral position, hydraulic oil from the main pump is cut off, and pressure at port P1 and P2 is the same. As a result, plunger (1) moves to the neutral position, and the opening area of circuit B decreases. ● At the same time, because of the inertia of external force, the motor does not stop rotating (pump effect), and pressure at port M2 rises and serves as the braking force of motor rotation.
In Ma t rk er n et a in ti o g n De al pt .
● When the pressure at port M2 reaches the set pressure of relief valve (8), cone valve (8-1) at port M1 overcomes the force of spring (8-2) and moves to the left, and hydraulic oil flows to the port M1. In this way, the impacting force due to inertia at port M2 is under control, and vacuum at port M1 is avoided.
8-1
8
8-2
Oil circuit B
司
公
销 营
Oil circuit C2
Oil circuit C1
M2
M1
Orifice D3
Orifice D1
Damper chamber A2
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
P2
P1
6-1
6-2
7-1
5-1
7-2
3
4-1
2-1
1
2-2
4-2
5-2
ZX215-1002096
Fig. 4-87
4-96
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
E. Shuttle valve function for high pressure selection ● The double-balanced valve can function as a shuttle valve to release travel brake. ● When hydraulic oil is fed to port P1, plunger (1) moves to the right, as shown in fig. 4. At this time, drain passage F of motor housing is cut off, and passage D leading to cylinder chamber E for travel braking is opened. ● Hydraulic oil flows to passage G via the orifice, and enters travel brake cylinder chamber E to release the travel brake. In addition, plunger (1) moves to neutral position, as shown in fig 5 when motor stops. Passage D is closed and drain passage F of motor housing is opened.
In Ma t rk er n et a in ti o g n De al pt .
● Hydraulic oil in travel braking cylinder chamber E is conducted to the drain passage of motor housing, and travel brake is applied. 1
Passage D
Passage D
Orifice Passage F
Passage F Passage D
Passage G
司
公
销 营
Passage G
Cylinder chamber E
ZX215-1002097
Fig. 4-88
1
Passage D
Passage D
Passage F Passage D
Orifice Passage F
Passage G
Passage G
Cylinder chamber E
ZX215-1002098
Fig. 4-89
Shop Manual - April 2014
4-97
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.9.2 Operation of parking brake 1) When starting travel ● As the travel lever is operated, pressurized oil from the pump activates back pressure valve spool (10), opens the parking brake circuit, and flows to chamber A of brake piston (12). Pressurized oil overcomes the force of spring (11) and pushes piston (12) toward the left.
10
In Ma t rk er n et a in ti o g n De al pt .
● Since the pushing force to plate (13) and disc (14) disappears, plate (13) is separated from disc (14) and the brake is released.
Travel control valve
11
14
13 12
A
M
22
ZX215-1002099
Fig. 4-90
2) When travel is stopped
司
公
销 营
● As the travel lever is placed in neutral, back pressure valve spool (10) returns to the neutral position and closes the parking brake circuit. T
10
● he pressurized oil in chamber (A) of brake piston (12) passes through the orifice of the brake piston and is drained to the motor casing. Brake piston (12) is pushed to the right by spring (11).
● Plate (13) and disc (14) are pushed against each other, and the brake is applied. As brake piston (12) returns, a time delay is formed by making the pressurized oil pass through a throttle valve in the slow return valve (22). This time delay ensures an active brake after the machine is stopped.
4-98
Travel control valve
11
14
13 12
A
M
22
ZX215-1002100
Fig. 4-91
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.9.3 Operation of braking valve
Travel control valve
PA
● The brake valve consists of a suction safety valve (8A) and a counterbalance valve (18). As shown in the illustration on the right, functions and operations of respective components are described below.
PB
8A
18
MB
In Ma t rk er n et a in ti o g n De al pt .
MA
ZX215-1002101
Fig. 4-92
1. Counterbalance valve and check valve
Travel control valve
PA
Function
● When traveling downhill, the weight of the machine tends to make the travel speed faster than the motor speed. If the machine travels with the engine at low speed, the motor may rotate at zero load, resulting in runaway and inviting a very dangerous situation. These valves are used to avoid such a situation by controlling the machine to travel according to the engine speed (pump flow).
司
公
销 营
PB
8B
8A
19
MA
MB
ZX215-1002102
Fig. 4-93
Operation when pressurized oil is supplied
● Operating the travel control lever conducts the pressurized oil from the control valve to port (PA). The pressurized oil opens suction safety valve (8A) and then flows to motor outlet port (MB) via motor inlet port (MA). The motor outlet side is closed by suction safety valve (8B) and spool (19), so the pressure at the supply side rises, as shown in the right illustration.
Shop Manual - April 2014
4-99
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● The pressurized oil on the supply side flows to chamber (S1) via orifice (E1) and orifice (E2) of the spool (19). As the pressure in chamber (S1) goes above the spool shift pressure, spool (19) is pushed toward the right. Port (MB) and port (PB) are connected, the motor outlet port side opens and the motor starts rotating, as shown in the right illustration.
Travel control valve
PB
PA
S1
19 MB
In Ma t rk er n et a in ti o g n De al pt .
MA
E1 E2
ZX215-1002103
Fig. 4-94
Brake operation in downhill travel
● If the machine goes out of control while travelling downhill, the motor will be caused to rotate without load to decrease the inlet side oil pressure. Pressure in chamber (S1) drops via orifices (E1) and (E2). As the pressure in chamber (S1) goes below the spool shift pressure, spool (19) is returned to the left by spring (20) and outlet port (MB) is throttled. The pressure at the outlet port side rises, generating rotation resistance on the motor to prevent the machine from losing control. On the other hand, the spool moves to a position where the pressure on outlet port (MB) can be balanced against the machine's own weight and the inlet port pressure. Oil flow from the outlet circuit is reduced to ensure the travel speed corresponded to the pump delivery, as shown in the right illustration.
4-100
Travel control valve
PB
PA
20
司
公
销 营
S1
19
MA
E1
Fig. 4-95
Shop Manual - April 2014
E2
MB
ZX215-1002104
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
2. Safety valve Function
In Ma t rk er n et a in ti o g n De al pt .
● When the machine travel is stopped (or it is travelling downhill), the double-balanced valve closes the inlet and outlet circuits of the motor. Since the motor is rotated by inertial force, pressure in the motor outlet port side is abnormally increased, potentially resulting in damages on the motor and piping. The safety valve relieves this abnormal pressure to the inlet port side of the motor in order to prevent damages to the equipment. Operation
1) When travel is stopped (or when travelling downhill or swinging to the right)
● Reduction of the pressure at motor inlet (PA) decreases the pressure in chamber (S1). When it drops beyond the spool shift pressure, the spool is returned to the left by spring (20), throttling the oil outlet passage (B1). At this time, the motor continues rotating due to its inertial force, thus pressure on the outlet port (MB) is increased, as shown in the right illustration.
Travel control valve
PB
PA
20
司
公
销 营
S1
MA
MB
A1
B1 ZX215-1002105
Fig. 4-96
● When the pressure rises above the set pressure of the suction safety valve (8A), the spool opens. The pressurized oil passes through notch (A1) of the counterbalance valve spool (19) into chamber (MA) of the circuit at the opposite side, as shown in the right illustration.
Spool MB
MA ZX215-1002107
Fig. 4-97
Shop Manual - April 2014
4-101
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
2) When starting travel (or traveling normally) Travel control valve
● As the travel control lever is operated, the pressurized oil from the pump moves the counterbalance valve spool (19) toward right. In this case, the passage to the suction safety valve functions as a circuit which passes through notch (B2) of spool (19), producing large differential pressure. The pump pressure rises, providing a large tractional force to the valve, as shown in the right illustration.
PB
PA
8B
8A
S1
19 MB
In Ma t rk er n et a in ti o g n De al pt .
MA E1
B2
ZX215-1002106
Fig. 4-98
3. Overload relief valve
● The structure of the relief valve is shown in the right figure. This valve is an areadifferential and direct-acting relief valve. It has impact damping function during starting and braking.
司
公
销 营
ZX365-1304108
Fig. 4-99
A. Operating principle and function
● When the main control valve makes the motor to start or brake, front pressure of cone valve (2-9-2) rises above the set pressure and the force of spring (2-9-5), and moves cone valve (2-9-2) to the right and off the valve seat (2-9-3). Pressurized oil in the front of cone valve (2-9-2) is bypassed to the low pressure side. The impact due to inertia energy at the high pressure side is put under control and vacuum is prevented from occurring at the low pressure side through bypassing pressurized oil to the low pressure side. 4-102
2-9-2
2-9-5
2-9-3
ZX365-1304109
Fig. 4-100
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
B. Damping function ● When the relief valve begins to function, damping piston (2-9-9) moves to the left. As a result, low pressure is maintained in spring chamber D. At this time, the loaded area of cone valve (2-9-2) is S1, and generally it is much larger than the set loaded area S1-S2 of the relief valve. So, when damping piston (2-9-9) is moving, the functional pressure of relief valve is maintained at 1/3 of normal set pressure in order to absorb the impact at the high pressure circuit side due to inertial energy. When the movement of damping piston stops, pressure in spring chamber D rises. Pressure at both side of cone valve (2-9-2) is the same, and the relief valve is working at normal set pressure. In this way, the relief valve reduces the impact during motor starting and braking by a two-stage action to provide excellent performance.
2-9-2
Area S2
2-9-5
2-9-3 Area S1
2-9-9
Spring chamber D ZX365-1304110
In Ma t rk er n et a in ti o g n De al pt .
Fig. 4-101
司
公
Pressure (P)
销 营
O
Damping form
time (T) ZX215-1002111
Fig. 4-102
Shop Manual - April 2014
4-103
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Table 2 Repair standard of motor components Components
Check item
1. Boot sliding surface 1-4-2 Plunger 2. Plunger outer diameter assembly
Remedy
Grind the boot sliding surface. Replace the Roughness 0.8a or surface roughcylinder block assembly ness, scratch 0.02mm+ if the scratch cannot be corrected. Roughness 1.2a or surface roughness, scratch 0.02mm+ Replace the cylinder Clearance 0.060. block assembly. Clearance 0.4.
In Ma t rk er n et a in ti o g n De al pt .
3. Plunger outer diameter and cylinder block inner diameter 4. Boot head clearance
Allowable limit
Grind the boot sliding surface. Replace the 1. Valve leaf and sliding sur- Roughness 0.8a or surface roughcylinder block assembly face ness, scratch 0.02mm+. if the scratch cannot be corrected. Roughness 1.6a or surface rough1-4-1 Cylinder 2. Shaft hole inner diameter ness, scratch 0.02mm+. block 3. Shaft hole inner diameter Replace the cylinder and 4-2 plunger assembly Clearance 0.060. block assembly outer diameter Roller distance below 38.749 4. Spline at shaft joint (measuring pin diameter φ3.333(V1=2.80)); or damaged Grind the sliding surface. 1-21 Oil distriRoughness 0.8a, scratch 0.02mm+ Replace the valve sheet 1. Sliding surface bution plate on sliding surface or burned sign if the scratch cannot be corrected. 1-4-3 Retainer Roughness 0.8a, scratch 0.02mm+ Replace the retaining 1-4-4 Retain- 1. Sliding surface on sliding surface or sign of burning plate or the retainer. ing assembly Grind the sliding surface. Roughness 0.8a, abrasion on sling Replace the valve sheet 1. Sliding surface surface or scratch 0.02mm+ if the scratch cannot be corrected. 1-5 Swash Roughness 1.6a. plate 2. Hole for assembling steel Scratch on spherical surface ball Replace the swash plate. 0.02mm+ or surface roughness 3. Hole for assembling steel Ball depth 14.5 ball 司
公
销 营
4-104
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Components
1-3 Shaft
Check item
Allowable limit
Remedy
1. Oil seal sliding portion outer Roughness 1.6a, rough surface, or Replace the swash diameter scratch 0.02mm+ plate. Stick spans below 47.380 (testing 2. Cylinder block matching pin diameter φ3.00), or the stick spline breakage. Replace the shaft. Stick spans below 30.498 (testing 3. Drive gear connection pin diameter φ3.33), or the stick breakage. 1. Dimension Height 38.2 Roughness 2.5a Scratch 0.02mm+ or rough surface
Replace the brake piston.
In Ma t rk er n et a in ti o g n De al pt .
1-15 Brake pis- 2. Sliding surface ton 3. Appearance 1. Dimension
1-13 Disc plate
2. Appearance
1-8 Ball bearing 1. Rolling surface 1-9 Ball bearing 2. Action
Thickness 3.2 Deep scratch on sliding surface or friction material peeling Peeling or fracture Abnormal rotation (noise•uneven rotation)
Replace the disc plate. Replace the ball bearing.
Grind the sliding surface. Replace the Roughness 1.6a, rough surface, or flange plate parts if 1. Boot sliding surface scratch 0.02mm+ the scratch cannot be corrected 1-7 Plunger asRoughness 1.2a, rough surface, sembly 2. Plunger outer diameter scratch 0.02mm+ Replace the flange 3. Plunger outer diameter and Gap 0.040. plate parts. flange part inner diameter 4. Boot head clearance Clearance 1.0 Roughness 0.8 a, scratch 0.02mm+ 1. Plunger outer diameter or rough surface 1-2-2 Plunger Replace the valve assembly sheet. 2. Plunger outer diameter and Clearance 0.060. valve sheet inner diameter 1. Assemble the plunger as- Roughness 0.8 a, scratch 0.02mm+ sembly hole or rough surface 2. Valve sheet inner diameter Clearance 0.060 and plunger outer diameter 3. Valve spool assembly instal- Roughness 0.8 a, scratch 0.02mm+ 1-2-1 Valve Replace the valve lation hole or rough surface sheet sheet and the parts. 4. Spool valve sheet inner diameter and valve spool outer Clearance 0.060. diameter 司
公
销 营
5. Movable plunger sliding part Scratch 0.02mm+ or surface roughand seat of the relief valve ness
Shop Manual - April 2014
4-105
Structure and Functions
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
4-106
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Components
1-2-9 Spool assembly 1-2-7-9 Movable plunger 1-2-7-1 Case
Allowable limit
1. Valve spool out diameter 2. Valve spool outer diameter and valve sheet inner diameter 1. Sliding portion of valve sheet and valve seat 1. Sling portion of the movable piston (outer diameter) 1. Dimension
Roughness 0.8 a, scratch 0.02mm+ or surface roughness
Free length 61.0
2. Appearance
Deformation and surface damage
Clearance 0.060.
Remedy
Replace valve sheet and parts
Scratch 0.02mm+ or surface roughness
Replace relief valve Scratch 0.02mm+ or surface rough- assembly ness
In Ma t rk er n et a in ti o g n De al pt .
1-4-7 Spring
Check item
1-18 Spring 1-20 Spring
1-2-4 Spring
1-2-10 Spring
O-ring and oil seal
1. Dimension
Free length 39.0
2. Appearance
Deformation and surface damage
1. Dimension
Free length 41.5
2. Appearance
Deformation and surface damage
1. Dimension
Free length 48.5
2. Appearance
Deformation and surface damage
1. Dimension
Free length 28.3
2. Appearance
Deformation and surface damage 司
公
销 营
When removed
Shop Manual - April 2014
Replace o-ring and oil seal
4-107
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.10 Control system 8
9
7
In Ma t rk er n et a in ti o g n De al pt .
6
4
1
2
5
4
5
3
11
9
10
7
6
12
司
公
销 营
8
10
13
3
11
2
12
1
ZX365-1304112
Fig. 4-103
4-108
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
(1) Pilot valve (travel) (2) Control lever (left travel) (3) Control lever (right travel) (4) Pilot valve (Right) (5) Control lever (right work equipment) (6) Accumulator (7) Block (8) Hydraulic pump (9) Main control valve (10) Solenoid valve (11) Control lever (left work equipment) (12) Relay Control lever positions 1
HOLD
2
Boom UP
3
Boom DOWN
4
Bucket DUMP
5
Bucket DIG
6
HOLD
7
Arm IN
8
Arm OUT
9
Right swing
10
Left swing
11
Neutral
12
Travel BACKWARD
13
Travel FORWARD
司
公
销 营
Shop Manual - April 2014
4-109
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.11 Manual pilot valve P3
P2
A T
P
2
3 P
In Ma t rk er n et a in ti o g n De al pt .
1
4
P4
A
P1
19~22Nm
64~73.5Nm
司
公
销 营
ZX365-1304113
Fig. 4-104 P: From pilot pump relief valve P1: Left pilot valve: Arm OUT / Right pilot valve: Boom DOWN P2: Left pilot valve: Arm IN / Right pilot valve: Boom UP P3: Left pilot valve: Swing LEFT / Right pilot valve: Bucket DIG P4: Left pilot valve: Swing RIGHT / Right pilot valve: Bucket DUMP T: To tank 4-110
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
6 7
5
In Ma t rk er n et a in ti o g n De al pt .
8
4
9
3
司
公
销 营
10
2
1
A-A
ZX215-1002114
Fig. 4-105 (1) (2) (3) (4) (5)
Plunger Adjusting spring Center spring Piston Disc
(6) Nut (for control lever connection) (7) Connector (8) Plate (9) Retainer (10) Valve body
Shop Manual - April 2014
4-111
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Operation 1. When in neutral ● Ports (A) and (B) of the control valve and ports (P1) and (P2) of the pilot valve are connected to drain chamber (D) via orifice (f) in plunger (1).
D f
2. During fine control (Neutral to fine control)
T
1
● When piston (4) is pushed by disc (5), retainer (9) is pushed, plunger (1) is also pushed by adjusting spring (2), and moves down.
In Ma t rk er n et a in ti o g n De al pt .
P
● When orifice (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). Pilot pressurized oil of the control pump is led to port (A) from port (P1) via orifice (f). When the pressure at port (P1) becomes higher, plunger (1) is pushed back and orifice (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, plunger (1) moves up and down until the force of adjusting spring (2) is balanced with the pressure at port (P1).
● The relationship of the position of plunger (1) and body (10) [orifice (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts plunger (1). Adjusting 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. In this way, the control valve plunger moves to a position where the pressure of chamber (A) (same as pressure at port (P1)) and the force of the return spring of the control valve plunger are balanced.
Pilot pump
P1
M
A
P2
Control valve
M
B
ZX365-1304115
司
公
销 营
Fig. 4-106
D
f
T
1
P
Pilot pump
A
P1
M
P2
Control valve
M
B ZX365-1304116
Fig. 4-107 4-112
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3. Fine control (When control lever returns) ● When disc (5) starts to return, plunger (1) is pushed up by the force of center spring (3) and the pressure at port (P1). ● Because of this, orifice (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.
D f
● If the pressure of port (P1) is lowered excessively, plunger (1) is pushed down by adjusting spring (2).
T
1 P
In Ma t rk er n et a in ti o g n De al pt .
● Orifice (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. ● When the plunger of the control valve returns, the oil in drain chamber (D) flows in from orifice (f) in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
Pilot pump
P2
PP
M
A
司
公
销 营
P1
f1
Control valve
M
B ZX365-1304117
Fig. 4-108
4. At full stroke
● Disc (5) pushes down piston (4), and retainer (9) pushes down plunger (1).
● Orifice (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). ● Therefore, the pilot pressure oil from the self pressure reducing valve passes through orifice (f) and flows to chamber (A) from port (P1) to push the control valve plunger.
● The oil returning from chamber (B) passes from port (P2) through orifice (f) and flows to drain chamber (D).
D
f
T
1
P
f1 Pilot pump
A
P1
M
P2 PP
Control valve
M
B ZX215-1002118
Fig. 4-109 Shop Manual - April 2014
4-113
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.12 Travel pilot valve A
T
In Ma t rk er n et a in ti o g n De al pt .
T
P
P
P5
A
P5
P2
P4
P1
2
1
4
3
P6
司
公
销 营
P3
ZX215-1002119
Fig. 4-110
P: From pilot pump P1: L.H. reverse P2: L.H. forward P3: R.H. reverse
4-114
P4: R.H. forward P5: Travel signal P6: Travel signal T: To tank
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
37~30Nm
B
65~45Nm 1
8~6Nm
3 4 5 6 7
In Ma t rk er n et a in ti o g n De al pt .
2
C
C
2，4
1，3
B-B
司
公
销 营
B
13~11Nm
C-C
8~6Nm
ZX215-1002120
Fig. 4-111 (1) (2) (3) (4)
Plate Body Piston Collar
(5) Center spring (6) Adjusting spring (7) Valve
Shop Manual - April 2014
4-115
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.12.1 Operating principle 1) When in neutral ● Ports (A) and (B) of the control valve and ports (P1) and (P2) of the pilot valve are connected to drain chamber (D) via orifice (f) in spool (1).
D f T
2) Fine control (Neutral to fine control)
P
● When piston (4) is pushed by lever (5), retainer (9) is pushed, and plunger (1) is also pushed by adjusting spring (2), and moves downward.
1 Pilot pump
P2
In Ma t rk er n et a in ti o g n De al pt .
P1
● When orifice (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP).
A
Fig. 4-112
司
公
销 营
5 4 9
● As a result, plunger (1) moves up and down until the force of adjusting plunger (2) is balanced with the pressure at port (P1). ● The relationship of the position of plunger (1) and body (10) [orifice (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts plunger (1).
f
T
P
1
Pilot pump
P1
A
PP
P2
Control Valve
10
B
ZX215-1002122
Fig. 4-113
● In this way, the control valve spool moves to a position where the pressure of chamber (A) (same as pressure at port (P1)) and the force of the return spring of the control valve spool are balanced.
4-116
D
2
● Adjusting 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.
B
ZX215-1002121
● Pilot pressurized oil of the control pump is led to port (A) from port (P1) via orifice (f).
● When the pressure at port (P1) becomes higher, plunger (1) is pushed back and orifice (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1).
Control Valve
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3) Fine control (When control lever returns) ● When lever (5) starts to return, plunger (1) is pushed up by the force of center spring (3) and pressure at port (P1).
5
● Because of this, orifice (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.
3
D
2 f
● If the pressure of port (P1) is lowered excessively, plunger (1) is pushed down by adjusting spring (2).
T P f’ 1
● Orifice (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP).
Pilot pump
PP P1
In Ma t rk er n et a in ti o g n De al pt .
P2
A
● Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position.
● When the spool of the control valve returns, the oil in drain chamber (D) flows in from orifice (f) in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
Control Valve
B ZX215-1002123
Fig. 4-114
司
公
销 营
4) At full stroke
● Lever (5) pushes down piston (4), and retainer (9) pushes down plunger (1).
● Orifice (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). ● Therefore, the pilot pressure oil from the self pressure reducing valve passes through orifice (f) and flows to chamber (A) from port (P1) to push the control valve spool.
5 4
D
9 f
T
P
f’
1 PP
Pilot pump
● The oil returning from chamber (B) passes from port (P2) through orifice (f) and flows to drain chamber (D).
P1 A
P2
Control Valve
B ZX215-1002124
Fig. 4-115
Shop Manual - April 2014
4-117
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.13 Solenoid valve
P2
T
A1
A2
2
P1
In Ma t rk er n et a in ti o g n De al pt .
1
3
4
5
6
7
8
W365-1304125
Fig. 4-116
(1) Solenoid valve block
P1: To pilot fi lter 司
公
销 营
(2) Accumulator
P2: To main valve port G
(3) High-speed travel solenoid valve
T: To oil tank
(4) Backup valve
A1: To swivel joint port X
(5) Backup valve
A2: To pilot oil circuit block P
(6) Bucket confl uence solenoid valve (7) Backup
(8) Pilot pressure solenoid valve
4-118
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.14 PPC accumulator (1) Gas plug
1
(2) Shell (3) Poppet 2
(4) Holder (5) Bladder (6) Oil port
In Ma t rk er n et a in ti o g n De al pt .
3
4
Specifications
Gas capacity: 300 cc (for PPC)
5
6
司
公
销 营
ZX215-1002126
Fig. 4-117
Shop Manual - April 2014
4-119
Structure and Functions
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
4-120
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.15 Pilot oil filter K 1 K Model
2
Pressure Precision
3
In Ma t rk er n et a in ti o g n De al pt .
4
5
6
司
公
销 营
3
ZX215-1002127
Fig. 4-118 (1) (2) (3) (4) (5) (6)
Nameplate Head cover O-ring Seal ring Filter Casing
Specifications Max. delivery: 40 L/min Filter fineness: 10 um Operating pressure: 20 Mpa Max. operating pressure: 40 Mpa Pressure loss: 0.05 Mpa Max. allowable pressure difference: 1 Mpa Specification of inlet/outlet port O-ring: 30×3.1
Shop Manual - April 2014
4-121
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.16 Hydraulic cylinders Boom cylinder
1
2
7960N·m
3
56.9±10.7N·m
In Ma t rk er n et a in ti o g n De al pt .
367N·m
ZX335-1002035
Fig. 4-119
Arm cylinder
2
1
司
公
销 营
22200N·m
3
96.6±18.2N·m
711N·m
ZX335-1002036
Fig. 4-120
Bucket cylinder
2
1
9550N.m
3
56.9±10.7N.m
367N.m
ZX335-1002037
Fig. 4-121 4-122
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.16.2 Lubrication at every 100 service hours Unit: mm
1
2
3
Check Item Cylinder
Standard size
Boom
100
Arm
120
Bucket
100
Boom
100
Clearance between piston rod and bushing
Clearance between piston rod support pin and bushing
Criteria Tolerance Shaft Hole -0.012 +0.222 -0.034 +0.047 -0.012 +0.222 -0.047 +0.047 -0.012 +0.258 -0.034 +0.048 -0.036 +0.25 -0.071 +0.05 -0.036 +0.25 -0.071 +0.05 -0.036 +0.25 -0.071 +0.05 -0.036 +0.25 -0.071 +0.05 -0.036 +0.25 -0.071 +0.05 -0.036 +0.25 -0.071 +0.05
Remedy Standard clearance
Clearance limit
0.083-0.312
0.412
0.083-0.312
0.412
0.078-0.334
0.434
0.086-0.321
1.0
In Ma t rk er n et a in ti o g n De al pt .
No.
Clearance between cylinder bottom support pin and bushing
Arm
110
Bucket
90
Boom
90
Arm
110
Bucket
90
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
Replace the bushing.
Replace the pin or bushing.
司
公
销 营
4.6.16.1 Lubrication at every 500 service hours No.
1
2
3
Check Item
Clearance between piston rod and bushing
Clearance between piston rod support pin and bushing Clearance between cylinder bottom support pin and bushing
Criteria
Cylinder
Standard size
Boom
100
Arm
120
Bucket
100
Boom
100
Arm
110
Bucket
90
Boom
90
Arm
110
Bucket
90
Tolerance
Shaft
Hole
-0.012 -0.034 -0.012 -0.047 -0.012 -0.034 -0.036 -0.071 -0.036 -0.071 -0.036 -0.071 -0.036 -0.071 -0.036 -0.071 -0.036 -0.071
+0.222 +0.047 +0.222 +0.047 +0.258 +0.048 +0.25 +0.05 +0.25 +0.05 +0.25 +0.05 +0.25 +0.05 +0.25 +0.05 +0.25 +0.05
Standard clearance
Clearance limit
0.083-0.312
0.412
0.083-0.312
0.412
0.078-0.334
0.434
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
Shop Manual - April 2014
Unit: mm Remedy
Replace the bushing.
Replace the pin or bushing.
4-123
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.7 Work Equipment 4.7.1 Component dimensions
F D C G
In Ma t rk er n et a in ti o g n De al pt .
A
E
J
,
K
司
公
销 营
B
H
ZX365-1304500
Fig. 4-122
4-124
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
1
3
A-A
G-G
D-D
J-J
5
2
4
B-B H-H
K-K
In Ma t rk er n et a in ti o g n De al pt . E-E
6
F-F
C-C
I-I
ZX285-1002022
Fig. 4-123
司
公
销 营
Lubrication
No.
Item
Bushing
Lube
material
interval
Std. size
1
Clearance between the pin and bushing connecting the boom with swing platform
Copper
500 h
Ф110
2
Clearance between the pin and bushing connecting the boom with arm
Copper
500 h
Ф110
3
Clearance between the pin and bushing connecting the arm with rocker
Steel
100 h
Ф90
4
Clearance between the pin and bushing connecting the arm with bucket
Steel
100 h
Ф90
5
Clearance between the pin and bushing connecting the linkage with bucket
Steel
100 h
Ф90
6
Clearance between the pin and bushing connecting the linkage with rocker
Steel
100 h
Ф90
Std. tolerance 轴
孔
Std. clearance
–0.036
+0.063
0.036 ～
–0.071
0
0.134
–0.036
+0.087
0.036 ～
–0.071
0
0.158
–0.036
+0.054
0.036 ～
–0.071
0
0.125
–0.036
+0.054
0.036 ～
–0.071
0
0.125
–0.036
+0.2
0.036 ～
–0.071
0
0.271
–0.036
+0.054
0.036 ～
–0.071
0
0.125
Unit：mm
Clearance limit
Remedy
1.0
1.0
1.0 Replace
Shop Manual - April 2014
1.0
1.0
1.0
4-125
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.7.2 Arm dimensions 9
19
B
11
12 A
5
A
13
C
D 6
B
10
14
D
C
In Ma t rk er n et a in ti o g n De al pt .
8
7
司
公
16
18
销 营
15
A-A
B-B
3
2
17
1 4
D-D C-C
ZX285-1002501
Fig. 4-124 4-126
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
单位：mm
No. 1 2 3
SY365H-9 Standard size φ100 131 345 φ90
5
473
Tolerance +0.087 0 +1.5 0 0 -0.5 -0.036 -0.071 ±1
Standard size φ100 131 316 φ110 602
Tolerance +0.087 0 +1.5 0 0 -0.5 -0.071 -0.036 ±0.8
In Ma t rk er n et a in ti o g n De al pt .
4
SY365BH-9
6
354
±1
215
±0.5
7
989
±1
976.6
±0.8
8
2914
±3
2906
±2
9
3018
±3
3071
±2
10
473
±1
458
±0.8
11
740
±0.3
770
±0.3
12
728
±0.5
728
±0.5
13
520
±0.5
513.6
—
14
1,661
1570
15
φ90
16
345
17
φ90 345
— -0.036 -0.071 0 -0.5 -0.036 -0.071 0 -0.5
329
— -0.036 -0.071 +1 0 -0.03 -0.06 0 -0.5
Arm body
司
公
销 营
φ90 346
φ90
18 When bushing is pressed on Minimum
345
—
344
—
2,395
—
1,990
—
19
4,145
—
3,275
—
Maximum
Shop Manual - April 2014
4-127
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.7.2.1 Bucket dimensions
2
In Ma t rk er n et a in ti o g n De al pt .
1
4
6
3
5
司
公
8
7
销 营
9
10 11 12
W365-1304502
Fig. 4-125 4-128
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Unit：mm No.
SY365H-9
SY365BH-9
Standard size
Tolerance
Standard size
Tolerance
1
520
±0.5
567
±0.5
2
1661
—
1714
—
3
R100
—
R130
—
4
R125
—
R130
—
5
1478
—
1451
—
6
1570
1889
7
φ90
— +0.2 0 +0.2 0 —
— +0.2 0 +0.2 0 —
9
In Ma t rk er n et a in ti o g n De al pt .
8
φ100
φ90 36
10
34
11
346
12
486
φ90 36
36
— +1 0 —
346
500
— +1 0 —
司
公
销 营
Shop Manual - April 2014
4-129
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8 Operator Station and Its Attachments 4.8.1 Air conditioner lines
In Ma t rk er n et a in ti o g n De al pt .
C
C
C
C
B
A
司
公
7
1
销 营
6
2
3
5 4
Fig. 4-126 4-130
Shop Manual - April 2014
ZX335-1002042
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
(1) Air conditioner (2) Hot water pumping line (3) Air compressor (4) Refrigerant line (5) Condenser (6) Hot water return line (7) Duct A: Fresh air
In Ma t rk er n et a in ti o g n De al pt .
B: Recirculated air C: Warm air / cool air
司
公
销 营
Shop Manual - April 2014
4-131
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.1 Layout of A/C components
2 1 4
In Ma t rk er n et a in ti o g n De al pt .
3
5
司
公
销 营
7
6
ZX215-1002138
Fig. 4-127 (1) (2) (3) (4) (5) (6) (7)
Sunlight sensor Control panel Air conditioning unit Condenser Compressor Fresh air sensor Recirculated air sensor
4-132
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.2 A/C control panel
1
2
3
4
5
OFF TEMP
FULL AUTO AIRCONDITION
MODE
AUTO
In Ma t rk er n et a in ti o g n De al pt .
A/C
6
8
7
W365413093
Fig. 4-128 (1) (2) (3) (4) (5) (6) (7) (8)
OFF switch Fan speed control switch Temperature control switch Air outlet mode switch Auto mode switch Fresh air/recirculation control LCD display A/C power
Remark:
司
公
销 营
When auto mode switch (5), fresh air/recirculation control (6) and A/C power (8) are turned on, indicator lights above these switches will light up.
Shop Manual - April 2014
4-133
5
2
3
FL1
3
8
RLCC
10
11
7
8
8
1.25L D
1.256
FURM
20A
1.25R
RLBM
10
15
2
12
12
RLCH
10 BLCM 3
200W
2RL 1.25RL MR
2G
M
10
10
4
BLC
1
G
8
13
13
8
FUM
5A
+B 6
14
13
16
SW
H OFF ACC ON START
15
16
18
12
22
22
21
SSD
16
B G1 G2 ACC M ST
13
19
19
19
13
20
15
3
RLCC RLCD RLBM
16
16
14
17
15
THAM THW THI THF
28 15
12
15
23
27 4
15
20
28
ACM
21
27
29
2
M
MRF
25
1
MV1
31 22 32
31
25
26
24 22 26
23
24
25
22
25
24
30
30
M
32
GND
FUCD 15A
RLCD
9
9
ECC 40W
15
M
REC Vz Pt
60A
FLZ 40A
MCD SPCD M 80W
RLCH
03
SPHL
0.5B
MAM
FFE
2
1
5 5
SW 6
02
2B
9
15
35
10
34
26
32
34 35 35 22
38
33
M
MV2
Fig. 4-129
2
CMB
BAT
02
司
公
销 营
1.25R
0.50
7
RCD RLCH
02
03
2B
1
1
ACC
D1
D2
1.25B
7
4 4
02
2B
0.85B
4
CMB CM 02
02
In Ma t rk er n et a in ti o g n De al pt . G
01
1.25B
RLSF
3
06
06
Shop Manual - April 2014
4-134
SY365(B)H-9 Crawler Hydraulic Excavator
Structure and Functions
4.8.1.3 Diagram of electrical circuit
ZX215-1002140
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Diameter/Color Wire Color Code B Black
Wire No.
Diameter/Color Wire Color Code 0.5VW Violet+white
Br(R)
Brown
0.5YB
Yellow+black
0.85W
White
0.5WO
White+orange
RL
Red+blue
0.5PB
Pink+black
G
Green
0.5VR
Violet+red
0.5BL
Black+blue
0.5BG
Black+green
0.5R
Red+blue
0.5WY
White+yellow
0.5Y
Yellow
0.5WR
White+red
0.5BR
Black+red
0.5BrW
Brown+white
In Ma t rk er n et a in ti o g n De al pt .
Wire No.
0.5BrY
Brown+yellow
0.5GO
Green+orange
0.5BY
Black+yellow
0.5Sb
Sky blue
0.5GW
Green+white
0.5OW
Orange+white
0.5LO
Blue+orange
1.25V
Violet
0.5PG
Pink+green
1.25RG
Red+green
0.5RY
Red+yellow
1.25RW
Red+orange
0.5BW
Black+white
0.85GL
Green+Blue
0.5LgR
Light green+red
Code
Name
司
公
销 营
Code
Name
Code
ACM
A/C amplifier
FUCD
Condenser fuse
RLCH
BAT
Battery
FUM
A/C main fuse
RLSF
BLC
Speed regulating resistor
Alternator
SSD
CMB
Battery relay
MAM
A/M servo motor
SPCD
Diode
MB
Blower motor
SPHL
Diode 1
MCD
SW
Diode 2
MRF
ECC
Compressor clutch
MV1
Condenser motor Fresh/recirculated air servo motor Air outlet servo motor
FL1
Fuse
MV2
FRONT outlet servo motor
THI
FL2
Fuse
RCD
Condenser resistor
THW
FUBM
Blower fuse
RLBM
Blower main relay
RLCC
Compressor relay
RLCD
Condenser relay
D D1 D2
G
Shop Manual - April 2014
THAM THF
Name
Condenser high speed relay Protective relay Sunlight sensor Condenser pressure switch Hi\Lo pressure switch
Switcher Recirculated air thermistor Anti-frosting thermistor Recirculated air thermistor Water temp thermistor
4-135
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.4 Operating principle Refrigeration cycle diagram
Expansion valve
Cool air
Lo temp\Lo press\Liquid (Mist)
Evaporator
Blower motor
In Ma t rk er n et a in ti o g n De al pt .
Air in cab
Out side fresh air
Hi-temp hi-pres gas
Lo-pres. side
Hi temp\Hi press\Liquid
Lo temp\Lo press\Gas
Cooling fan
Hi-pres. side
Reservoir
Compressor
司
公
销 营
Lo-pressure part
Hi-pressure part
Warm air
ZX215-1002141
Fig. 4-130
Heating cycle diagram
Water valve switch
Water tank radiator
Water pump
Warm air
Engine
Blower motor Air in cab
Low temp water High temp water
ZX215-1002142
Fig. 4-131 4-136
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.5 Compressor 3 1
4
2
16
In Ma t rk er n et a in ti o g n De al pt .
15 14
5
13
司
公
销 营
6
12
11
10
9
8
7
ZX215-1002143
Fig. 4-132
(1) Stator (2) Front radial bearing (3) Thrust bearing (4) Front radial bearing (5) Rear cylinder head (6) Safety valve (7) Rear cylinder block (8) Swash plate (9) Slipper (10) Front cylinder block (11) Piston (12) Front cylinder head (13) Shaft seal (14) Main shaft (15) Boss (16) Rotor
Operating principle
Compressor type: 10S15C. This compressor has 5 plungers in total with a piston at both sides of each plunger. The rotation of the swash plate drives the pistons to move back and forth and transforms the refrigerant sucked from the evaporator from low temperature and low pressure gas state to high temperature and high pressure state.
Shop Manual - April 2014
4-137
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Process1
Process2
HI press.end pipe LO press.end pipe
HI press.end pipe LO press.end pipe
Valve plate
Outlet valve disc
Intlet valve disc
In Ma t rk er n et a in ti o g n De al pt .
Main shaft and swash plate
Process6
Process3
HI press.end pipe LO press.end pipe
HI press.end pipe LO press.end pipe
司
公
销 营
Process5
Process4
HI press.end pipe LO press.end pipe
HI press.end pipe LO press.end pipe
ZX215-1002144
Fig. 4-133
4-138
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.6 Clutch ● The electromagnetic clutch is used to transmit moment of torsion. When the engine is operating, the compressor may not be working. The clutch controls the operation of the compressor only when the air conditioner is under refrigerating mode.
1 2 3 4
● Operating principle When the A/C power is turned on, the clutch coil with an electromagnet generates a magnetic field and attracts the metal piece. The stator and rotor of the clutch are engaged and bring the main shaft of the compressor into rotation.
In Ma t rk er n et a in ti o g n De al pt .
5
6
Fig. 4-134
司
公
销 营
ZX215-1002145
(1) (2) (3) (4) (5) (6)
Rotor Stator coil Clasp Ball bearing Stator Center piece
Shop Manual - April 2014
4-139
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.7 Condenser
1 2
4
In Ma t rk er n et a in ti o g n De al pt .
3
5
ZX215-1002146
Fig. 4-135
司
公
销 营
(1) (2) (3) (4) (5)
Condenser core Bracket Bolt with washer Refrigerant inlet Refrigerant outlet
4-140
Function
● The condenser changes high-temperature, high-pressure gas refrigerant (16Kg/cm², approx. 80 ℃ ) to high-temperature and high-pressure liquid refrigerant (16Kg/cm², below approx. 60℃ ) through radiating.
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.8 Expansion valve Operating principle
Evaporator
Refrigerant from the reservoir spurts out via the orifice, turns into low-temperature, lowpressure liquid (mist) after immediate expansion, and enters the evaporator.
2
In Ma t rk er n et a in ti o g n De al pt .
1
4
Reservoir
3
Compressor ZX215-1002147
Fig. 4-136
司
公
销 营
(1) (2) (3) (4)
Spring Diaphragm Probe Needle valve
4.8.1.9 Evaporator
Operating principle
The evaporator is a kind of heat exchanger that looks like a condenser. Warm air in the cab is conducted into the evaporator via the blower motor and undergoes heat exchange with the surface of the evaporator. Heat is absorbed and warm air turns into cool air, which flows into the cab through the air ducts. Evaporator surface absorbs heat → Refrigerant in the evaporator absorbs heat → Refrigerant evaporates . Evaporated refrigerant (gas) is absorbed by the compressor.
1
2
ZX215-1002148
Fig. 4-137 (1) Expansion valve (2) Evaporator
Shop Manual - April 2014
4-141
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.10 Dehydrator
2 1
Function ● Temporary storage of refrigerant ● Dehydration of refrigerant ● Removing dust from refrigerant 3
● Measuring the volume of refrigerant
In Ma t rk er n et a in ti o g n De al pt .
4
司
公
销 营
ZX215-1002149
Fig. 4-138
(1) (2) (3) (4)
4-142
Inlet Outlet Receiver/dehydrator Desiccant
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.11 Pressure switch Function
Pressure
● The pressure switch is installed between the reservoir and the expansion valve (hipressure pipe). It is a combination switch (Hi-Lo pressure combination switch).
1 7
2
6
● When pressure is excessively high, the compressor stops.
In Ma t rk er n et a in ti o g n De al pt .
● When pressure is excessively low, the lowtemperature condition disappears. 3
5
4
ZX215-1002150
Fig. 4-139
司
公
销 营
(1) (2) (3) (4) (5) (6) (7)
O-ring Mobile contact point Hood Plug and fixed contact Spring Chamber Diaphragm
Operating features:
Feature
DIFF
DIFF
ON
High pressure
Above 0.02 MPa
0.59±0.2 MPa
OFF Low pressure
0.196±0.02 MPa
2.94~3.19 MPa
0.196~0.250 MPa
ON Medium pressure
OFF 1.23±0.1 MPa
1.52±0.08 MPa
Shop Manual - April 2014
4-143
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.12 Fresh air sensor Fresh air temperature sensor is mounted beside the condenser or at the fresh air inlet. Consisting of thermistors, it is used to detect ambient temperature.
Resistance /Kȍ
12
Specification Item
Specification 4.4~5.6 V
Applicable temperature
-30~60 ℃
Storage temperature
-40~90 ℃
8 6 4
In Ma t rk er n et a in ti o g n De al pt .
Applicable voltage
10
Resistance
1700±85Ω
B Constant Permissible working current
3900±195 K
2
-10
10
20
30
40
AT
ZX215-1002151
Fig. 4-140
1.6 mA (MAX)
司
公
销 营
4-144
0
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.2 Refrigerant 1. General property ● High heat absorption and easy liquefaction ● Non-flammable, nonexplosive ● Stable chemical composition and quality ● Non-toxic ● Non-corrosive
In Ma t rk er n et a in ti o g n De al pt .
● No hazard to clothing
2. Refrigerant circulation
● After evaporation in the evaporator, refrigerant turns from gas into liquid via the compressor and the condenser, which finishes a refrigerant cycle.
司
公
销 营
Compressor IntakeėDischarge
Compressor LO press. side (inlet): LO temp?LO press.?Gas Pressure/Temperature:2Kg/cm²，approx. 8ć Evaporator Absorb heatėEmit cold air
Compress HI press. side(outlet): HI temp\HI press.\Gas Pressure/Temperature:16Kg/cm²ˈapprox. 80ć
Condensor (outlet): LO temp\LO press.\Mist Pressure/Temperature: 2Kg/cm²ˈapprox. 0~2ć
Condensor Via radiating:Gas refrigerantėLiquid refrigerant
Condensor (outlet)˖HI temp?HI pressure?Liquid Pressure/Tempterature˖16Kg/cm²ˈBelow 60ć
Shop Manual - April 2014
Expansion valve Hi pressureėLo pressure Hi tempėLo temp LiquidėMist
4-145
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Refrigerant cycle principle (pressure - enthalpy diagram)
lgp Liquefaction completed
Refrigerant cyclic curve Liquefaction starts
Condensor
Throttling point
Condensing process Liquid Expansion throttle
Compressing process
Compressor
In Ma t rk er n et a in ti o g n De al pt .
Expansion valve
Evaporating process Evaporator
Gas-liquid mixture
Gasification completed
司
公
销 营
h=u+Apv(kJ/kg)
UInternal energy
pPressure
VSpecial volume
AJoule equivalent
ZX215-1002152
Fig. 4-141
4-146
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3. Feeding of refrigerant ● Filling method and volume: 1) Refrigerant: HFC-134a 2) Feeding volume: 900±50 g (for reference)
In Ma t rk er n et a in ti o g n De al pt .
3) Feeding method: Feeding of liquid refrigerant from the low-pressure end is not allowed. If feeding operation fails, discharge the refrigerant that has been fed before re-feeding.
● Inspect the state of the refrigerant in the A/C circulation system through the sight glass: 1) Correct feeding: Foam is hardly observed when the refrigerant is flowing. When engine speed increases from idling to 1500 rpm, foam disappears and the refrigerant turns clear.
ZX215-1002153
Fig. 4-142
Sight glass
司
公
销 营
2) Over-feeding: No foam can be observed when refrigerant is flowing.
Proper filling
3) Under-feeding: Foam is always observed when refrigerant is flowing.
4. Evacuation
Inadequate filling
● Reason of evacuation
No moisture shall be mixed inside the air conditioning unit. Refrigerant (R134a) is soluble in water. Very small amount of moisture in the unit can cause the orifice of the expansion valve to ice up, or cause the valve of the compressor to rust. To avoid such problems, moisture in the system shall be removed before refrigerant is fed. To reduce the residual moisture in the system to the minimum, moisture in the system can evaporate through evacuating. No better means is available so far.
ZX215-1002154
Fig. 4-143
Shop Manual - April 2014
4-147
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Evacuating steps 1) Connection of manifold pressure gauge:
Valve Lo-pres. gauge
a) Close the high-pressure valve (HI) and low-pressure valve (LO) of the manifold pressure gauge.
Lo-pres.gauge above 750mmHg LO HI OFFOFF ON ON LO
HI
Hi-pres. gauge
Hi-pres. valve(ON)
Lo-pres. valve (ON) Green
b) Connect the air hose (red, blue) to the auxiliary valve of the compressor.
Red
D
Blue
Red hose——High pressure side (Mark D)
In Ma t rk er n et a in ti o g n De al pt .
S
Blue hose——Low pressure side (Mark S)
★ Connect the end of the air hose with a L to the auxiliary valve of the compressor. If connected inversely, the valve will not open. Besides, do not inversely connect the highpressure end and the low-pressure end.
Vacuum pump (running)
ZX215-1002155
Fig. 4-144
司
公
销 营
c) Connect the middle hose (green) to the vacuum pump. 2) Evacuating
a) Open the high-pressure valve (HI) and low-pressure valve (LO) on the manifold pressure gauge.
b) Turn on the vacuum pump and evacuate for about 15 minutes.
c) When negative pressure reading on the gauge (degree of vacuum) reaches above 750 mmHg, turn off the vacuum pump and close the Hipressure valve and the Lo-pressure valve on the gauge.
4-148
Compressor
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3) Air - proof check
Valve
a) Keep the Hi- and Lo-pressure valve of the manifold pressure gauge under closed state for more than 5 minutes, and make sure the pointer on the gauge does not return to zero.
Lo Hi Left at least OFFOFF for 5 minutes
Lo-press gauge backs to zero.
Lo-press gauge
Pointer backs to zero.
b) If the pointer returns to near zero, a leakage is available somewhere. Check and adjust the pipe joint. Tighten the joint and conduct another evacuating operation until no leakage is detected. 4) Leak check
Tighten the connector ZX215-1002156
In Ma t rk er n et a in ti o g n De al pt .
Fig. 4-145
Valve
a) Connect the air hose (green) that is previously connected to the vacuum pump to the fluorine cylinder.
b) Connect the other end of the hose (green) to the pressure gauge. Open the valve of the cylinder and press the vent valve of the pressure gauge. (Do not press the valve with naked hand to avoid frostbite caused by refrigerant). Release the air in the hose with the pressure of the refrigerant. (Release the vent valve when you hear a squeezing sound).
Lo Hi OFF OFF
Vent valve Release air
Open the valve
司
公
销 营
c) Add refrigerant until pressure reading on the Lo-pressure gauge is 1kgf/cm2. Hi-pressure valve of the gauge is open at this time. Close the Hi-pressure valve when feeding is finished.
d) Use a leak detector to check if leakage is present in the cooling system.
Blue
Air hose (green) Red
R134a
Fluorine cylinder
To compressor
ZX215-1002157
Fig. 4-146
Valve Lo
Hi
Lo-pres. gauge OFF ON reads1kg/cm2
Lo-pres.valve (OFF) Cylinder valve (ON)
Lo-pres. gauge reads1kg
1kg/cm2
Lo Hi OFFOFF
Open Hi-pres.valve
D
e) Make necessary repairs (tightening) if leakage is observed.
S R134a
Compressor
Fluorine cylinder ZX215-1002158
Fig. 4-147 Shop Manual - April 2014
4-149
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
5. Refrigerant filling operation
Performance testing
Air leak check
Fill refrigerant
normal
Air leak check
Pres. gauge
Fill refrigerant kg/cm2
Wait 5 min.
Air-proofness check
More than 15 min.
Evacuation ends
75cm-Hg or more
In Ma t rk er n et a in ti o g n De al pt .
Evacuation starts
● When evacuation is finished, fill refrigerant into the cooling system as per the following instruction:
Pres. gauge
Tighten pipe joint
(1) Compressor stopped, fill at hi pressure end
abnormal
Repair any leak.
(2)Compressor running, add at lo pressure end
● Fill from the hi-pressure side
1) Remove the air hose (green) of the manifold pressure gauge from the vacuum pump and connect it to the fluorine cylinder. 2) Open the valve of the cylinder and press the vent valve on the pressure gauge. Use the pressure of the refrigerant to release the air in the hose.
Valve Lo Hi OFFOFF
司
公
销 营
Vent valve
Open the valve
Loosen this nut
Blue
Release the vent valve when you hear a squeezing sound. Do not press the vent valve with naked hand to avoid frostbite.
Air hose (green)
Red
To compressor
R134a
Fluorine cylinder ZX215-1002159
Fig. 4-148
4-150
(Note) Refrigerant is released when squeaking is heard.
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3) With the engine stopped, open the high-pressure valve on the manifold pressure gauge and the fluorine cylinder valve and fill in one and a half cylinder of fluorine (approximate 600g).
Valve
Filling one cylinder
Lo Hi (about 600g) OFF ON
Lo
Hi
OFF OFF
(Never) ·Run the compressor ·Open the low-press valve
Do not run the compressor at this moment. Once the compressor is started, the refrigerant could flow back, causing the fluorine cylinder and hose to burst.
Lo press valve (OFF)
Open the high-press valve
Fluorine cylinder valve (ON)
D S
Operating the compressor without refrigerant will burn the compressor. Never run the compressor without refrigerant.
In Ma t rk er n et a in ti o g n De al pt .
R134a
ZX215-1002160
Fig. 4-149
Do not open the low-pressure valve on the manifold pressure gauge (liquid compression will occur, causing damage tot he compressor).
4) Close the high-pressure valve on manifold pressure gauge and the fluorine cylinder valve.
司
公
销 营
● Fill from lo-pressure side (additional filling) 1) Confirm the hi-pressure valve of the manifold pressure gauge is closed.
Manifold Press gauge
4) Adjust engine speed to 1300 – 1500 rpm.
ON
H I
2) Start the engine and open the cab door.
3) Turn on the air conditioner, and set Temperature control switch to minimum.
Hi-press valve (OFF)
(Note) Engine started Opening the high-pressure valve can cause the fluorine cylinder 1300~1500rpm to explode, resulting in serious ZX215-1002161 injury
Fig. 4-150
5) Open the Lo-pressure valve of the manifold pressure gauge and the valve of the fluorine cylinder, and fill refrigerant into the reservoir until no foam is observed.
Shop Manual - April 2014
4-151
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Note: Manifold pressure gauge reading (for reference): High pressure 13~17kg/cm2 (ambient temperature 30℃ ); Low pressure 1.5~2kg/cm2 (ambient temperature 30℃ ). 6) When refrigerant filling is finished, close the Lo-pressure valve of the manifold pressure gauge and the valve of the fluorine cylinder.
Valve
Fill until no foam is not observed via sight glass Lo Hi OFFOFF
In Ma t rk er n et a in ti o g n De al pt .
Lo Hi ON OFF Lo-pressure gauge (1.5~2.5kgf/cm2)
7) Check carefully for air leaks with a leak detector.
Never open the Hi-pressure valve of the manifold pressure gauge. If it is opened, high-pressure gas will counterflow and cause the air hoses and the fluorine cylinder to explode, resulting in serious injury.
Do not position the fluorine cylinder upside down (when engine is operating and filling in progress). If the cylinder is placed upside down, liquid refrigerant will be sucked directly into the compressor and cause liquid compression, resulting in damage to the compressor valve and the gaskets. Place the cylinder vertically and fill gas refrigerant.
Lo-pressure valve (open)
Compressor running
司
公
销 营
Fluorine cylinder (never placed upside down)
ZX215-1002162
Fig. 4-151
Valve
Fill until no foam is seen via the sight glass
Lo Hi ON OFF
Lo-pressure valve (open) Cylinder valve (open)
Warm water less than 40°C (Do not heat with hot water)
9) When ambient temperature is high
4-152
Hi-pressure valve (close) (Never open it)
Fluorine cylinder valve (open)
8) When ambient temperature is low When refrigerant filling can not be performed due to low ambient temperature, place the cylinder in water of less than 40 ℃ to increase the pressure of the refrigerant inside the cylinder. When ambient temperature is very high, cool the compressor with an electrical fan.
Hi-pressure gauge (13~17kgf/cm2)
Lo Hi OFF OFF
Hi-pressure valve (close)
Compressor running ZX215-1002163
Fig. 4-152
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Replace the fluorine cylinder Handle
When the refrigerant in a cylinder is used up, replace the cylinder as per the following instruction: 1) Close the Hi- and Lo-pressure valves of the manifold pressure gauge.
Air hose port Needle valve
2) Raise the needle and disc plate of the cylinder and remove the empty cylinder.
Gasket Disc plate Refrigerant cylinder
In Ma t rk er n et a in ti o g n De al pt .
3) Install a new cylinder onto the cylinder valve. 4) Release the air in the hose as per the following instruction:
Fig. 4-153
a) Tighten the valve of the fluorine cylinder, and then, loosen it a bit.
Valve Lo Hi Loosen Close
b) Open the Lo-pressure valve of the manifold pressure gauge a bit. c) Press the vent valve and allow a little refrigerant to come out. Immediately close the valve of the cylinder and the Lo-pressure valve of the manifold pressure gauge.
ZX215-1002164
Close the Lo-pressure valve immediately after the refrigerant squeaks.
司
公
销 营
★ Do not press the vent valve with naked hand to avoid frostbite by refrigerant.
5) Turn the handle of the cylinder valve to pierce the cylinder and continue filling operation.
Loosen the valve a bit
Lo-pressure valve
Green
Blue
Red
To compressor
R-134a
Refrigerant cylinder ZX215-1002165
Fig. 4-154
Shop Manual - April 2014
4-153
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
6. Troubleshooting with manifold pressure gauge After the engine has been preheated, read the pressure value on the gauge under the following conditions: 1) Temperature at air inlet: 30 – 35℃ 2) Engine speed: 1500 rpm 3) Fan speed: High 4) Temperature control: Minimum.
In Ma t rk er n et a in ti o g n De al pt .
5) Air mode: Recirculation
● Refrigerating system under normal condition Gauge reading:
Lo-pressure end 0.15~0.25 Mpa (1.5~2.5 Kg/ cm²)
Hi-pressure end 1.37~1.57 Mpa (14~16 Kg/ cm²)
司
公
销 营
04
3
4
06
6
2
07
{cmHg kgf/cm2} 8 0 8.5 -50
0
-76
-01
15
20
1
10
7
1
2
15
5
02
01
15
05
03
05
5
25
{cmHg kgf/cm2}
0
085
30
3
0
08
25
-76 35
-01
MPa
35
MPa
R134a
ZX215-1002167
Fig. 4-155
4-154
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Moisture in the refrigerating system Fault: Intermittent refrigeration to non-refrigeration
04
3
4
07
{cmHg kgf/cm2} 8 0 8.5 -50 -76
05
5
25
{cmHg kgf/cm2}
30 3
0 08
25
-76 35
In Ma t rk er n et a in ti o g n De al pt .
0
10
7
1
20
1
06
6
2
2
15
5
02
01
15
05
03
-01
15
0
085
MPa
-01
35
MPa
ZX215-1002168
Fig. 4-156
Symptom
Cause
司
公
Analysis
Remedy
销 营
● Replace receiver/ ● Moisture in the system ● Over-saturation of dedehydrator ● When the system is hydrator. ices up at the expan● Remove the moisoperating, pressure sion valve causing ● Moisture in the system at the Lo-pressure ture in the system temporary stop of ices up at the expanend unstable (somethrough constant circulation. When ice sion valve and hinders times vacuum, pumping. melts, the system bethe circulation of the sometimes normal) ● Add proper volume comes normal again. refrigerating system. of new refrigerant.
Shop Manual - April 2014
4-155
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Insufficient refrigeration Fault: Insufficient refrigeration.
04
3
4
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
7
1
-76 15
05
5
25
{cmHg kgf/cm2}
0
085
30 3
0 08
25
-76
35
-01
35
In Ma t rk er n et a in ti o g n De al pt .
-01
20
1
06
6
2
2
15
5
02
01
15
05
03
MPa
MPa
ZX215-1002169
Fig. 4-157
Symptom
Cause
Analysis 司
公
销 营
● Pressure at both Hi- and Ho-pressure ends very low
● Air leaks somewhere in the refrig● Foam is continuously oberating sysserved via the sight glass tem ● Insufficient refrigeration.
4-156
● Insufficient refrigerant in the system
● Leak of refrigerant
Shop Manual - April 2014
Remedy
● Check for air leakage with a leak detector. Make necessary repairs. ● Add proper amount of refrigerant. ● When connected with the gauge, if the reading is near zero, set the system under vacuum state after inspection and repair.
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Defective refrigerant circulation Fault: insufficient refrigeration
04
3
4
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
7
1
-76 -01
15
20
1
06
6
2
2
15
5
02
01
15
05
03
05
5
25
{cmHg kgf/cm2}
30
0 08 0
085
3
35
-01 35 MPa
In Ma t rk er n et a in ti o g n De al pt .
MPa
-76
25
ZX215-1002170
Fig. 4-158
Symptom
● Pressure at both Hi- and Lo-pressure sides very low ● Frosting on the piping between parts and reservoir
Cause
Analysis
Remedy
司
公
销 营
● Contaminant in the reservoir hinders the flow of refrigerant.
● Blocked reservoir
Shop Manual - April 2014
● Replace reservoir
4-157
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Refrigerant not circulating Fault: Non-refrigeration (intermittent refrigeration)
04
3
4
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
7
1
-76 15
05
5
25
{cmHg kgf/cm2}
30 3
0 08 0
085
25
-76
35
-01
35
In Ma t rk er n et a in ti o g n De al pt .
-01
20
1
06
6
2
2
15
5
02
01
15
05
03
MPa
MPa
ZX215-1002171
Fig. 4-159
Symptom
Cause
Analysis
司
公
销 营
● Vacuum at Lo-pressure side; pressure at Hi-pressure side extremely low
● Frosting or condensation on the pipes around the expansion valve or receiver/dehydrator
4-158
● Moisture or contaminant in the refrigerant hinders the flow of refrigerant.
● Refrigerant not circulating
● Air leak at the thermal pipe of the expansion valve hinders the flow of refrigerant.
Shop Manual - April 2014
Remedy
● Check the expansion valve and ERP. ● Blow the contaminant in the expansion valve or replace the expansion valve if necessary. ● Replace the receiver ● Release internal air and add refrigerant. If air leaks from thermal pipe, replace expansion valve.
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Over-filling of refrigerant or insufficient refrigeration of condenser Fault: Insufficient refrigeration
04
3
4
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
7
1
-76 15
05
5
25
{cmHg kgf/cm2}
30 3
0 08 0
085
25
-76
35
-01
35
In Ma t rk er n et a in ti o g n De al pt .
-01
20
1
06
6
2
2
15
5
02
01
15
05
03
MPa
MPa
ZX215-1002172
Fig. 4-160
Symptom
Cause
Analysis
Remedy
● Clean the condenser ● Excessive refrigerant in ● Pressure at both Hi● Over-filling of refrigersystem → Over-filling of ● Check the working and Lo-pressure condition of fan moant in the system. Rerefrigerant sides very high tor frigerating performance ● Insufficient refrigeration ● No foam can be obinadequate. ● If the two above of condenser → Raserved via the sight items are normal, ● Insufficient refrigeration diator fins of condenser glass even when check the volume of of condenser plugged or failure of fan engine speed drops. refrigerant. Add remotor frigerant as required. 司
公
销 营
Shop Manual - April 2014
4-159
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Air present in refrigerating system Fault: Poor refrigeration If refrigerant is added with no evacuation operation performed, the following gauge reading will appear:
04
15
05
03 3
4
02
20
1
06
6
10
25
25
In Ma t rk er n et a in ti o g n De al pt .
2
2
15
5
7
1
01
07
{cmHg kgf/cm2} 8 0 8.5 -50
0
-76
-01
15
05
5
{cmHg kgf/cm2}
30
3
0
08
0
085
MPa
-76 35
-01
35
MPa
ZX215-1002173
Fig. 4-161
司
公
销 营
Symptom
Cause
● Pressure at both Hi- and Lo-pressure ends very high ● Lo-pressure piping feeling hot
● Air enters the refrigerating system
Analysis
Remedy
● Air enters the refrigerant system
● Check if compressor oil is contaminated or inadequate.
● Insufficient evacuation
● Foam is observed through the sight glass
4-160
Shop Manual - April 2014
● Evacuate and add new refrigerant.
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Improper installation of expansion valve/ thermal pipe defect (wide opening) Fault: insufficient refrigeration
04
3
4
0
10
7
1
07
{cmHg kgf/cm2} 8 0 8.5 -50 -76 15
05
5
25
{cmHg kgf/cm2}
30 3
0 08 0
085
25
-76
35
-01
35
In Ma t rk er n et a in ti o g n De al pt .
-01
20
1
06
6
2
2
15
5
02
01
15
05
03
MPa
MPa
ZX215-1002174
Fig. 4-162
Symptom
Cause
Analysis
Remedy
司
公
● Pressure at both Hi- and Lo-pressure ends very high ● Frosting or condensation on Lo-pressure piping
销 营
● ● Improper installation of thermal pipe/defective thermal pipe (exces● sively wide opening)
● Check the installation of Excessive refrigerant in Lothermal piping pressure piping ● If thermal piping is normal, Expansion check the expansion valve. valve opening Replace expansion valve if too wide found defective.
Shop Manual - April 2014
4-161
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Compressing error Fault: No refrigeration
04
3
4
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
7
1
-76 -01
15
20
1
06
6
2
2
15
5
02
01
15
05
03
05
5
{cmHg kgf/cm2}
0
085
-76 35 - 01
35
MPa
In Ma t rk er n et a in ti o g n De al pt .
MPa
30 3
0 08
25
25
ZX215-1002175
Fig. 4-163
Symptom
● Pressure at Lo-pressure side very high ● Pressure at Hi-pressure side very low
4-162
Cause
Analysis
Remedy
● Compressing fault;
司
公
销 营
● Compressor internal leakage
● Leaking or damaged valve, or missing parts
Shop Manual - April 2014
● Repair or replace compressor
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.2.1 Compressor oil
Oil shall be added into the A/C system for lubrication. Compressor oil is solved in the refrigerant and circulates in the system. When the air conditioning system is shut down, compressor oil will stay inside the components. If no compressor oil is added into the system when replacing components, inadequate lubrication will result. Add compressor oil according to the chart below:
Replaced component Condenser
Evaporator
See "NOTICE" below
40
40
ND8# (10P, 10PA, 10S series compressor)
In Ma t rk er n et a in ti o g n De al pt .
Volume (CC)
Compressor
Compressor oil grade
ND9# (TV series compressor)
NOTICE
● Add oil into a new compressor according to the required volume of the system. When the compressor is to be replaced, discharge the surplus oil in it. 司
公
销 营
● Filling of improper amount of compressor oil: Over-filling of compressor oil will reduce the refrigerating capacity. Short of compressor oil in the system will lead to an abnormal compressor. ● Keep the pipe connectors and O-ring seals free from contamination when disassembling the compressor.
Shop Manual - April 2014
4-163
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.9 Engine Control
5
4
Z
3
In Ma t rk er n et a in ti o g n De al pt .
1
2
6
9
7
8
司
公
销 营
Z
W365-1304503
Fig. 4-164 (1) (2) (3) (4) (5) (6) (7) (8) (9)
Battery relay Battery Start switch Fuel control dial Start motor Controller Fuel injection pump Throttle motor Shutdown device
Outline
● The engine is only started and stopped with the start witch (3). ● The engine controller (6) receives the signal from the fuel control dial (4) and transmits the drive signal to the throttle motor (8) to control the governor lever angle of fuel injection pump (7) in order to regulate engine speed. ● When the start switch (3) is turned to the OFF position, the shutdown device (9) closes the injection nozzle of the fuel injection pump to cut off the engine fuel supply. Then, the engine stops.
4-164
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.9.1 System operation 4.9.1.1 Engine starting
(Power supply) Engine Lo
Hi
Hi
Governor motor
(Start signal)
B BR
C
Alternator (Driving signal)
Shutdown device
When it happens, the engine controller detects the signal voltage sent from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.
P
Throttle ON
Start switch
Safety relay s B E C R
L B E
M
Throttle OFF
Lo
s E
(Potentiometer signal)
● When the start switch is turned to the START position, the starting signal is sent to the start motor. Then, the start motor starts the engine.
Start motor
Battery relay
Pilot switch Start relay
Shutdown relay
(Start signal)
Fuel control dial
Shutdown delay relay
Monitor - controller (Regulating signal)
(Start switch ON siganl)
ZX335-1002044
In Ma t rk er n et a in ti o g n De al pt .
Fig. 4-165
4.9.1.2 Engine speed control
(Power supply)
Engine
Lo
Shutdown device
司
公
销 营
Start switch
Safety relay s B E C R
(Start signal)
L BE
M P
Throttle ON
B BR
C
Alternator (Driving signal)
Hi
s E
(Potentiometer signal)
According to the signal voltage, the controller sends a driving signal to throttle motor in order to control the fuel injection pump, hence controlling the engine speed.
Lo Hi Governor motor
Throttle OFF
● The fuel control dial sends to the controller a signal voltage corresponding to its angle.
Start motor
Battery relay
Pilot switch Start relay
Shutdown relay
(Start signal)
Fuel control dial
Shutdown delay relay
Monitor - controller
(Regulating signal)
(Start switch ON siganl)
ZX335-1002045
Fig. 4-166
4.9.1.3 Engine shutdown
(Power supply)
Lo
Hi
Throttle OFF
● When the start switch is turned to the STOP position, the shutdown controller controls the shutdown device to stop fuel supply to the fuel feed pump. The engine is then stopped.
Governor motor
Start motor s E
(Start signal)
Start switch
Safety relay s B E C R
L B E
Throttle ON
Shutdown device
Battery relay
Shutdown relay
Monitor - controller
B BR
C
Alternator
Pilot switch Start relay
(Start signal)
Engine
Shutdown delay relay
(Start switch ON siganl)
ZX335-1002046
Fig. 4-167
Shop Manual - April 2014
4-165
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.9.2 System components 4.9.2.1 Fuel control dial
140° 9×10°
1
Gear position 1
25°
2 Leftmost position
5
Rightmost position
In Ma t rk er n et a in ti o g n De al pt .
3
4
Gear position 10
司
公
销 营
6
Yellow
1
2
1
2
3
3
Blue
Red
5V
VR
0V
ZX215-1002180
Fig. 4-168 (1) (2) (3) (4) (5) (6)
Knob Dial Spring Ball Potentiometer Plug
4-166
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Function ● Turning of the fuel control dial changes the resistance of the sliding rheostat inside the dial and the voltage signal collected by the controller. The controller calculates the collected signals and drives the governor motor via signal output and controls the injection of the fuel pump so that the engine can run at an optimal speed.
（%） Dial angle
100
● When throttle voltage is beyond the area, the controller sends out alarm code and the engine runs at low idle. The area under the sloping line is the abnormality detection area.
0
0.25 1.72
4.49 4.75 5（V） Voltage (V)
ZX215-1002181
In Ma t rk er n et a in ti o g n De al pt .
Fig. 4-169
Remark:
The leftmost position is 0%; and the rightmost position is 100%.
司
公
销 营
Shop Manual - April 2014
4-167
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.9.2.2 Controller
In Ma t rk er n et a in ti o g n De al pt .
SEHC-281A (Huaxing)
司
公
销 营
J1-2（40 pins）
J1-1（81 pins）
WT365-1304001
Fig. 4-170
Controller ports
........ ........ ........ ........
................... ................... ................... ...................
J1-2 Fig. 4-171
4-168
Shop Manual - April 2014
J1-1
W365K-1304002
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Controller signal distribution J1-1
J1-2 Signal name
1 2 3 4 5 11 13 15 23 28 30 31 34 38 39 40 41 42 48 49 50 51 52
Power ground Power ground Power ground Power（24V） Power（24V） Fuel level sensor signal GPS detecting signal Throttle position signal RX232 Air filter plugging sensor signal Water temp sensor signal Oil temp sensor signal Fuel control dial signal Engine speed signal 2RS RS TX232 2nd boost button signal Engine oil pressure signal L. travel pressure sensor Bucket-dig pressure sensor Boom-down pressure sensor Arm-in pressure sensor Rear pump principal pressure sensor Sensor power ground Sensor power ground Sensor power Monitor CAN low Calibrator CAN high Pilot switch Coolant temp high R. travel pressure sensor Swing pressure sensor Bucket-dump pressure sensor Boom-up pressure sensor Arm-out pressure sensor Front pump principal pressure sensor Sensor power ground Sensor power Sensor power Monitor CAN low Calibrator CAN high Engine shutdown signal Engine start signal
53 54 55 56 58 60 65 66 67 68 69 70 71 72 73 74 75 77 78 79 80
No.
I/O
82 88 89 98 99 100 101 105 113 114 115 116 117 118 119 120 121
Input Input Input Input Input Input Input Input
Signal name
I/O
High/low speed shift valve Front pump proportional valve Rear pump proportional valve Bucket confluence valve Engine start control Shutdown delay signal Bucket solenoid valve Throttle motor drive signal+ Throttle motor drive signalPower ground Power ground Power ground Power ground Power（24V） Power（24V） Power（24V） Power（24V）
In Ma t rk er n et a in ti o g n De al pt .
No.
Input Input Input Input Input
司
公
销 营
Input
Input Input Output
Input Input Input Input Input Input
Input Input Output Output
Shop Manual - April 2014
4-169
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10 Electrical Control System 4.10.1 Control function
Engine - pump combination control
In Ma t rk er n et a in ti o g n De al pt .
Pump control
Valve control
Dual-speed Travel control
Electrical control system
Engine preheat/overheat alarm
司
公
销 营
Low Engine oil pressure alarm
Auto deceleration/acceleration control
Engine speed calibration
Self-diagnostic function
4-170
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.2 Diagram of machine control system Battery relay drive
Battery
Fuel control dial
Power supply
Shutdown delay relay
Power supply
Preheating signal
Starting signal
Start switch
Energizing signal
Fuse
Power regulator valve signal 1
Monitor controller integration
Travel speed select signal
Right travel signal
CAN bus Working mode signal Travel speed select signal Auto deceleration signal Signal monitoring info
Left travel signal
In Ma t rk er n et a in ti o g n De al pt . Signal monitoring info
4
Boom-down siganl Arm-in signal
Fuel level sensor
2 3
Boom-up signal
Fuel level signal
11
5 6
Arm-out signal
7
Bucket-dig signal
8
Bucket-dump signal Swing signal
9 10
Controller HCU
司
公
销 营
R pump outlet press signal 12
F pump outlet press signal 13
F pump control signal
Start relay
14
Engine speed sensor Motor Engine oil pressure
Safety relay
Coolant temp signal Charge indicator
Battery charge signal
15
16
feedback signal
Starting signal
PPC lock signal
Real throttle position
Engine speed
Motor drive signal
R pump control signal
Potentiometer
Eng oil press sensor Eng coolant temp sensor Alternator
Engine
Air filter plugging switch
Start signal
Start motor Preheater relay
Electric air heater
Preheat signal
W365413081
Fig. 4-172 Shop Manual - April 2014
4-171
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
1
2
R. travel pressure sensor
3
L. travel pressure sensor
4
Boom-up pressure sensor
5
Boom-down pressure sensor
6
Arm-in pressure sensor
7
Arm-out pressure sensor
8
Bucket-dig pressure sensor
9
Bucket-dump pressure sensor
10
PPC valve
15
PPC basic pressure
13
Frong pump oil feed device
14
Work equipment rotating device
11
In Ma t rk er n et a in ti o g n De al pt .
Swing pressure sensor
司
公
销 营
12
PPC
16
lock valve
Rear pump Front pump Two-speed proportional proportional solenoid valve valve valve
Port for each action control valve
Power limit solenoid valve
Servo
F
Main valve
Swing motor
Servo
R
Swing motor
Main pump
Swing motor Rear pump oil feed device Work equipment rotating device
W365413082
Fig. 4-173 Note: The diagram above is a schematic diagram of electrical control. See the hydraulic section for more information on the hydraulic circuits.
4-172
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.3 Engine-pump combination control Cab
Pilot valve B
Travel
Travel
MAX Boom up/down Bucket dig/dump
Arm in/out Swing
F1
F2
Esc
F3
F4
MIN Fuel control dial
F5
Enter
Pressure sensor
In Ma t rk er n et a in ti o g n De al pt .
MC controller input H/S/L/B Cancel auto deceleration Shift travel speed Alarm output
Pilot oil pressure
A
司
公
销 营
Main control valve
Engine chamber
P1
Pressure sensor
P2
Controller
Engine feed regulation
Pump
Pump proportional pressure reducing solenoid valve
Throttle motor
Potentiometer
Motor
Control rear pump inclination Fuel, coolant temp & others Control front pump inclination Engine speed Control motor Actual throttle position feedback
W365413083
Fig. 4-174 Shop Manual - April 2014
4-173
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Function ● This function allows operator to select a working mode and change the engine power output according to the kind of job that the machine is to be engaged. The working modes include H, S, L and B. A selector button on the monitor is available for selection of a working mode.
10
● Pump controller controls the pump so that the pump is able to absorb all torques at engine output point. These torques are determined by the pump absorption torque specification, fuel control dial setting and real engine speed under each mode.
7
6
In Ma t rk er n et a in ti o g n De al pt .
1 9
Fig. 4-175
Technical specifications
H
Speed (rpm)
~1750
Power(KW)
143
1750~1900 1900~2180
司
公
销 营
S mode
159
174
Speed (rpm)
~1750
1750~2180
Power(KW)
133
166
L mode
S
Engine power KW
H mode
L
Engine speed N
ZX335-1002051
Speed (rpm)
~1850
Power(KW)
150
Fig. 4-176
H
Pump flow Q
S
L, B
Pump output pressure P ZX335-1002052
Fig. 4-177
4-174
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Mode control methods ● Mode H ● H mode matching point: Rated speed Engine torque T
184kW/2180rpm ● Engine speed decreases when pump load increases and the pressure rises. In this case, engine speed will be up to the proximity of matching point, allowing pump controller to reduce output. On the contrary, when pump load reduces and the pressure decreases, the pump controller will keep increasing pump output until engine speed reaches the proximity of matching point.
In Ma t rk er n et a in ti o g n De al pt .
Engine speed N
司
Engine power KW
Fig. 4-178
公
销 营
ZX335-1002053
Engine speed N ZX335-1002054
Pump flow Q
Fig. 4-179
Pump output pressure P ZX335-1002055
Fig. 4-180 Shop Manual - April 2014
4-175
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Power output percentage corresponding to each mode Mode Power output percentage
H
S
L
B
95%
90%
80%
80%
10
● The controller maintains the pump suction force along the stable horse power curve and controls engine speed through enginepump combination control.
7
6
1 9
In Ma t rk er n et a in ti o g n De al pt .
Fig. 4-181
H
Engine power KW
司
公
销 营
S L
Engine speed N
ZX335-1002051
Fig. 4-182
H
Pump flow Q
S
L, B
Pump output pressure P ZX335-1002052
Fig. 4-183
4-176
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.4 Pump control function
Engine Injection pump
Main pump Governor motor
Pressure sensor
F
M P
Speed sensor
Pressure sensor R
Servo
In Ma t rk er n et a in ti o g n De al pt .
Servo
Lo
(Engine speed signal)
Hi
(Control signal)
Fuel control dial
Valve
(Control signal)
Valve
司
公
销 营
Right travel signal
Left travel signal
Boom UP signal
Boom DOWN signal
Arm IN signal
Arm OUT signal
Bucket DIG signal
Bucket DUMP signal
Swing signal
Controller
W365413084
Fig. 4-184
Shop Manual - April 2014
4-177
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Pump 1 delivery amount Boom RAISE PPC pressure Pump 1 delivery amount
Pump 1 delivery amount
In Ma t rk er n et a in ti o g n De al pt .
Arm IN PPC pressure
Arm OUT PPC pressure
Pump 1 delivery amount
MAX
Corresponding delivery output
Bucket CURL PPC pressure
Pump 1 delivery amount
司
公
销 营
Bucket DUMP PPC pressure
Pump 1 delivery amount
Pump 1 delivery amount
Swing PPC pressure
L. Travel PPC pressure
ZX215-1002197
Fig. 4-185
4-178
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Pump 2 delivery amount Boom RAISE PPC pressure Pump 2 delivery amount Arm IN PPC pressure
In Ma t rk er n et a in ti o g n De al pt .
Pump 2 delivery amount
Arm OUT PPC pressure
Pump 2 delivery amount
MAX
Corresponding delivery output
Bucket CURL PPC pressure
Pump 2 delivery amount
司
公
销 营
Bucket DUMP PPC pressure
Pump 2 delivery amount
Boom LOWER PPC pressure
Pump 2 delivery amount
R. Travel PPC pressure
ZX215-1002198
Fig. 4-186 Function
Use the work equipment and swing pilot pressure signal directly as the hydraulic pump discharge control signal. Pilot pressure is applied on the valve stem and, on the other hand, is collected by the controller. The controller keeps the discharge amount of the hydraulic pump at the specified value of the corresponding pilot pressure according to the functional relation between the set hydraulic pump dis-
charge amount and pilot pressure. During combined operation, the set discharge amount of each operation shall be added. Operation When the work equipment is operating, the controller collects the signal of pilot pressure sensor, and determines the control discharge amount of pump 1 and pump 2 according to the pressure signal.
Shop Manual - April 2014
4-179
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.4.1 Constant power control Function ● It is mainly used to calculate the theoretical maximum displacement. The system employs constant power control. Two regulators are interconnected hydraulically, enabling synchronized operation of two actuators of the same specification at the same time. Change of pump flow is determined by the sum P ∑ of working pressures of both hydraulic pumps. So long as it satisfies 2P0 ≤ P ∑ ≤ 2 PMax, the sum of powers of both hydraulic pumps remains constant, exceeding not the power of diesel engine.
Flow
Q
PMax
Pump curve P-Q
P0
In Ma t rk er n et a in ti o g n De al pt .
PMax
Operation ● When work equipment is working, the controller collects throttle position signal and gives a constant current in order to control power of pump.
P
Pressure
ZX215-1002199
Fig. 4-187
司
公
销 营
4.10.4.2 ESS control Function
● Changing of the engine speed due to load change controls the pump power, and engine output can be used more efficiently. (This function can also prevent the engine from losing control when the machine is operating under harsh conditions (eg. high - altitude area). Operation
The engine control panel controls the target operating speed of the engine.
● The engine controller collects the actual speed signal from the speed sensor, and preform a loop control with the target operating speed. Then, the controller involves the output of loop control with the calculation of the solenoid valve control signal, and sends the final regulating current signal to the pump proportional solenoid valve. ● The solenoid valve controls pump flow by feeding pilot oil to the pump regulator according to the signal sent from the controller.
4-180
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.5 Valve control function
Bucket confluence
Swing priority
Main control valve Pressure sensor
Pressure sensor
Engine
Main pump
Governor motor
Injection pump
F
M P
Servo
Servo
Valve
Valve
司
公
Lo
(Control signal)
Hi
销 营
(Control signal)
Fuel control dial
(Engine speed signal)
(Motor drive signal)
(Throttle position feedback signal)
In Ma t rk er n et a in ti o g n De al pt .
Speed sensor
R
Controller
A
Right travel signal
Left travel signal
Boom UP signal
F5
Boom DOWN signal
F4
Arm IN signal
F3 Enter
Arm OUT signal
F2
Bucket DIG signal
F1 Esc
Swing signal
CAN bus
Bucket DUMP signal
B
W365413086
Fig. 4-188 ● Bucket fl ow control ● Swing priority control
Shop Manual - April 2014
4-181
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
1) Bucket flow control Swash plate angle
Function Control the pump swash plate angle according to the operation of bucket control lever.
Max
Operation
Min
When the bucket control lever is operated, the controller collects the signal from the bucket DUMP pressure sensor and bucket CURL pressure sensor, and controls the bucket confluence proportional valve.
Bucket joystick pilot pressure
ZX215-1002201
In Ma t rk er n et a in ti o g n De al pt .
Fig. 4-189
Bucket confluence valve current
450mA
400mA
司
公
销 营
Bucket joystick pilot pressure
ZX305-1002202
Fig. 4-190
2) Swing priority control Function
● Pressurized oil from pump 1 bypasses bucket 1 valve spool, and flows first to swing motor valve spool to activate swing first. Operation
● When signals from pump 1 pressure sensor, arm pressure sensor and swing pressure sensor meet the following conditions, the controller activates the solenoid valve. The solenoid valve conducts pilot pressure oil to arm flow controller and limits the alternate circuit of arm 1 valve spool. Swing valve spool first ensures swing motor power, preventing the counter acting force when the arm is retracting from affecting the positioning of the upper swing structure. Operating condition ● Swing pressure sensor: signal output available
4-182
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.6 Dual travel speed control
Travel Motor
Right travel pressure sensor
Main Control Valve
Governor Motor
Servo
Servo 司
公
销 营
(Control signal)
(Control signal)
(Throttle position feedback signal)
(Motor drive signal)
Main Pump R
F
M P
Hi
Travel Speed Solenoid Valve
Engine
Injection Pump
Fuel Control Dial
Lo
Regulator
In Ma t rk er n et a in ti o g n De al pt .
Left travel pressure sensor
Regulator
Controller
A
F1 Esc
F2
F3
B
F4
F5
Enter
(CAN Bus) W365413085
Fig. 4-191
Shop Manual - April 2014
4-183
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Function Travel mode control Operation ● When travel mode is set to LOW, the angle travel motor swashplate reaches its maximum and travel speed is slow.
In Ma t rk er n et a in ti o g n De al pt .
● When the controller receives signal from travel pressure sensor under the following condition, it activates the solenoid valve. The solenoid valve delivers pilot oil to the travel motor swashplate angle control valve in order to reduce the angle to its minimum and increase travel speed. Operating condition
Fast travel function on the monitor is on.
Note: When lifting the track on one side with the help of work equipment and running the track, the pump control pressure on the side increases to enable fast running of the track. When the machine is traveling under HIGH mode, the travel mode cannot be changed even if work equipment is operated (work equipment pressure sensor is turned ON).
4-184
司
公
销 营
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.7 Engine preheat/overheat alarm Start switch Heat
Main Control Valve
Preheat Relay
Engine
In Ma t rk er n et a in ti o g n De al pt .
Main Pump
Governor motor
F
Coolant Temp Sensor
R
M
A
B
司
公
销 营
(Control signal)
Lo
Servo
Servo
(Control signal)
Hi
(Throttle position feedback signal)
(Motor drive signal)
P
Controller
(CAN bus) F1 Esc
F2
F3
F4
F5
Enter
W365413087
Fig. 4-192
Shop Manual - April 2014
4-185
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
1) Engine preheating Function ● Preheat control Operation ● The excavator starts preheating when it is powered on. Operating condition ● Low temperature switch is closed; excavator is energized; auto preheating begins at starting.
Function
In Ma t rk er n et a in ti o g n De al pt .
2) Engine overheat alarm
● When coolant temperature is high (over 103℃ ) during operation, the monitor displays alarm. Operation
● The controller collects signal from coolant temperature sensor. If coolant temperature is too high, alarm message will be generated and sent to the monitor. Receiving the alarm message, the monitor will illuminate the alarm indicator light. 司
公
销 营
Operating condition ● Power on
● Coolant temperature greater than 103℃ 3) Alarm - low engine oil pressure Function
● The controller collects signal from engine oil pressure sensor. When engine speed is greater than 600 rpm and engine oil pressure is too low, alarm message will be generated and sent to the monitor. Receiving the alarm message, the alarm indicator lights up.
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SY365(B)H-9 Crawler Hydraulic Excavator
4.10.8 Auto deceleration/acceleration control
Right Joystick control Bucket
Boom
RIGHT LEFT
Swing
Arm
A
FWD BWD
Left travel
Travel Control Levers
Right travel
FWD BWD
(Throttle signal)
In Ma t rk er n et a in ti o g n De al pt .
Fuel Control Dial
Left Joystick Control
IN OUT
Engine throttle controller
DIG DUMP
DOWN UP
Engine
B
Controller 司
公
销 营
F1
Esc
F2
F3
F4
Enter
F5
CAN Bus
Control lever signal
ZX225-1002022
Fig. 4-193 Function
Speed (rmp)
● When all control levers are in the neutral position, lower engine speed in order to reduce fuel consumption and noise.
● When any control lever is operated, engine speed will be back to the setting of the fuel control dial.
Set speed
Drop 100 rpm
Auto deceleration
(1400rpm)
3.2S
0.5S
0.5S
0.2S
Operated
Control lever
Unoperated
Time (s)
Operated
ZX335-1002061
Fig. 4-194 Operation ● Engine speed will drop to the speed of gear position 1 (100 rpm lower than the set speed) 0.2 second after the control levers are placed in the neutral position. The engine will run at low speed (1400 rpm) after another three (3) seconds. This can reduce void flow of hydraulic system and wear of the engine, hence saving energy and reducing noise. When any control lever is operated to resume the operation, the engine speed will be restored. ● When any control lever is operated during engine deceleration, engine speed will increase immediately to the speed set by the fuel control dial. Shop Manual - April 2014
4-187
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.9 Engine speed calibration function
Bucket confluence
Swing pripority
Main valve
Injection pump
Pressure sensor
Pressure sensor
Engine
Main pump
Governor motor
F
M
Speed sensor
In Ma t rk er n et a in ti o g n De al pt .
P
R
Servo
Servo
司
公
（Control signal）
Lo
（Engine speed signal）
Hi
（Control signal）
销 营
Fuel control dial
R. Travel signal
L. Travel signal
Fig. 4-195
4-188
A
B
(CAN bus)
Boom UP signal
Boom DOWN signal
Arm IN signal
Arm OUT signal
Bucket DIG signal
Bucket DUMP signal
Swing signal
Controller
Shop Manual - April 2014
F1 Esc
F2
F3
F4
F5
Enter
W365413088
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Function Enter the maximum engine speed for each working mode as a criteria for engine speed control.
Throttle Help Info
Operation Current Gear
1. Auto calibration of engine speed requires starting the engine.
N：
Engine Speed rpm：
2. Call the interface of System Information and select Throttle Installation Aid.
Gear Position
A. Turn the fuel control dial to position 1.
V：
In Ma t rk er n et a in ti o g n De al pt .
Throttle Position V：
B. Press the key [F4] to start speed calibration process.
s
C. Turn the fuel control dial after calibration. D. Repeat step (2) to finish calibration of speed at all positions.
E. Press the key [F5] or [ESC] to end calibration.
AUTO
n/min
rpm
XP2051203013
Fig. 4-196
司
公
销 营
Shop Manual - April 2014
4-189
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.10 System parts and components 1) Pump pressure sensor
Connector
Housing
Pressure joint
B C
In Ma t rk er n et a in ti o g n De al pt .
A
Connection Diagram
Terminal No.
Signal Name
A
Power (+5V)
司
公
B
Ground
C
Output
销 营
W365-1304208
Fig. 4-197
Operation
(V)
● The illustration on the right shows the relationship between the pressure acting upon the sensor and the output voltage.
Ӵᛳ఼䕧ߎ⬉य़
(MPa)
⊍य़ ZX335-1002067
Fig. 4-198
4-190
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
2) Pilot pressure sensor
Connector
Housing
Pressure joint
B C
A
In Ma t rk er n et a in ti o g n De al pt .
Connection Diagram
Fig. 4-199
Terminal No.
Signal Name
A
Power (+5V)
B
Ground
C
Output
W365-1304208
司
公
销 营
Operation
(V)
● The illustration on the right shows the relationship between the pressure acting upon the sensor and the output voltage.
Ӵᛳ఼䕧ߎ⬉य़
(MPa)
⊍य़ ZX335-1002067
Fig. 4-200
Shop Manual - April 2014
4-191
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3) Engine speed sensor
2
1
In Ma t rk er n et a in ti o g n De al pt .
ZX335-1002070
Fig. 4-201 Function
● Engine speed sensor is mounted on the gear ring of flywheel. It calculates the number of gear teeth passing before the sensor and sends the result to the controller. Note: If the engine speed sensor has not been tightened to the specific torque, it may fail to produce signal. Always tighten the engine speed sensor to the specific torque. 司
公
销 营
4) Engine oil pressure switch
1
2
W365413089
Fig. 4-202 (1) Pressure detector
Function
(2) Connector
Engine oil pressure switch is mounted on the delivery pipe of engine oil filter. It detects engine oil pressure and sends generated pressure signal or alarm signal to the controller.
4-192
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
5) Fuel level sensor 2
3
4
In Ma t rk er n et a in ti o g n De al pt .
1
ZX215-1002246
Fig. 4-203 (1) Float
(2) Lever (3) Shell
(4) Connector
司
公
销 营
Function
Signal from the sensor will be collected by the controller and displayed on the monitor. Resistance output sensors like hydraulic oil temperature sensor, fuel level sensor and coolant temperature sensor send signal to the controller. The controller collects, process and calculate voltage signals and converts it into related information that will be displayed on the monitor. Specifications
Electrical parameters:
● Total resistance: 100Ω ● Tolerance: ±5%
● Upper limit: Ru ≤ 9.6Ω ● Lower limit: Rd ≥ 86Ω ● Variation: Nonlinear
● Max. input volt: 12VDC Mechanical parameters: ● Rotor angle: 105° ● Vertical distance between upper and lower limits of the float (measurable range of fluid level): 500 mm Shop Manual - April 2014
4-193
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
6) Coolant temperature sensor
ZX335-1002071
Fig. 4-204 Function
The output resistance of engine coolant temperature sensor changes with the temperature. The controller collects signal and works out a cooling temperature.
4-194
司
公
销 营
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11 Monitoring System
Monitor
A
B
CAN signal
In Ma t rk er n et a in ti o g n De al pt .
Controller
F1
F2
Esc
F3
F4
F5
Enter
Each sensor
Power
司
公
销 营
Battery
ZX335-1002073
Fig. 4-205
● The machine condition is monitored by the sensors mounted on different locations of the machine. The controller processes the signals and transmits the signals to the monitor display, informing the operator of the machine condition.
● The monitor panel also contains mode selector, functional keys and machine operation control outputs.
● Information on the monitor display includes primarily: 1. Alert information in case of machine failure 2. Operating condition (coolant temperature, hydraulic oil temperature, fuel level, etc. )
Shop Manual - April 2014
4-195
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.1 Monitor SECD_5I7D
$
In Ma t rk er n et a in ti o g n De al pt .
%
F1
F2
Esc
F3
F4
F5
Enter
司
公
销 营
WX215-1204002H
Fig. 4-206 Outline
IMPORTANT
● The monitor is used to display monitoring information and select a working mode.
● The monitor has a CPU (Central Processing Unit) which processes, displays, and outputs information. ● The monitor uses a LCD (Liquid Crystal Display). Port I/O signals No.
Signal name
I/O
1 3 4 8 9 10 12
Digital input A CAN high CAN low Trigger power (24V) Power supply (24V) Ground Ground
Input
4-196
● Technical specification allows a screen to have not-more-than 10 dark spots (not illuminated) or bright spots. ● It is normal to have blue bright spots on the screen when the monitor is on for a quite period of time. ● It is normal to have blinking strips on the screen when the monitor initializes.
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.2 Monitor panel NOTICE
A
A
B
● Stop operation immediately when the alert indicator is on. Check and repair related parts. B
● The monitor does not display all working conditions of the machine.
In Ma t rk er n et a in ti o g n De al pt .
● Do not solely depend on what is displayed on the monitor when maintaining and checking the machine.
F1
The monitor panel performs the functions of monitoring and displaying, selecting a working mode, and switching on/off an electrical element.
C
Overview
The monitor consists of three parts:
Esc
F2
F3
F4
F5
Enter
XP235-13001
Fig. 4-207
司
公
销 营
A: Alert indicators B: LCD display
C: Operation keys
4.11.2.1 Alert and signal indicators Alert indicator
When the excavator has a problem, the alert indicator flashes five times along with five buzzing. If the fault is still there, the indicator light A will be kept on, telling user to solve the problem.
$
%
XP235-13002
Fig. 4-208
Shop Manual - April 2014
4-197
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.2.2 LCD display When start switch of excavator is turned to the ON position, the monitor is energized by machine batteries and enters the initializing screen. As shown by the figure on the right, a fully displayed screen includes the following information:
Sany Hydraulic Excavator
1
S
1
10
2
(1) Working mode
C
H
E
F
(2) Coolant temperature gauge (3) Fuel level gauge
3
(4) Failure code
In Ma t rk er n et a in ti o g n De al pt .
4
(5) Total service hours
5 6
(6) Function icons
0032h25m
s
E101
11/11/01 09:32:24
9 8 7
AUTO
n/min
(7) Local time
XP235-13003
(8) Local date
Fig. 4-209
(9) GPS signal indication (10) Engine speed level
司
公
销 营
Coolant temperature gauge
There are a total of 13 segments (yellow) for the full range from zero to 120 degrees. A: When the engine is just started.
B: When temperature is between zero and 110 degrees.
A
C: When temperature is over 110 degrees, the last segment turns red and the alert indicator is on at the same time. When the temperature goes back to a level under 110 degrees, the alert indicator goes off automatically.
B
C
Fig. 4-210 4-198
Shop Manual - April 2014
XP235-13004
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Fuel level gauge There are 13 yellow segments indicating a range from 0 to 100%. A: Fuel level is lower than 8%. There is no segment shown. Alert indicator is on at the same time.
A
B: Fuel level is over 8%. Alert indicator goes off.
In Ma t rk er n et a in ti o g n De al pt .
C: Fuel level is 100%.
B
C
司
公
销 营
XP235-13005
Fig. 4-211
4.11.2.2 Operation keys
The operation keys include function keys and navigation keys. A: Function keys
B: Navigation keys
F1
A
Esc
F2
F3
F4
F5
Enter
B
XP235-13006
Fig. 4-212
Shop Manual - April 2014
4-199
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Function keys There are five function keys, i.e. F1, F2, F3, F4 and F5. These keys are defined by the icons displayed above them. ● Function of the same key may vary as the icon above it changes. ● A key is disabled when no icon is displayed above it. Common icons and corresponding keys are given in the following table. Function keys
Icon displayed
F1
s
F3 F4
Display range
Change working mode.
H→S→L→B
In Ma t rk er n et a in ti o g n De al pt .
F2
Functions
AUTO
n/min
Shift to full speed/auto idling.
Full speed/auto idling
Shift to high/low travel speed.
High/low speed
Enter an option/setup item.
Same as the Enter key
View system information.
F5
Back to previous page.
——
Same as the ESC key
司
公
销 营
Operation keys
Operation keys
Functions
Enter
Enter an option/setup item.
ESC
Back to previous page.
UP (The highlight goes to the bottom item after the top one.) Increase the value of digit at the cursor. DOWN (The highlight goes to the top item after the bottom one.) Decrease the value of digit at the cursor. LEFT (The highlight goes to the right most item after the left most one.) Move the cursor leftward. RIGHT (The highlight goes to the left most item after the right most one.) Move the cursor rightward.
4-200
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3 Monitor display and operation Sany Hydraulic Excavator
4.11.3.1 Default page S
Default page is shown during normal operation of the excavator. Operation
1 C
H
E
F
1. Working mode Press the key F1 to change working mode to H, S, L or B in a cycle manner.
0032h25m
H mode - Heavy-duty operation
s
11/11/01 09:32:24
AUTO
n/min
In Ma t rk er n et a in ti o g n De al pt .
S mode - Standard operation
E101
L mode - Light-duty operation
XP235-13007
Fig. 4-213
B mode - Breaker operation
NOTE: S is the default mode after the machine is powered on.
3. Selecting high/low travel speed
2. Selecting auto idling
Press the key F2 to disable/enable auto idling function.
司
公
销 营
When the icon appears above the key F2 , press the key to disable auto idling; when the icon appears above the key F2 , press the key to enable auto idling. AUTO
n/min
n/min
NOTE: When the machine is powered on, auto idling is enabled as default.
● Auto idling is active as default. When all control levers are in neutral position for more than 0.2 seconds, engine speed will drop by 100 rpm immediately and then enter auto idling after another 3 seconds (controller will reduce engine speed to idling) in order to reduce fuel consumption and noise. ● In idling, if the controller detects any maneuver or gear change, engine speed will restore respective level.
Press the key F3 to switch between high and low travel speeds. When the symbol appears above the key F3 , press the key to select high speed travel; when the symbol appears above the key F3 , press the key to select low speed travel. NOTE: When the machine is powered on, low speed is the default travel speed. 4. Viewing failure information
When alert indicator of the monitor is on, a failure code will appear on bottom line of monitor screen. Meanwhile, a red tick appears above the key F4 . Press the key to see failure information. 5. Viewing system information Press the key F5 to see system information. NOTE: To see system information requires password. Please contact your Sany distributor.
Shop Manual - April 2014
4-201
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.2 Password entry to system information Press F5 on the default page to enter the password entry to system information. You need to enter the correct password prior to access to System Information.
System Information
Key operation Please enter password:
● Press F1 or or to increase or decrease the number on the digit with the cursor.
In Ma t rk er n et a in ti o g n De al pt .
● Press F2 or or to move the cursor to the left or right digit. ● Press F3 to enter System Unlock.
● Press F4 to enter Backlight Adjustment.
● Press F5 or ESC to return to the default page. ● Press Enter to check the validity of password. If the password is valid, you have access to the Main Menu.
XP235-13008
Fig. 4-214
司
公
销 营
4.11.3.3 Main menu
Key in the correct password and press Enter on the password entry to access System Information.
Main Menu
This page contains a list of system functions. You can pick up an item and enter respective page.
Operating Information
Failure Information Throttle Help Info
Key operation
Language Selection
SYS Clock Setup
● Press F1 or or to scroll up or down the menu. When you scroll down the menu, the highlight returns to the top item after the bottom one.
GPS Information
Running parameters of engine, main pump and main valve.
● Press F2 or Enter to enter highlighted item. ● Press F4 to go to System Setup. ● Press F5 or ESC to return to the default page.
4-202
XP1251203007
Fig. 4-215
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.4 Engine & throttle signals Select Running information on the Main Menu and press F2 or Enter to see Engine & Throttle Signals.
Engine & Throttle Signals
This page contains operating parameters of engine and throttle signals.
Coolant Temp ℃：10 Fuel Level
Key operation
%：10
Eng Oil Press kPa：10
● Press F1 to see Pilot Pressure Signals.
Throttle Gear
● Press F5 or ESC to return to the Main Menu.
Engine Speed rpm：10 V：10
In Ma t rk er n et a in ti o g n De al pt .
Gear Position
N：10
Throttle Position
V：10
XP1251203008
Fig. 4-216
4.11.3.5 Pilot pressure signals
司
公
销 营
Press F1 on the page of Engine & Throttle Signals to see Pilot Pressure Signals.
Pilot Press Signals
This page shows pilot pressure signals.
Boom UP kg：10
Key operation
Boom DOWN kg：10
● Press F1 to see Main Pump & Main Valve Signals.
Arm IN kg：10
Arm OUT kg：10
Bucket DIG kg：10
● Press F5 or ESC to return to the Main Menu.
Bucket DUMP kg：10 Swing kg：10
Left travel kg：10
Right Travel kg：10
XP2051203009
Fig. 4-217
Shop Manual - April 2014
4-203
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.6 Main pump & main valve signals Press F1 on the page of Pilot Pressure Signals to see Main Pump & Main Valve Signals. This page shows main pump and main valve signals.
Main Pump & Main Valve Pump_1 Main Press Kg：10 Pump_2 Main Press Kg：10
Key operation
Prop Valve_1 Current mA：10
● Press F1 to see Engine & Throttle Signals.
Prop Valve_2 Current mA：10 Bucket Confl valve
○
Swing Priority valve
○
Boom Priority valve
○
High/Low Speed Shift
○
In Ma t rk er n et a in ti o g n De al pt .
● Press F5 or ESC to return to the Main Menu.
XP2051203010
Fig. 4-218
司
公
4.11.3.7 Failure codes
销 营
Select Failure Codes on the Main Menu and press F2 or Enter to enter the page. This page contains failure codes and failure information.
Failure Information
Current failure code：E101 E101：Controller failure
E102：Controller temp abnormal
Key operation
E103：Sensor power abnormal E202：Voltage high
● Press F1 to see next page of failure codes.
E203：Backup battery volt low
● Press F5 or ESC to return to the Main Menu.
H101：F. pump press abnormal
E401：CAN bus abnormal
E501：Fuel control dial abnormal H102：R. pump press abnormal
H105：F. pump valve current abnormal
H108：R. pump valve current abnormal H112：Backup pilot press abnormal
H201：Bucket-dig pilot press abnormal
H202：Bucket-dump pilot press abnormal H203：Arm-in pilot press abnormal
H204：Arm-out pilot press abnormal
H205：Boom-up pilot press abnormal
XP2051203011
Fig. 4-219
4-204
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.8 Throttle help information Select Throttle Help Info on the Main Menu and press F2 or Enter to enter the page. Throttle Help Info
This page contains help information for throttle installation.
Current Gear
Key operation
N：
● Press F2 to select auto idling or full speed.
Engine Speed rpm：
● Press F3 to select high or low speed travel.
Gear Position
● When SYFCS controller is used, the icon rpm will appear in blue or red color.
Throttle Position V：
In Ma t rk er n et a in ti o g n De al pt .
V：
● Press F5 or ESC to return to the Main Menu.
s
rpm
AUTO
n/min
Note: Only a SYFCS controller allows the change of rpm between blue and red colors.
XP2051203013
Fig. 4-220
4.11.3.9 Language selection
司
公
销 营
Select Language Selection on the Main Menu and press F2 or Enter to enter the page.
This page is used to select a language for the system.
Language Selection
Key operation
中文系统
● Press F2 to select Chinese System ( 中文 系统 ).
English Systems
● Press F3 to select English System.
● Press F5 or ESC to return to the Main Menu. ● Press or to highlight a language up or down the list.
中文
Eng XP2051203014
Fig. 4-221
Shop Manual - April 2014
4-205
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.10 System clock setup Select System Clock Calibration on the Main Menu and press F2 or Enter to enter the page. This page is used to set up system clock.
SYS Clock Setup
Key operation
Local time and time zone：
● Press or to increase or decrease the number on the digit with the cursor.
1234·12·12 12:12：12 12W
Time and time zone setup：
● Press or to move the cursor to the left or right digit.
1234·12·12 12:12：12 12W
In Ma t rk er n et a in ti o g n De al pt .
● Press F1 or Enter to finish calibration. You will be prompted by “Calibration finished! Please restart your machine.”
Use [↑][↓][←][→] to set p system clock.
● Press F5 or ESC to return to the default page. NOTE: System clock can only be set up once after the machine is powered on. When the machine is powered on, the prompt of successful calibration remains on the screen if you press F1 or the Enter key.
4-206
XP2051203015
Fig. 4-222
司
公
销 营
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.11 GPS information Select GPS Information on the Main Menu and press F2 or Enter to enter the page. This page shows GPS monitoring information.
GPS Information
Key operation
Longitude °：121.0W
Press F5 or ESC to return to the default page.
Altitude m：28.79P
Latitude °：31.40N Velocity Km/h：4.037 Number of Satellites ：0006
Note:
Communication Indicator ：1023 Signal to noise ratio 1：
dB
Signal to noise ratio 2：
dB
In Ma t rk er n et a in ti o g n De al pt .
1. The letter “E” stands for East Longitude and “W” for West Longitude. 2. The letter “N” stands for North Latitude and “S” for South Latitude. 3. The letter “P” stands for a height above the seal level and “N” for a height below the seal level.
4. The signal-to-noise ratio ranges from 0 to 99, which is indicated by a bar. The value on the right of the bar is real S/N ratio.
Signal to noise ratio 3：
dB
Signal to noise ratio 4：
dB
XP20512003026
Fig. 4-223
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5. If the elevation value is not zero and no value is displayed for the longitude and latitude, GPS data are being received but the location has not been precisely defined yet. 6. When the communication signal is 1023, GPRS communication is regular. When it is 615, the GPRS communication is abnormal. 7. When the communication signal changes from 7 to 0, the SIM card or the antenna has a bad connection.
8. When the communication signal changes from 15 to 0, GPRS service is not available, the SIM card has insufficient fund, or GPRS network is abnormal. 9. When the communication signal changes from 31 to 0, the monitoring center is closed. 10. This page is required for remote system locking, remote system unlocking and remote downloading.
Shop Manual - April 2014
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.12 System setup Press the key F4 on the Main Menu to enter System Setup. System Setup
This page is used to configure your machine. Note: Access to System Setup requires entering the password. For method of entering password see “Password entry to system information” on page 4-202.
Machine Configuration Service Hour Setup Machine Configuration Setup Hydraulic Oil Temperature
Key operation
In Ma t rk er n et a in ti o g n De al pt .
● Press F1 or or to scroll up or down the menu. When you scroll down the menu, the highlight returns to the top item after the bottom one. ● Press F2 or Enter to enter highlighted item.
XP2051203016
● Press F5 or ESC to return to the Main Menu.
Fig. 4-224
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4.11.3.13 Machine configuration
Select Machine Configuration on the Main Menu and press F2 or Enter to enter the page.
This page shows machine configuration information.
Machine Configuration
Note: Access to System Setup requires entering the password. For method of entering password see “Password entry to system information” on page 4-202.
Machine Model： SY215C \V217
Key operation
HYD SYS Model： KPM_P
Machine S/N： 11SY0216 00008 Engine Model： CUMMINS_II
● Press F5 or ESC to return to System Setup.
Control SYS： KC-MB-001
Note: “V217” following machine model is software version. XP2051203018
Fig. 4-225
4-208
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.14 Service hour setup Select Service Hour Setup on the page of System Setup and press F2 or Enter to enter the page.
Service Hour Setup
This page is used to set up service hours of the machine.
Current Service Hours ： 100 h 50 m
Note: Access to System Setup requires entering the password. For method of entering password see “Password entry to system information” on page 4-202.
Service Hour Setup ： 100 h 50 m
In Ma t rk er n et a in ti o g n De al pt .
Key operation
● Press F1 or Enter to save the change after calibration. You will see on the screen “Calibration finished! Please restart your machine.”
Use [↑][↓][←] and [→] to set up service hours.
XP2051203021
Fig. 4-226
● Press F5 or ESC to return to System Setup.
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Shop Manual - April 2014
4-209
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.15 Machine configuration setup Select Machine Configuration Setup on the page of System Setup and press F2 or Enter to enter the page.
Machine Configuration Setup
This page is used to set up machine configuration after monitor installation.
Machine Model：SY215C\GPS 32
Note: Access to System Setup requires entering the password. For method of entering password see “Password entry to system information” on page 4-202.
Engine Model：CUMMINS_II
Key operation
Machine S/N：11SY0216 00008
HYD SYS Model：KPM P
In Ma t rk er n et a in ti o g n De al pt .
Controller Model：KC-MB-001
● When “215” after machine model is blinking, each pressing of F1 will bring the number up by 10; when “32” after GPS is blinking, each pressing of F1 will bring the number up by 10.
Use [↑][↓][←] and [→] to change machine S/N.
Model Eng
Fig. 4-227
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● Press F4 to change controller model.
● Press F5 to save the change. You will see on the screen “Calibration finished! Please restart your machine.”
● Press or to increase or decrease the selected machine S/N by 100. ● Press or to increase or decrease the selected machine S/N by 1. Depress the key to increase S/N quickly. ● Press ESC to return to System Setup.
● Each pressing of the key Enter enables the number after machine S/N or model to blink. A blinking number can be modified using the keys.
4-210
Ctrl
XP2051203023
● Press F2 to change Engine Model.
● Press F3 to change Hydraulic System Model.
Hyd
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.16 Hydraulic oil temperature Select Hydraulic Oil Temp on the page of System Setup and press F2 or Enter to enter the page.
HYD Oil Temp
This page shows temperature of hydraulic oil. Hydraulic Oil Temp ℃：49
Key operation
In Ma t rk er n et a in ti o g n De al pt .
● Press F5 or ESC to return to System Setup.
XP2051203028
Fig. 4-228
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4.11.3.17 Screen brightness setup
销 营
Press F4 on the page of password entry to system information to enter the page. This page is used to adjust backlight brightness of the screen.
Screen Brightness Setup
Screen Brightness：20%
Key operation
● Press F1 to dim backlight.
● Press F2 to enhance backlight.
● Press F3 to safe brightness change.
● Press F5 to return to System Information.
Press F3 to save setup！
XP2051203029
Fig. 4-229
Shop Manual - April 2014
4-211
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.18 System lockout (level 1) When this page appear on monitor, it indicates that the excavator is locked out in level 1. System Lockout
Key operation ● Press F5 to enter the page for unlocking.
Machine Model：SY205C
NOTE: After 5 seconds according to the command, corresponding state (Level 1 lockout, level 2 lockout or no lockout) will be displayed. (Waiting for 5 seconds performs a function of filtration.)
Machine S/N：00008 Lockout State：Level 1
In Ma t rk er n et a in ti o g n De al pt .
Current time：12：12：11
System Locked
Contact your Sany distributor to unlock your machine.
XP2051203024
Fig. 4-230
4.11.3.19 System lockout (level 2)
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When this page appear on monitor, it indicates that the excavator is locked out in level 2.
System Lockout
Key operation
● Press F5 to enter the page for unlocking.
Machine Model：SY205C Machine S/N：00008
NOTE: After 5 seconds according to the command, corresponding state (Level 1 lockout, level 2 lockout or no lockout) will be displayed. (Waiting for 5 seconds performs a function of filtration.)
Lockout State：Level 2
Current time：12：12：11
System Locked
Contact your Sany distributor to unlock your machine.
XP2051203025
Fig. 4-231
4-212
Shop Manual - April 2014
Structure and Functions
BLMaInt e r AkNe rn a tKi t i ng o PAD nal eGp tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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Shop Manual - April 2014
4-213
Structure and Functions
BLM In t aAr e kNe rn a tKi t i nP o gA n al DG ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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4-214
Shop Manual - April 2014
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Standard Values 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
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Shop Manual - April 2014
5-1
Standard Values
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
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5-2
Shop Manual - April 2014
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
5 TABLE OF STANDARD VALUES 5.1 Standard Values for Engine-Related Parts
Item
SY365(B)H-9
Engine
ISUZU AA-6HK1-XQP-01 Standard values for Repair limits new machine 2,250 ± 25 2,250 ± 25
Measurement condition
Unit
High idling
rpm
Low idling
rpm
1,050 ± 25
1,050 ± 25
In Ma t rk er n et a in ti o g n De al pt .
Engine speed
Applicable Models
Rated speed
rpm
2,000
2,000
Air cleaner outlet location Arm-in relief ＋ max rpm
kPa {mmH2O}
Min 133 {Min 1,000}
Min 133 {Min 1,000}
Valve clearance
At sudden acceleration At high idling Intake valve Exhaust valve
Bosch Index mm mm
Max 25 — 0.4 0.4
35 — 0.3– 0.5 0.3 – 0.5
Compression pressure
Oil temp：75℃ Engine speed 250 rpm
Mpa {kg/cm2}
Min 3.0 {31}
2.5 {26}
kPa {mmH2O}
Max 0.98 {Max 100}
1.96 {200}
High idling
MPa {kg/cm2}
Min 0.29 {Min 3.0}
0.25 {2.5}
Low idling
MPa {kg/cm2}
Min 0.10 {Min 1.0}
0.07 {0.7}
Engine oil temp
Full speed range (in oil pan)
℃
80 – 110
120
Fan belt tension
Between fan belt pulley and alternator belt pulley Deflection when pressed with finger force of 58.8 N {6 kg}
mm
8.5
Min 7，Max 10
Between fan belt pulley and compressor belt pulley A/C compressor belt tension Deflection when pressed with finger force of 58.8 N {6 kg}
mm
5–8
5–8
Intake pressure (Negative pressure) Exhaust color
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Blow-by pres- Coolant temp：working range armsure in relief ＋ max rpm
Engine oil pressure
Shop Manual - April 2014
5-3
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
5.2 Standard Values for Chassis-Related Parts Applicable Models category
Measurement Condition
Unit
Standard Value for New Machine
Permissible Value
● Engine coolant temperature: Within operational range ● Hydraulic oil temperature: Within operational range ● Engine running at high idle ● Heavy-load operating mode (H) ● Arm-in relief condition
rpm
2,050±50
2,050±50
2 pumps at relief + boosting (if available)
● Engine coolant temperature: Within operational range ● Hydraulic oil temperature: Within operational range ● Engine running at high idle ● Heavy-load operating mode (H) ● Arm-in relief condition + boost switch on
rpm
2,050±50
2,050±50
Speed when auto deceleration is operated
● Engine running at high idle ● Auto idling switch on ● All control levers neutral
rpm
1,350±50
1,400±100
mm
11.5±0.5
11.5±0.5
mm
9.5±0.5
9.5±0.5
mm
11.5±0.5
11.5±0.5
mm
9.5±0.5
9.5±0.5
Item
In Ma t rk er n et a in ti o g n De al pt .
Engine Speed
2 pumps at relief
Boom control valve Spool Stroke
SY365(B)H-9
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Raise
Lower ● Engine stopped In ● For measurArm control valve ing points see Out Control Valve Bucket control valve Curl/dump on page 3-10. Swing control valve Travel (L&R)
mm
9.5±0.5
9.5±0.5
mm
9.5±0.5
9.5±0.5
Travel control valve
mm
9.5±0.5
9.5±0.5
mm
85±10
85±10
● Engine stopped mm ● Control lever grip at center Bucket control lever ● Max. reading up to stroke end (except mm lever play in NEUTRAL position) Swing control lever mm Travel control lever mm ● Engine stopped ● Slightly push Work Equipment mm the control lever with your hand. Play of control lever Stop pushing when you feel clear resistance Travel mm ● Max. reading up to stroke end
85±10
85±10
85±10
85±10
85±10 115±12
85±10 115±12
Max 15
Max 20
Max 20
Max 25
Forward & Reverse
Boom control lever
Travel of Control Lever
Arm control lever
5-4
Shop Manual - April 2014
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Applicable Models
Standard Value for New Machine
Permissible Value
Boom control lever
Max 19.6 {Max 2.0}
Max 24.5 {Max 2.5}
Arm control lever
Max 19.6 {Max 2.0}
Max 24.5 {Max 2.5}
Bucket control lever
Max 15.6 {Max 1.6}
Max 21.6 {Max 2.2}
Max 15.6 {Max 1.6}
Max 21.6 {Max 2.2}
Max 30.4 {Max 3.1}
Max 39.2 {Max 4.0}
Max 93.1 {Max 9.5}
Max 107.6 {Max 11}
3.5 ± 1.0 {36 ± 10}
3.5 ± 1.0 {36 ± 10}
34.3 ± 1.0 {350 ± 10}
33.3 – 35.3 {340 – 360}
34.8 ± 1.0 {355 ± 10}
33.3 – 36.8 {340 – 375}
34.8 ± 1.0 {355 ± 10}
33.3 – 36.8 {340 – 375}
25.5 ± 1.0 {261 ± 10}
24.5 － 27.5 {250 － 280}
33.4 ± 1.0 {342±10}
32.4 – 34.4 {330 – 351}
3.9±0.2 {40±2}
3.7 – 4.1 {37 – 41}
Item
Measurement Condition
● Hydraulic oil temp：Within operational range ● Engine running at high idle Swing control ● Control lever grip at center ● Pedal at tip lever ● Max reading at stroke end Travel control lever
Unit
N {kg}
In Ma t rk er n et a in ti o g n De al pt .
Operating Force of Control Lever and Pedal
Category
SY365(B)H-9
Travel control pedal
● Hydraulic oil temp：Within operational range ● Engine running at high idle Unloaded ● Working mode：H pressure ● Hydraulic pump output pressure with all control levers in neutral position ● Hydraulic oil temp：Within opBoom relief erational range ● Operate corresponding control lever after the engine runs at Arm relief high idling speed. ● Working mode：H ● Hydraulic pump output pressure Bucket relief with all measurement circuits MPa relieved {kg/cm2} ● Hydraulic oil temp：Within opSwing relief erational range ● Operate corresponding control lever after the engine runs at high idling speed. ● Working mode：H Travel relief ● Hydraulic pump output pressure with all measurement circuits relieved ● Hydraulic oil temp：Within operational range Control circuit ● Engine running at high idle source pres● Self pressure reducing valve sure output pressure with all control levers in NEUTRAL position 司
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Hydraulic Pressure
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Shop Manual - April 2014
5-5
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Applicable Models
5-6
Measurement Condition
Unit
● ● ● ●
Hydraulic oil temp：Within operational range Engine running at high idle Working mode: H degree Swing circle misalignment amount when stopping mm after one turn ● For measuring posture see Swing 1 on page 3-10. ● Hydraulic oil temp：Within operational range 90° ● Engine running at high idle ● Working mode: H ● Time required for passing points 90° and 180° from starting point ● For measuring posture see Swing 180° 1 on page 3-10.
Standard Value Permissible for New MaValue chine
Max 100 (—)
Max 130 (—)
sec.
3.1 ± 0.3
Max 3.7
sec.
4.4 ± 0.4
Max 5.5
In Ma t rk er n et a in ti o g n De al pt .
Time taken to swing
Travel speed (unloaded)
Travel
Motor leakage
Hydraulic drift
Swing
Time taken to start swing
Swing brake angle
CateItem gory
SY365(B)H-9
● ● ● ●
Hydraulic oil temp：Within operational range Engine running at high idle Working mode: H Time required for 5 turns after making initial one turn ● For measuring posture see Swing 1 on page 3-10. 司
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sec.
● Hydraulic oil temp：Within operational range ● Engine stopped ● Keeping the upper structure transverse on a grade of 15° . For more information see Swing 2 on page 3-10. mm ● Notching a mating mark on inner and outer races of the swing circle ● Mating mark misalignment amount during 5 minutes. ● Hydraulic oil temp：Within operational range ● Engine running at high idle ● Swing lockout switch: ON ml/min ● Leakage amount for one minute during swing relief ● Hydraulic oil temp：Within operational range Lo ● Engine running at high idle ● Working mode: H ● Time required for track shoes to make 5 turns after making one initial turn ● For more information on measur- Hi ing posture see Travel 1 on page 3-11. Shop Manual - April 2014
31
+4 -2
Max 35
0
0
Max 5
Max 10
11.8± 3
8.8-14.8
7.6 ± 3
4.6-10.6
sec.
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Applicable Models Item
Measurement Condition
Standard Permissible Unit Value for New Value Machine
● ● ● ● ●
Hydraulic oil temp：Within operational range Engine running at high idle Lo Working mode: H Level ground sec. Time required for traveling 10 m after 10 m trial run Hi ● For measuring posture see Swing 2 on page 3-10. ● ● ● ● ● ●
22 ± 2.5
19.5-24.5
14 ± 2.5
11.5-16.5
Hydraulic oil temp：Within operational range Engine running at high idle Working mode: H Travel Speed: Low Hard level ground mm Amount of deviation (χ) while traveling 20 m after initial 10 m trial run ● For measuring posture see Travel 2 and 3 on page 3-11.
Max 800
Max 900
● Hydraulic oil temp：Within operational range ● Engine stopped ● Park the machine on a grade of 12° , with the sprockmm et in the downhill direction ● Measure the sliding distance for 5 minutes ● For measuring posture see Travel 4 on page 3-12.
0
0
13.6
27.2
In Ma t rk er n et a in ti o g n De al pt . Deviation
Hydraulic drift Arm cylin- Boom Bucket cylinder der cylinder
Work Equipment
Bucket tips
Leakage amount of travel motor
Hydraulic drift
Travel
Travel speed (Actual run)
Category
SY365(B)H-9
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● ● ● ●
Hydraulic oil temp：Within operational range Engine running at high idle Traveling with the sprocket locked mm Oil leakage amount for one minute with traveling in relief condition
● ● ● ●
mm
Max 600
Max 900
mm
Max 20
Max 27
mm
Max 20
Max 20
mm
Max 35
Max 40
Hydraulic oil temp: Within operational range Flat and level ground Bucket full of earth or with rated load (0.8m3: 1,440 kg) Boom horizontal, arm fully retracted and bucket cylinder fully extended ● Engine stopped ● Work equipment control lever in neutral position ● Measure total amount of falling for 15 minutes by measuring the falling every 5 minutes immediately after initial setting ★ Bucket tip lower distance ★ Boom cylinder: Cylinder retracting distance ★ Arm cylinder: cylinder extending distance ★ Bucket cylinder: cylinder retracting distance ● For measuring posture see Work Equipment 1 on page 3-12.
Shop Manual - April 2014
5-7
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Applicable Models Cate-
Item
gory
SY365(B)H-9
Measurement Condition
Unit
Standard Value for Permissible New Machine Value
● Hydraulic oil temp：Within operational range ● Engine running at high idle ● Working mode: H ● Time required for the bucket to raise from the ground to its stroke end
UP
● For measuring posture see Work Equipment 2 on page 3-12. ● Hydraulic oil temp：Within operational range
sec.
3.8 ± 0.3
Max 4.8
In Ma t rk er n et a in ti o g n De al pt .
Work Equipment Speed
Work Equipment
Boom
IN
sec.
3.5 ± 0.3
Max 4.5
OUT
sec.
3.0± 0.3
Max 3.5
DIG
sec.
3.1 ± 0.3
Max 3.4
sec.
2.0 ± 0.3
Max 2.3
● Engine running at high idle ● Working mode: H
Arm
● Time required from dumping stroke end to digging stroke end ● For measuring posture see Work Equipment 3 on page 3-13.
● Hydraulic oil temp：Within operational range
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● Engine running at high idle
● Working mode: H Bucket ● Time required from dumping stroke end to digging stroke end DUMP ● For measuring posture see Work Equipment 4 on page 3-13.
5-8
Shop Manual - April 2014
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Applicable Models Category
Item
Measurement Condition
Unit
● Hydraulic oil temp：Within operational range ● Engine running at low idle ● Working mode: H ● Time required from maneuvering the joystick to the moment that the sec. bucket reaches the ground and begins to push the machine upward, within 50 mm off the ground ● For measuring posture see Work Equipment 5 on page 3-13. ● Hydraulic oil temp：Within operational range ● Engine running at low idle ● Working mode: H ● Average time required for operatsec. ing the control lever back and forth till the arm starts to move ● For measuring posture see Work Equipment 6 on page 3-14. ● Hydraulic oil temp：Within operational range ● Engine running at low idle ● Working mode: H ● Average time required for operatsec. ing the control lever back and forth till the arm starts to move ● For measuring posture see Work Equipment 7 on page 3-14. ● Hydraulic oil temp：Within operational range ● Engine running at high idle ml/min ● Leakage amount for one (1) minute with cylinder or travel measured at relief condition
Standard Value for New Machine
Judgement Criteria
Max 1.0
Max 1.2
Time Delay
In Ma t rk er n et a in ti o g n De al pt .
Work Equipment
Boom
SY365(B)H-9
Arm
Max 2.8
Max 1.0
Max 3.6
5
20
10
50
Max 200
Max 220
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Internal Leakage
Bucket
Performance in Combined Operations
Max 2.0
Cylinders Central Swivel Joint
● Hydraulic oil temp：Within operational range ● Engine running at high idle Amount of devia● Working mode: H tion in simultane● Travel Speed: Low ous operation of ● Amount of deviation measured for work equipment 20 m after traveling about 10 m on and travel a hard level ground ● For measuring posture see Travel 2 and 3 on page 3-11.
mm
Shop Manual - April 2014
5-9
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Machine attitudes applicable to performance test and testing procedure of all machine models
In Ma t rk er n et a in ti o g n De al pt .
Control valve: Spool stroke
ZX335-1003002
Fig. 5-1
Swing 1: Swing brake angle, time taken to start swing and time taken to swing
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ZX335-1003004
Fig. 5-2
Swing 2: Hydraulic drift of swing
15°
Sprocket ZX335-1003006
Fig. 5-3 5-10
Shop Manual - April 2014
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Travel 1: Travel speed (without load)
ZX335-1003003
In Ma t rk er n et a in ti o g n De al pt .
Fig. 5-4
Travel 2: Travel speed (actual run), Travel deviation
45°
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销 营
ZX335-1003005
Fig. 5-5
Travel 3: Travel deviation
x 10m
ZX335-1003007
Fig. 5-6
Shop Manual - April 2014
5-11
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Travel 4: Hydraulic drift of travel
12°
ZX335-1003008
In Ma t rk er n et a in ti o g n De al pt .
Fig. 5-7
Work equipment 1: Hydraulic drift of work equipment
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销 营
ZX335-1003010
Fig. 5-8
Work equipment 2: Boom speed
ZX335-1003012
Fig. 5-9
5-12
Shop Manual - April 2014
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Work equipment 3: Arm speed
ZX335-1003009
In Ma t rk er n et a in ti o g n De al pt .
Fig. 5-10
Work equipment 4: Bucket speed
司
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销 营
ZX335-1003011
Fig. 5-11
Work equipment 5: Boom delay
ZX335-1003013
Fig. 5-12
Shop Manual - April 2014
5-13
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Work equipment 6: Arm delay
ZX335-1003014
In Ma t rk er n et a in ti o g n De al pt .
Fig. 5-13
Work equipment 7: Bucket delay
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ZX335-1003015
Fig. 5-14
5-14
Shop Manual - April 2014
Standard Values
BLMaInt e r AkNe rn a tKi t i ng o PAD nal eGp tE.
SY365(B)H-9 Crawler Hydraulic Excavator
司
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Shop Manual - April 2014
5-15
Standard Values
BLM In t aAr e kNe rn a tKi t i nP o gA n al DG ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
司
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5-16
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Testing and Adjusting 6 Testing and adjusting
6.1 Engine Speed - Test and Adjust............................................................................... 6-3 6.2 Exhaust Gas Color - Test ......................................................................................... 6-5 6.3 Valve Clearance - Adjust.......................................................................................... 6-7 6.3.1 Testing............................................................................................................ 6-8 6.3.2 Adjusting ........................................................................................................ 6-9 6.4 Compression force - Test ....................................................................................... 6-10 6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13 6.5.1 Testing.......................................................................................................... 6-14 6.5.2 Adjusting ...................................................................................................... 6-18 6.6 A/C Compressor Belt Tension - Test and Adjust .................................................... 6-19 6.6.1 Testing ......................................................................................................... 6-19 6.6.2 Adjusting ...................................................................................................... 6-19 6.7 Swing Bearing Clearance - Test ............................................................................ 6-20 6.8 Track Tensioner - Test and Adjust .......................................................................... 6-21 6.8.1 Testing.......................................................................................................... 6-21 6.8.2 Adjusting ...................................................................................................... 6-22 6.9 Oil in Hydraulic Circuits - Test and Adjust .............................................................. 6-23 6.9.1 Testing.......................................................................................................... 6-23 6.9.2 Adjusting ...................................................................................................... 6-25 6.10 Control Oil Circuit Pressure - Test and Adjust...................................................... 6-28 6.10.1 Testing........................................................................................................ 6-28 6.10.2 Adjusting .................................................................................................... 6-28 6.11 Solenoid Valve Output Pressure - Test ................................................................ 6-29 6.12 Pilot Valve Output Pressure - Test ....................................................................... 6-31 6.13 Work Equipment and Swing Pilot Valves - Adjust ................................................ 6-33 司
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Shop Manual - April 2014
6-1
Testing and Adjusting
Hydraulic Drift of Work Equipment - Test ............................................................. 6-34 Remaining Pressure in Hydraulic Lines - Relieve................................................ 6-36 Oil Leakage Amount - Test................................................................................... 6-37 Air in Each Component - Purge ........................................................................... 6-41
In Ma t rk er n et a in ti o g n De al pt .
6.14 6.15 6.16 6.17
SY365(B)H-9 Crawler Hydraulic Excavator
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6-2
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6 TESTING AND ADJUSTING 6.1 Engine Speed - Test and Adjust Testing Start the engine and keep the engine running until coolant temperature enters operational range. Key in the password on the monitor and check if the engine speed is normal in each gear position.
Main Menu Operating Information Failure Information Throttle Help Info
Testing Items:
In Ma t rk er n et a in ti o g n De al pt .
Language Selection SYS Clock Setup
1. Engine speed at low idle
GPS Information
2. Engine speed at fuel control dial position 11 (H and S modes)
Running parameters of engine, main pump and main valve.
3. Engine speed at relief, with fuel control dial in position 11 (H and S modes) 4. Engine speed at auto deceleration
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XP1251203007
Fig. 6-1
Shop Manual - April 2014
6-3
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
Calibration 1. Preconditions for auto speed calibration: A. Start the engine. Throttle Help Info
B. Check the throttle position voltage for gear position 1 on the Throttle Help Info page on the monitor. Normal voltage should be 1.3±0.3V under normal speed range of 1050±50. If the voltage is out of the specified range, manually adjust the throttle pull rod. Otherwise abnormality would occur in speed calibration and a red question mark“?” would appear after Engine Speed on the Throttle Help Info page on the monitor.
Current Gear
N：
Engine Speed rpm： Gear Position
V：
In Ma t rk er n et a in ti o g n De al pt .
Throttle Position V：
s
2. Enter the speed calibration page.
Press F5 on the default page of monitor and key in the password to access the Main Menu. Choose Throttle Help Info on the Main Menu to enter the page like the figure on the right.
rpm
XP2051203013
Fig. 6-2
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3. Speed calibration
Press F4 on the Throttle Help Info page to execute speed calibration. The system enters speed calibration (when the icon turns red) and it automatically shifts to full speed (when the icon turns red). 4. Successful calibration
If the calibration is done successfully, the icon for calibration indication turns blue. The switching to full deceleration requires pressing F2 to switch it manually.
6-4
AUTO
n/min
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.2 Exhaust Gas Color - Test ● Tools used for testing exhaust gas color No.
Part Name
1
Smoke meter
2
Opacimeter
CAUTION
In Ma t rk er n et a in ti o g n De al pt .
● Be careful not to touch any hot part when installing or removing a testing equipment. 1. Testing with smoke meter
A. Put the filter paper in the smoke meter.
B. Insert the waste gas intake pipe into the exhaust pipe. C. Start the engine and keep the engine running until engine coolant temperature is within the operational range.
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D. When engine speed increases suddenly or is kept at high idle, direct exhaust gas through smoke meter to the filter paper.
ZX335-1004002
Fig. 6-3
E. Remove the filter paper from the smoke meter. Read the smoke value through the apparatus provided. F. Remove the testing tools after testing. Make sure the machine goes back to its normal state. 2. Testing with opacimeter A. Mount the opacimeter onto the exhaust pipe by clamping it to the pipe outlet.
ZX335-1004003
Fig. 6-4
Shop Manual - April 2014
6-5
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
B. Open the opacimeter and preheat it for about 15 minutes. C. Start the engine and keep the engine running until engine coolant temperature is within the operational range. D. When engine speed increases suddenly or is kept at high idle, use the opacimeter to read the smoke value of exhaust gas. E. Remove the testing tools after testing. Make sure the machine goes back to its normal state.
ZX335-1004004
In Ma t rk er n et a in ti o g n De al pt .
Fig. 6-5
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6-6
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.3 Valve Clearance - Adjust ● Service Standard (Unit: mm) Location
Service Item
Standard Value
Limits
—
Valve clearance (with engine cold)
0.4
—
Correction method Adjust
● Special tools Symbol
Tool name and shape
Part Number
Application
In Ma t rk er n et a in ti o g n De al pt .
Flat-head screwdriver
MH060008
Adjustment of valve clearance (carried on machine)
ZX335-1004006
Check and adjust the valve clearance in cold state as per the following procedure: 司
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Shop Manual - April 2014
6-7
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.3.1 Testing In cold state, valve clearance is to be checked and adjusted as per the following procedure: Aligning point
1. Remove the rocker arm cover. 2. Turn the No.1 piston or the No.6 piston to the top dead center (TDC) of compression stroke by following the steps below. ● Turn the engine until the TDC line on the crankshaft pulley is in line with the timing pointer.
In Ma t rk er n et a in ti o g n De al pt .
● Turn the No.1 piston or the No.6 piston to the TDC of compression stroke.
Note: When the rocker arm at the intake side and rocker arm at the exhaust side cannot be turned by hands, it is indicated that the piston has reached the TDC of compression stroke. Turning the engine by one more turn, the TDC of compression stroke of No.1 piston and No.6 piston swaps.
ZX335-1004007
Fig. 6-6
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3. When the No.1 piston is at the TDC, adjust the valve clearance in a sequence marked with a black dot ( ● ). Cylinder Exhaust Intake
1
2
●
●
3
○
●
4
●
○
5
○
●
6
●
○
○
○
A. When a feeler gauge is used for such measurement, resistance to a moving feeler gauge in the clearance should be felt.
ZX335-1004008
Fig. 6-7
B. If the feeler gauge moves easily in the clearance, it is impossible to obtain accurate result. 4. If the measured value is out of specification, readjustment shall be performed according to the following method.
6-8
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.3.2 Adjusting 1. In adjustment of valve clearance, loosen the locknut before adjusting the adjusting screw. A standard clearance is achieved when slight resistance to the feeler gauge is felt when pulling it out from the clearance.
Adjusting screw
Locknut
2. After adjustment, hold the adjusting screw with a screwdriver to prevent it from turning, and tighten the locknut. Locknut: 21-30 N.m{2.1- 3.1 kgf.m}
In Ma t rk er n et a in ti o g n De al pt .
Valve clearance
3. Go on with the next step until all valve clearances marked with a black dot ( ● ) have been adjusted
ZX335-1004009
Fig. 6-8
4. Recheck the clearances with the feeler gauge. Readjustment should be made if deviation from the standard valve is found. 5. When the engine is carried in vehicle, using to turn the adjusting screw will make the job easy.
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Shop Manual - April 2014
6-9
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.4 Compression force - Test ● Service standard Location
—
Service Item
Limits
Correction method
2.5MPa {25.5kgf/cm2}
Check
390 kPa { ≤ 4kgf/cm2 }
Check
Standard value
Every cylinder (200 3.0MPa {30.6kgf/cm2} Compression rpm/h) Inter-cylinder presforce — sure difference
Symbol
In Ma t rk er n et a in ti o g n De al pt .
● Special tool Tool name and shape
Part number
Pressure gauge connector
Application
5-85317-001-0 (JKM- Checking the compres1015) sion force
1. Reduction of compression force can be an indication for engine overhaul.
2. Check the compression force regularly and pay attention to its variation from time to time. Understanding the variation of compression force is helpful for troubleshooting. In addition, in a new vehicle or when new parts are installed for replacement, the pressure may be higher due to running-in of the piston ring, valve seat, etc. The pressure will become normal as the parts wear.
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Pressure gauge connector
ZX335-1004010
Fig. 6-9
3. Before testing, make sure that the engine oil, start motor and battery are in normal condition. 4. The vehicle is to meet the following conditions. A. Preheat the engine until engine coolant temperature reaches 75~85℃ .
B. Switch off all lamps and auxiliary devices. C. Place the gear lever in a neutral position.
6-10
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
5. Remove the entire fuel injector. 6. Cover the fuel injector mounting opening with a rag. 7. Activate the start motor in order to run the engine. Check the cloth if it is stuck with foreign substances. 8. According to the substances (engine oil and/or coolant) adhering to the cloth, the following factors might be involved.
WARNING ● When coolant and/or engine oil is found attached to the rag, running the engine may cause the hot coolant and engine oil to squirt out through the mounting hole of the fuel injector. This is very dangerous. Never touch or look into the fuel injector mounting hole when the engine is running.
In Ma t rk er n et a in ti o g n De al pt .
A. When engine oil is found, it might be improper sealing caused by piston ring. Check the piston ring.
B. When engine oil and coolant are found, it might be cracking of cylinder. Replace the crankcase. 9. Mount the gasket and to the fuel injector mounting hole and fix them with the injector cap. Install the compression force gauge.
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10. Start the engine and measure the compression force of each cylinder. Calculate the differential pressure between the cylinders. 11. When the compression force and the differential pressure between cylinders deviate from their limits, inject a small amount of engine oil through the fuel injector mounting hole, and measure the compression force again.
● If the compression force is higher, it is probably due to worn or damaged piston ring or cylinder inner surface. ● If the compression force is still low, it is probably due to stuck valve or improper seating, or improperly mounted gasket of cylinder head.
Shop Manual - April 2014
6-11
Testing and Adjusting
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
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6-12
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.5 Fuel Injection Timing - Test and Adjust ● Service standard Location
Service Item
Standard value
Limits
—
Fuel injection timing (BTDC)
8 degrees
7~9 degrees
Correction method Adjust
● Tightening torque (Unit: N·m) Part tightened
Tightening torque
Remark
—
Body, fuel delivery valve
39~44
—
—
Nut, injection tube
28~32
—
In Ma t rk er n et a in ti o g n De al pt .
Symbol
● Common tool (Unit: N·m) Symbol
Tool name and shape
Universal connecting rod with extension
Application
MH061099
Inspection and adjustment of fuel injection timing
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A
14
Part number
A
ZX335-1004011
NOTICE
● Take care not let dust or foreign materials get into the fuel injection pump when adjusting the injection timing.
Shop Manual - April 2014
6-13
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.5.1 Testing 1. Align the TDC mark on the crankshaft pulley with the pointer. Remove the cap of the inspection hole on the timing gear cover in front of the fuel injection pump.
Aligning point
Check if the pointer on the nut-fixing plate on the gear of fuel injection pump is aligned with the outstanding mark on the gear chamber of fuel injection pump.
In Ma t rk er n et a in ti o g n De al pt .
In case of misalignment, turn the crankshaft pulley one more turn and repeat the above steps in order to obtain proper alignment. Check if the marking lines are aligned with each other.
ZX335-1004007
Fig. 6-10
(The marking lines have been aligned properly when assembling the body of fuel injection pump and fixing the flange at factory)
Now, test the angle of crankshaft at the beginning of fuel injection.
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2. Turn the crankshaft pulley counterclockwise approximate 30 degrees.
1
ZX335-1004012
Fig. 6-11
6-14
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
3. Remove the injection tube from No.1 plunger. This allows you to observe the fuel when it begins to flow out from No.1 plunger.
ZX335-1004013
In Ma t rk er n et a in ti o g n De al pt .
Fig. 6-12
4. Remove from No.1 plunger the valve body ① , seat ② , spring ③ and spool ④ .
1
5. Reassemble the valve body ① and tighten it to the specific torque. Do no reassemble the spring, seat and spool now. Leave them for later reassembly.
2
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3
4
ZX335-1004014
Fig. 6-13
6. Secure the fuel control lever in the fully open position.
ZX335-1004015
Fig. 6-14
Shop Manual - April 2014
6-15
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
7. Slowly turn the crankshaft pulley clockwise while operating the hand pump to feed the fuel constantly. Stop operating the pump immediately when no fuel is seen coming out of No.1 fuel delivery valve. The crankshaft angle is now the engine’s fuel injection beginning angle.
ZX335-1004016
In Ma t rk er n et a in ti o g n De al pt .
Fig. 6-15
8. Observe and make sure that the mark (of fuel injection beginning angle) on crankshaft pulley is in line with the timing pointer. The timing mark is the engine’s fuel injection beginning angle. Discharge the remaining fuel from the body of delivery valve. Make sure that no fuel is delivered from the delivery pump. Note: Engines of the same type may have a fuel injection pump that is different in injection timing. To obtain an engine of required specification, please contact machine supplier or local ISUZU engine service station. These specifications are provided by ISUZU or engine manufacturer.
6-16
TD
C
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Damping pulley
ZX335-1004017
Fig. 6-16
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
9. Remove the body of fuel delivery valve from No.1 plunger. 10. Install the internal parts (valve seat, spring and spool) on the body.
Body
11. Reassemble the fuel delivery valve AS on No.1 plunger and tighten it to the specific torque.
Seat Spring
12. Install the injection tube to No.1 cylinder and tighten it to the specific torque.
Spool ZX335-1004018
NOTICE
In Ma t rk er n et a in ti o g n De al pt .
Fig. 6-17
● Do not tighten the fuel injection pump body more than specified. The pump body is aluminum and it can be deformed by over-tightening, resulting in unfavorable impact on the operation of control rack.
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Shop Manual - April 2014
6-17
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.5.2 Adjusting 1.
Align the timing pointer with the specific mark on the crankshaft pulley.
2. Perform step 3 through step 6 described in the testing procedure. 3.
Loosen the four (4) nuts on the fuel injection pump. Loosen the nuts. (Also loosen the nuts on the back.)
In Ma t rk er n et a in ti o g n De al pt .
4. Injection timing turns the fuel injection pump in advance along the drive shaft of fuel injection pump in order to make it face outward (getting away from the cylinder block).
ZX335-1004019
Fig. 6-18
Injection timing turns the fuel injection pump in retard along the drive shaft of fuel injection pump in order to make it face inward (approaching the cylinder block). Ref: 1 mm difference between the two marking lines approximates 2º of crankshaft angle.
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5. Keep operating the hand pump to transfer the fuel while slowly turning the fuel injection pump. Stop turning the injection pump when no oil is seen coming out of the fuel delivery valve body of No.1 cylinder. Adjustment of fuel injection pump position is now finished. 6. Tighten the four (4) nuts of fuel injection pump.
7. Remove again the fuel delivery valve body and assemble the spool, spring and seat. Tighten the valve assembly to the specific torque.
Pressure gauge connector
ZX335-1004010
Fig. 6-19
8. Install the injection tube of No.1 cylinder and tighten it to the specific torque.
6-18
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.6 A/C Compressor Belt Tension - Test and Adjust 6.6.1 Testing
Compressor belt pulley
Press the intermediate point of the belt between the drive pulley and the compressor belt pulley with a finger force of about 58.8 N(6 kgf), and check the deflection (A) of the belt, which shall be 5~8 mm (0.20 in~0.31 in).
A
In Ma t rk er n et a in ti o g n De al pt .
Drive belt pulley
ZX335-1004021
Fig. 6-20
6.6.2 Adjusting
● If the belt deflection is abnormal, adjust it according to the following procedure. 1. Loosen the bolts (1) and (2).
4
1
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2. Move the compressor (3) and the bracket (4) together to adjust belt tension.
3. After positioning the compressor (3), tighten the bolts (1) and (2).
2
4. Recheck belt tension after adjustment. Note:
3
ZXT335-1004022
Fig. 6-21
● Check each belt for damage. Check the V-groove and the V-belt for wear. In addition, it is especially important to keep the V-belt free from friction with bottom of the V-groove. ● Contact local Sany dealer and replace the belt in case of the following conditions.
● The fan belt has been stretched and little margin is left for adjustment. ● Cuts or cracks are found in the belt. ● Abnormal sliding or noise. ● When a new belt is mounted, readjust the belt tension after one hour operation. Shop Manual - April 2014
6-19
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.7 Swing Bearing Clearance - Test ● Tool used for testing swing bearing clearance Symbol
Part Number
Part Name
H
60033930
Dial gauge
● The following steps are to be followed when testing the clearance of swing bearing.
H
ZX335-1004023
WARNING
In Ma t rk er n et a in ti o g n De al pt .
Fig. 6-22
● Park your machine on a level ground. Lower your work equipment to the ground.
● Do not put your hands or feet under the undercarriage during testing. 1. Fix the dial gauge (H) to the track frame and make the pointer point the lower end of the outer race.
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2. Place the work equipment to the maximum reach position. Raise the bucket to a height that the bucket tips and the swing frame bottom are on the same level.
At the moment, the front of upper structure lowers while the rear rises. 3. Reset the dial gauge (H) to zero.
4. Set the arm almost perpendicular to the ground and lower the boom until the front track shoe tilts.
ZX335-1004024
Fig. 6-23
At the moment, the front of upper structure rises while the rear lowers.
150～200mm
5. Read the dial gauge (H). The value indicated by the dial gauge (H) is the clearance of the bearing. 6. Restore the machine to the condition of step 2. Check the dial gauge (H) to see if it reads zero. Repeat step 3 through step 5 if the dial gauge (H) reads a value other than zero. 6-20
ZX335-1004025
Fig. 6-24
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.8 Track Tensioner - Test and Adjust 6.8.1 Testing 1. Move your machine forward at a distance that is equal to the length of track on the ground. Keep running the engine at low idle. Park your machine slowly.
3
2 a
2. Place a straight edge on top of the track grousers between the idler (1) and the front carrier roller (2).
In Ma t rk er n et a in ti o g n De al pt .
A straight edge of angle steel is recommended for this purpose as angle steel bends little. In addition, an L-shaped beam has good performance against bending.
1
3. Measure the maximum clearance (a) between the upper surface of track and the bottom of straight edge.
ZX335-1004026
Fig. 6-25
Max clearance (a): 10~30 mm(0.4~1.2 in)
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Shop Manual - April 2014
6-21
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.8.2 Adjusting If the track tension is incorrect, adjustment is to be made in the following way. 1. Decreasing the tension A. Loosen the valve (1) to discharge grease. Tighten the valve after discharging. 1
WARNING 2
In Ma t rk er n et a in ti o g n De al pt .
● Never loosen the valve over one turn. If the valve is loosened too much, the grease under high pressure may cause the valve to shoot.
ZXT335-1004027
B. Recheck the track tension as per the above method after adjustment. 2. Increasing the tension
A. Add grease through the grease fitting (2) with a grease gun.
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B. Recheck the track tension as per the above method after adjustment. ● Add grease until the gap (b) between the idler guide and the track frame end becomes zero. If the tension is till low, it indicates that the pins and bushings are seriously worn. Replace the pins and bushings, or remove one track shoe.
b ZX335-1004028
Fig. 6-26
6-22
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.9 Oil in Hydraulic Circuits - Test and Adjust Tools used for testing and adjusting hydraulic pressure in work equipment, swing and travel circuits ID —
Part Number
Part Name
60038932
Hydraulic Tester
B210770000084
Adaptor
In Ma t rk er n et a in ti o g n De al pt .
● The hydraulic pressure in work equipment, swing and travel (hydraulic pump output pressure) circuits can be viewed on the monitor.
6.9.1 Testing
1. Preparatory work before measuring
Lower the work equipment to the ground and stop the engine. After the engine is stopped, operate the control levers for several times in order to release the remaining pressure in hydraulic circuits. Open the butterfly nut on the breather valve. Press the relief button to release pressure in the hydraulic tank.
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A. Remove the plug (1) and plug (2) for testing the hydraulic pressure. Plug (1): For oil circuit of back hydraulic pump
Plug (2): For oil circuit of front hydraulic pump
1
B. Install the priming adaptor and connect it to the hydraulic tester. Use an oil pressure gauge with a capacity of 40 MPa {408 kg/cm2}. C. Start the engine and keep it running until the hydraulic pressure rises to a point within the operational range.
ZXT335-1004029
Fig. 6-27
Shop Manual - April 2014
6-23
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
2. Testing the unloading pressure A. Start the engine. B. Test the hydraulic pressure when the engine is running at high idle and all control levers are in neutral position. The hydraulic pressure indicated is the pressure when the unloading valve unloads. 3. Testing the relief pressure of work equipment A. Start the engine and move the cylinder to be measured to its stroke end. B. Test the hydraulic pressure when the engine is running at high idle and the cylinder is in relief condition.
In Ma t rk er n et a in ti o g n De al pt .
The hydraulic pressure indicated is the pressure when the main relief valve is in relief condition. 4. Testing the swing relief pressure
A. Start the engine. Reach out the work equipment as far as possible. Lower the work equipment on the ground in order to restrict swinging. B. Test the hydraulic pressure when the engine is running at high idle and the swing circuit is in relief condition. The hydraulic pressure indicated is the pressure when the swing motor relief valve is in relief condition. 司
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The relief pressure of swing motor is lower than the main relief pressure. 5. Testing the relief pressure of travel circuit
A. Start the engine and lock the travel mechanism.
Place the pin ① between the sprocket and the track frame in order to block the travel mechanism. B. Test the hydraulic pressure when the engine is running at high idle and the travel circuit is in relief condition.
The hydraulic pressure indicated is the pressure when the main relief valve is in relief condition. When the travel circuit is in relief condition, the pressure indicated is always the pressure at high relief.
6-24
1
ZXT335-1004031
Fig. 6-28
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.9.2 Adjusting The unloading valve and safety valve for the boom are not adjustable. 1. Adjusting the main relief pressure (at the high pressure setting side) If the high relief pressure in work equipment and travel circuits is abnormal, adjust the high pressure setting side of the main relief valve (3) according to the following procedure.
In Ma t rk er n et a in ti o g n De al pt .
3
A. Disconnect the pilot hose.
ZXT335-1004900
Fig. 6-29
B. Loosen the locknut (4). Turn the adjusting screw (5) to adjust the pressure. The pressure increases as the retainer is turned right.
The pressure decreases as the retainer is turned left.
Each turn of the retainer approximates: 12.5 MPa {128 kg/cm2}
4
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Locknut:
53.5±4.9 Nm{5.5±0.5 kgm}
5
C. Check the pressure again after adjustment. Test the pressure according to the procedure described above.
Connect the pilot hose before testing the pressure.
ZX335-1004033
Fig. 6-30
Adjustment of the high pressure setting side will affect the low pressure setting side. The low pressure setting side is, therefore, to be adjusted too.
Shop Manual - April 2014
6-25
Testing and Adjusting
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
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6-26
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
2. Adjusting the swing relief pressure If the swing relief pressure is abnormal, adjust the swing motor relief valve (6) according to the following procedure. 6 6
77
In Ma t rk er n et a in ti o g n De al pt .
8 8 ZXT335-1004034
Fig. 6-31
A. Loosen the locknut (7). Turn the adjusting screw (8) to adjust the pressure. Pressure increases as the retainer is turned right. The pressure decreases as the retainer is turned left.
7
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Each turn of the retainer approximates: 6.71 MPa { 68.4 kg/cm2} Locknut:
78-103 Nm{8.0-10.5 kgm}
B. Check the pressure again after adjustment. Test the pressure according to the procedure described above.
8 ZX335-1004035
Fig. 6-32
Shop Manual - April 2014
6-27
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.10 Control Oil Circuit Pressure - Test and Adjust 6.10.1 Testing Tools used for testing and adjusting the pressure in control oil circuit. ID —
Part Number
Part Name
21008760
Hydraulic Tester
B210770000084
Adaptor
In Ma t rk er n et a in ti o g n De al pt .
Lower the work equipment to the ground and stop the engine. After the engine is stopped, operate the control levers for several times in order to release the remaining pressure in hydraulic circuits. Open the butterfly nut on the breather valve. Press the relief button to release pressure in the hydraulic tank. 1. Remove the hydraulic pressure testing plug (1). 2. Install the priming adaptor and connect it to the hydraulic tester.
● Use an oil pressure gauge with a capacity of 6 MPa {61 kg/cm2}
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3. Start the engine and keep it running until the hydraulic pressure rises to the operational range. 4. Test the oil pressure with the engine running at high idle and all control levers in neutral position.
1
2
ZXT215-1004007
Fig. 6-33
6.10.2 Adjusting
1. If the oil pressure measured is lower than 3.5 MPa {36 kgf/cm²}, loosen the locknut (2) and screw in the stud (3). Observe pressure change on the gauge at the same time. Tighten the nut (2) when desired pressure is reached.
3
2
2. Remove all measuring tools after testing. Make sure that the ZX215-1004031
Fig. 6-34 6-28
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.11 Solenoid Valve Output Pressure - Test Tools used for testing the output pressure of solenoid valve ID —
Part Number
Part Name
21008760
Hydraulic Tester
B210770000084
Adaptor
● Make sure that the initial pressure of control oil circuit is normal before testing the output pressure of solenoid valve.
In Ma t rk er n et a in ti o g n De al pt .
Lower the work equipment to the ground and stop the engine. After the engine is stopped, operate the control levers for several times in order to release the remaining pressure in hydraulic circuits. Open the butterfly nut on the breather valve. Press the relief button to release pressure in the hydraulic tank. 1. Disconnect the hose of solenoid valve in order to test the pressure at the outlet.
6
No. 1 2 3 4 5 6
Solenoid valve to be tested
High travel speed valve
5
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4 3 2 1
Backup proportional valve Backup proportional valve Bucket confluence valve Backup
Pilot pressure valve
W365613091
Fig. 6-35
2. Install a tee to location (A) on each solenoid valve and connect the hose. 3. Mount the adaptor onto the tee and connect it to the hydraulic tester. ● Use a hydraulic tester with a capacity of 6 MPa {61 kg/cm2} .
4. Start the engine and keep it running until the hydraulic oil temperature rises to the operational range. 5. Run the engine at full speed. Operate the control levers to open or close each solenoid valve, and measure the pressure. ● The function of each solenoid valve can be checked through the monitor's monitoring function. (This is a special function of the monitor.) 6. Remove all measuring tools after measurement. Make sure that the machine returns to its normal condition. Shop Manual - April 2014
6-29
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
Pilot locking solenoid valve Functioning state Hydraulic lockout control
Function Lock
OFF
Free
ON
Travel speed shift solenoid valve Functioning State
Function
When the 2nd level overheat setting is on Fuel control dial reads lower than 1500 rpm.
In Ma t rk er n et a in ti o g n De al pt .
When travel speed switch is in Lo position Travel signal OFF
When travel speed switch is in Hi position
Travel signal ON
If pressure of both front and back pump is 24.5 MPa {250 kg/cm2} If pressure of both front and back pump is 15.3 MPa {150 kg/cm2}
Other states
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6-30
OFF
Shop Manual - April 2014
ON
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.12 Pilot Valve Output Pressure - Test ● Tools used for testing the output pressure of pilot valve ID —
Part Number
Part Name
21008760
Hydraulic Tester
B210770000084
Adaptor
In Ma t rk er n et a in ti o g n De al pt .
● Make sure that the initial pressure of control oil circuit is normal before testing the output pressure of pilot valve. 1. Remove the pilot oil pressure switch or plug. No. 1 2 3 4 5 6
Oil circuit
No.
Oil circuit
Left travel
7
Boom DOWN
Right travel
8
Left swing
Arm IN
9
Bucket DIG
Right swing
10
Arm OUT
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1
2
3
4
5
6
7
8
9
10
Bucket DUMP Boom UP
ZXT335-1004902
2. Install the adaptor and connect it to the hydraulic tester.
● Use a hydraulic tester with a capacity of 6 MPa{61 kg/cm2}.
3. Start the engine and keep it running until the hydraulic oil temperature rises to the operational range. 4. Measure the output pressure with the engine running at high idle and all control levers of the tested circuit in neutral position. ● When the measured output pressure reads the following values, the pilot valve is normal. 5. Remove all the tools after testing. Make sure that the machine returns to its normal condition.
Control lever
Hydraulic pressure
Neutral position
0{0} Close to the average initial pressure of oil control circuit
Full stroke
(See Table of Standard Values)
Shop Manual - April 2014
6-31
Testing and Adjusting
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
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6-32
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.13 Work Equipment and Swing Pilot Valves - Adjust ● If the play of work equipment or swing control lever is too big, adjustment can be made through the following steps.
2 3
1. Remove the work equipment and swing pilot valve assembly.
1
2. Remove the bellows (1). 4
In Ma t rk er n et a in ti o g n De al pt .
3. Loosen the locknut (2). Screw on the disc (3) until it contacts with the four heads of plunger (4). ● Do not move the plunger.
ZX215-1004032
4. When the disc (3) is fixed, tighten the locknut (2) to the specified torque. Locknut: 98~127 Nm {10~13 kgm}
5. Restore the bellows (1).
6. Restore the work equipment and swing pilot valve assembly.
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Shop Manual - April 2014
6-33
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.14 Hydraulic Drift of Work Equipment - Test ● If hydraulic drift occurs to the work equipment (cylinder), check it according to the following procedure. It is to determine whether the failure is caused by cylinder seal or control valve. 1. Check the boom and bucket cylinders.
In Ma t rk er n et a in ti o g n De al pt .
A. Park your machine in an attitude as shown in the illustration on the right, and stop the engine. ● Load the bucket fully with soil or apply rated load to the bucket.
B. Operate the control levers in order to keep the boom in the UP position and the bucket in the DIG position. ● If the lowering speed increases, it is failure of cylinder seal. ● If nothing changes, it is failure of control valve.
ZX215-1004033
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● Operate the control levers with engine start switch in the ON position.
● If the pressure in accumulator drops, recharge the accumulator after running the engine for about 10 seconds. 2. Check the arm cylinder.
A. Park your machine in an attitude as shown in the illustration on the right. The distance between the arm cylinder and the digging stroke end is 100 mm. Stop the engine.
B. Operate the control levers in order to place the arm in the DIG position. ● If the lowering speed increases, it is the failure of cylinder seal. ● If nothing changes, it is the failure of control valve. ● Operate the control levers with engine start switch in the ON position. 6-34
Shop Manual - April 2014
ZX215-1004034
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
● If the pressure in accumulator drops, recharge the accumulator after running the engine for about 10 seconds. [Ref.] If the hydraulic drift is caused by failure of the cylinder seal, the reason for increase of lowering speed during the above operation is described below: A. If the machine is set in the above position (where the holding pressure is applied to the head end), the oil leaks from the head end to the rod end. The pressure in the rod end is increased as a result. B. As the pressure in the rod end decreases, the pressure in the head end increases to keep a balance. This process is repeated until balance is reached at a certain level depending on the amount of leakage.
In Ma t rk er n et a in ti o g n De al pt .
C. When the pressure is balanced, the lowering speed decreases. If the control levers are operated according to the above procedure, the oil circuit in the rod end opens to the drain circuit (while the head end is closed by a check valve), and the oil flows to the drain circuit from the rod end. As a result, the lowering speed increases. 3. Check the pilot valve.
Test the hydraulic drift respectively while the accumulator is pressurized and the hydraulic lockout control in the LOCK/FREE position. ● Operate the control levers with engine start switch in the ON position.
● If the pressure in accumulator drops, recharge the accumulator after running the engine for about 10 seconds. 司
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● If there is a difference in hydraulic drift between the LOCK position and the FREE position, it is the failure (internal fault) of the pilot valve.
Shop Manual - April 2014
6-35
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.15 Remaining Pressure in Hydraulic Lines - Relieve Before disconnecting the lines between the hydraulic cylinders or between the hydraulic motor and the control valve, perform the following steps in order to release the remaining pressure in the hydraulic lines. Even if there is no pressure remaining in the swing motor line and the travel motor line, they will be influenced by the internal pressure of hydraulic tank. The breather valve must therefore be opened to release pressure prior to operation. 1. Stop the engine, loosen the butterfly nut on the breather valve, and press the release button to release the pressure in hydraulic tank.
In Ma t rk er n et a in ti o g n De al pt .
2. Turn the engine start switch to the ON position and operate the control levers for several times. ● The pilot lock valve must be energized. Operate the control levers with the engine start switch in the ON position. ● Operate the control levers 2 or 3 times to release the pressure in the accumulator. 3. Start the engine and keep the engine running at low idle for about 10 seconds in order to increase the pressure in accumulator. And then stop the engine. 4. Repeat the above step 2 through step 3 several times. 司
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6-36
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.16 Oil Leakage Amount - Test 1. Testing the oil leakage amount of boom cylinder A. Start the engine and keep the engine running until the hydraulic oil temperature reaches the operational range. And then fully extend the boom cylinder.
1
In Ma t rk er n et a in ti o g n De al pt .
To release the pressure remaining in the lines see “Remaining Pressure in Hydraulic Lines - Relieve” on page 6-36. B. Disconnect the hose (1) on the cylinder rod end and plug the hose opening.
Take care not to disconnect the hose on the cylinder head end.
C. Start the engine and apply relief pressure to the head end of the cylinder while the engine is running at high idle.
D. Hold this state for 30 seconds and then test the amount of oil leakage for one minute.
ZXT335-1004039
Fig. 6-36
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E. Make sure that the machine returns to its normal condition after testing.
2. Testing the oil leakage amount of arm cylinder
A. Start the engine and keep the engine running until the hydraulic oil temperature reaches the operational range. And then fully extend the arm cylinder.
To release the pressure remaining in the lines, See: Chapter 4 Testing and Adjusting, “Remaining Pressure in Hydraulic Lines - Relieve” on page 6-36. B. Disconnect the hose (2) on the cylinder rod end and plug the hose opening.
2
ZXT335-1004040
Fig. 6-37
Take care not to disconnect the hose on the cylinder head end.
Shop Manual - April 2014
6-37
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
C. Start the engine and apply relief pressure to the head end of the cylinder while the engine is running at high idle. D. Hold this state for 30 seconds. Test the amount of oil leakage for one minute. E. Make sure that the machine returns to its normal condition after testing. 3. Testing the oil leakage amount of bucket cylinder
In Ma t rk er n et a in ti o g n De al pt .
A. Start the engine and keep the engine running until the hydraulic oil temperature reaches the operational range. And then fully extend the bucket cylinder.
3
To release the pressure remaining in the circuits see “Remaining Pressure in Hydraulic Lines - Relieve” on page 6-36. B. Disconnect the hose (3) on the cylinder rod end and plug the hose opening.
ZXT335-1004041
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Fig. 6-38
Take care not to disconnect the hose on the cylinder head end. C. Start the engine and apply relief pressure to the head end of the cylinder while the engine is running at high idle.
D. Hold this state for 30 seconds and then test the amount of oil leakage for one minute. E. Make sure that the machine returns to its normal condition after testing.
6-38
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
4. Testing the oil leakage amount of swing motor A. Fully extend the work equipment. Lower the bucket on the ground and raise the machine slightly. Stop the engine. 5
B. Disconnect the drain hoses (4) and (5). Blind the hose ends with caps. 4
C. Start the engine and apply swing relief pressure while the engine is running at high idle. Measure the amount of oil leakage under this condition.
ZXT335-1004042
Fig. 6-39
In Ma t rk er n et a in ti o g n De al pt .
● Hold the state described in step 3) for 30 seconds. Measure the amount of oil leakage for one minute.
● After the first measurement, swing the upper structure 180º and measure the leakage again in the same way.
D. Make sure that the machine returns to its normal condition after testing.
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5. Testing the oil leakage amount of the travel motor A. Remove the cover of the travel motor. B. Start the engine and lock the travel.
Insert the pin ① between the sprocket and the track frame in order to prevent traveling.
1
ZXT335-1004031
Fig. 6-40
Shop Manual - April 2014
6-39
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
C. Disconnect the drain hose (6) of the travel motor. Blind the hose end with a cap.
6
6
D. Start the engine and apply swing relief pressure while the engine is running at high idle. Measure the amount of oil leakage under this condition.
WARNING ● During testing, misoperation of the control levers can cause serious accidents. Make sure that all signals are correct.
ZXT335-1004043
In Ma t rk er n et a in ti o g n De al pt .
Fig. 6-41
● Hold the condition described in step 4) for 30 seconds. Test the amount of oil leakage for one minute.
● Rotate the motor slightly. Swap the positions of the oil distributor and the cylinder and of the cylinder and piston. Repeat the testing several times.
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E. Make sure that the machine returns to its normal condition after testing.
6-40
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.17 Air in Each Component - Purge Purging Steps Item to Be Purged Job Description
1 2 3 Hydraulic Engine Oil CylinPump Starting der
4 Swing Motor
5 6 Travel Operation Motor Starting
● Changing the hydraulic oil ● Cleaning the filter element
○
○
○
(Note)
(Note)
○ ○
○
○
○
○ ○
○
In Ma t rk er n et a in ti o g n De al pt .
● Replacing the return filter element ● Repairing/replacing the hydraulic pump ● Disassembling the suction hose
○
● Repairing/replacing the control valve
○
○
○
● Replacing the oil cylinder ● Disassembling the cylinder piping
○
○
○
● Replacing the swing motor
○
● Disassembling the swing motor ● Replacing the travel motor
● Disassembling the travel motor
Note:
○
○
○
○ ○
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Purge air from the swing motor and travel motor only when the oil in the motor cases is drained. 1. Purging air from hydraulic pump
1
A. Loosen the plug (1) and make sure that oil leaks through the plug.
B. If you are sure of the leak, tighten the plug (1). Plug: 7.8~9.8 N·m{0.8~1.0 kgf·m}
● Engine starting precaution:
When engine is started after bleeding the air as described above, run the engine at low idle for 10 minutes.
ZXT335-1004500
Fig. 6-42
Shop Manual - April 2014
6-41
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
2. Bleeding air from hydraulic cylinder A. Start the engine and keep the engine running at low idle. B. Raise and lower the boom 4-5 times with the engine running at low idle. ● Do not apply relief pressure and stop the piston at about 100 mm to stroke end. C. Repeat step 2) with the engine running at high idle. D. Apply relief pressure when the piston comes to stroke end with the engine running at low idle. E. Purge air from arm cylinder and bucket cylinder. Repeat step 2) through step 4).
In Ma t rk er n et a in ti o g n De al pt .
● When a new cylinder is used for replacement, it is recommended to purge air from new cylinder before it is installed to work equipment. Especially the boom cylinder, It must be purged prior to installation because its piston is unable to reach the boom-down side stroke end after installation. ● For an excavator whose hydraulic oil has been changed or which has been in storage for a long period of time, slowly operate the boom, arm and bucket cylinders in full stroke at low engine speed under zero load in order to purge the air. Immediate pressurization and loaded operation after change of oil should be avoided. 3. Bleeding air from swing motor
A. Start the engine and run it at low idle.
B. Bleed air from swing motor by slowly turning the upper structure. 司
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4. Bleeding air from travel motor
C. Start the engine and run the engine at low idle.
D. Loosen the bleeder plug (1) and make sure that oil oozes through the plug. E. If you are sure of the leak, tighten the plug (1). Bleeder plug: 27.5 - 35.3 Nm {2.8 - 3.6 kgm}
6-42
Shop Manual - April 2014
Testing and Adjusting
BLMaInt e r AkNe rn a tKi t i ng o PAD nal eGp tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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Shop Manual - April 2014
6-43
Testing and Adjusting
BLM In t aAr e kNe rn a tKi t i nP o gA n al DG ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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6-44
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Troubleshooting 7 Troubleshooting
7.1 Checks before Troubleshooting ............................................................................... 7-5 7.2 Failure Symptoms and Troubleshooting Codes ....................................................... 7-6 7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-9 7.3.1 Connector location layout ............................................................................ 7-13 7.3.2 Diagram of system electrical elements ........................................................ 7-18 7.3.3 Diagram of electrical control system ........................................................... 7-20 7.3.4 SWP connectors .......................................................................................... 7-22 7.3.5 A/AMP connectors ....................................................................................... 7-23 7.3.6 DT connectors.............................................................................................. 7-24 7.4 Troubleshooting with an Event Code ..................................................................... 7-25 7.5 Troubleshooting Electrical System (E-Mode)......................................................... 7-49 7.6 Troubleshooting Hydraulic and Mechanical Systems (H-mode) ............................ 7-81 司
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Shop Manual - April 2014
7-1
Troubleshooting
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
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7-2
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7 TROUBLESHOOTING WARNING ● Stop the machine on a level ground, and check that lock pins, blocks, and parking brake are effective. ● When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. ● If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting.
In Ma t rk er n et a in ti o g n De al pt .
● Be extremely careful not to touch any hot parts or to get caught in any rotating parts. ● When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. ● When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure fi rst. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the fault, to carry out repairs swiftly, and to prevent reoccurrence of the fault. 司
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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 some idea of possible causes of the fault that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any fault occurs: ● Parts that have no connection with the fault or other unnecessary parts will be disassembled. ● It will become impossible to find the cause of the fault.
It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fi xed procedure. 2. Points to ask user or operator: A. Have any other problems occurred apart from the problem that has been reported? B. Was there anything strange about the machine before the fault occurred? C. Did the fault occur suddenly, or were there problems with the machine condition before this? D. Under what conditions did the fault occur? E. Had any repairs been carried out before the fault? When were these repairs carried out? Shop Manual - April 2014
7-3
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
F. Has the same kind of fault occurred before? 3. Check before troubleshooting A. Check the oil level. B. Check for any external leakage of oil from the piping or hydraulic equipment. C. Check the travel of the control levers. D. Check the stroke of the control valve spool. E. Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming fault
In Ma t rk er n et a in ti o g n De al pt .
Confirm the extent of the fault yourself, and judge whether to handle it as a real fault or as a problem with the method of operation, etc. When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting
Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of fault, then use the troubleshooting flowchart to locate the position of the fault exactly. ● The basic procedure for troubleshooting is as follows. 司
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A. Start from the simple points.
B. Start from the most likely points.
C. Investigate other related parts or information. 6. Measures to remove root cause of fault
Even if the fault is repaired, if the root cause of the fault is not repaired, the same fault will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
7-4
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.1 Checks before Troubleshooting Criterion
1. Check fuel level and type of fuel
—
Add fuel
2. Check for impurities in fuel
—
Clean, drain
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
1. Check for looseness, corrosion of battery terminal and wiring
Tighten or replace
2. Check for looseness, corrosion of alternator terminal and wiring
—
3. Check for looseness, corrosion of start motor terminal and wiring
—
Tighten or replace
1. Check for abnormal noise and smell
—
Repair
2. Check for oil leakage
—
Repair
3. Bleeding air
—
Bleed air
20-30V
Replace
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1. Check battery voltage (with engine stopped)
Electrics, electrical equipment
Remedy
In Ma t rk er n et a in ti o g n De al pt .
Hydraulic, mechanical Electrical equipment equipment
Lubricating oil, coolant
Item
Tighten or replace
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
5. Check for wet wires (esp. wet connectors or terminals)
—
Disconnect connector and dry
—
Replace
6. Check for blown or corroded fuses
7. Check alternator voltage (with engine speed at middle or higher)
8. Check operating sound of battery relay (when start After running for Replace several minutes: switch is turned ON or OFF) 27.5~ 29.5V Replace —
Shop Manual - April 2014
7-5
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.2 Failure Symptoms and Troubleshooting Codes Troubleshooting No.
Code disE mode H mode played Action to be taken concerning Service Code, Failure code and Failure Code
7
Display Failure code in monitor panel AccordDisplay Service Code in electrical system after ing to checking failure history displayed Display Failure Code in mechanical system after code checking failure history Engine-related failure Engine does not start up easily. (It always takes some time to start up the engine) Engine misfires. Color of exhaust gas is too dark.(Incomplete combustion) Engine pickup is poor.
8
Engine runs rough or is unstable.
9
Engine is short of output, or lacks power
2 3
4 5 6
E-1
E-2
H-2
10 Auto Idle fails. Excessive engine oil consumption, or color of ex11 haust gas is blue 12 Premature engine oil contamination 司
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E-5
H-5
13 Excessive fuel consumption Engine cooling water is mixed with engine oil, spurts 14 out or decreases 15 Engine oil amount increases. (Water or fuel gets in) 16 Abnormal noises are heard
17 Excessive vibrations are caused
Failure related to work equipment, swing and travel
18 Power supply of machine cannot be cut off. There are abnormal noises from around hydraulic 19 pump 20 All work equipment, travel and swing do not move Speeds of all work equipment, travel and swing are 21 slow When Machine Swings and Travels Simultaneously, 22 Travel Speed Lowers Largely
7-6
(Engine)
In Ma t rk er n et a in ti o g n De al pt .
1
Symptom
Shop Manual - April 2014
E-3
H-4
H-3 H-1 H-13
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
No.
Symptom
Troubleshooting Code disE mode H mode played Work equipment-related failure
23 All the equipment do not work
(Engine)
E-7
24 Cylinder do not work singly
H-9
25 Drift of cylinder is too large
H-10
26 Work equipment time lag is too big Other work equipment moves, when specific 27 work equipment is relieved 28 Boom-up speed or power is low.
H-11 H-12 H-6
In Ma t rk er n et a in ti o g n De al pt .
E-8
29 Arm speed or power is low.
E-9
H-7
30 Bucket speed or power is low.
E-10
H-8
31 Travel speed or power is low.
E-11
H-15
32 Dual Speed Travel Not Functioning
E-14
Travel-related failure
33 Machine tends to swerve while in travel
H-14
34 Machine is difficult to steer, or lacks power
H-16
35 Travel speed cannot be shifted
司
公
销 营
36 Track shoe does not move (only on one side)
H-17
H-18
Swing-related failure
37 Machine does not swing Swing acceleration is poor, or swing speed is 38 slow Upper structure overruns remarkably when 39 stopping swinging 40 Large shock is made when stopping swinging
H-22
41 Large sound is made when stopping swinging
H-23
42 Hydraulic drift of swing is large
H-24
Shop Manual - April 2014
H-19
H-20
H-21
7-7
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Troubleshooting No.
Symptom
Code disE mode played Monitor panel-related failure E-12
43 Monitor display is blank. 44 Monitor displays nothing. 45
H mode
(Engine)
E-13
Engine coolant temperature reading is incorrect.
E-15 E-16
47 Arm-in pilot pressure reading is incorrect.
E-18
48 Arm-out pilot pressure reading is incorrect.
E-19
49 Boom-up pilot pressure reading is incorrect. Boom-down pilot pressure reading is incor50 rect. Bucket-close pilot pressure reading is incor51 rect. Bucket-open pilot pressure reading is incor52 rect. 53 Swing pilot pressure reading is incorrect.
E-20
In Ma t rk er n et a in ti o g n De al pt .
46 Fuel level reading is incorrect.
E-21 E-22 E-23
E-24
54 Left travel pilot pressure reading is incorrect. Right travel pilot pressure reading is incor55 rect. Other failure
E-25
56 Preheat function fails.
E-6
57 Wiper does not work.
E-17
司
公
销 营
7-8
Shop Manual - April 2014
E-26
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3 Connector Location and Electrical Circuit Diagram Type
Number of pins
Component
Stereogram
CN-101M
A
2
Platform lamp
E-5
CN-102M
S
1
Fuel level sensor
F-6
CN-104M
A
2
Boom lamp (L)
E-7
CN-105M
A
2
Boom lamp (R)
E-7
T-117
Terminal
1
High-temp switch
K-7
T-101
Terminal
1
Battery relay coil (+)
M-2
In Ma t rk er n et a in ti o g n De al pt .
Connector No.
T-102
Terminal
1
Battery relay coil (-)
M-2
T-103
Terminal
1
Battery relay contact (output)
M-2
T-104
Terminal
1
Battery relay contact (input)
M-2
T-105
Terminal
1
Preheater fuse line 21#
M-2
T-106
Terminal
1
Preheater fuse line 16#
M-2
T-118
Terminal
1
Battery ground
M-2
T-500
Terminal
1
Battery ground
M-2
T-107
Terminal
1
Compressor clutch
K-7
T-109
Terminal
1
Engine oil pressure switch
J-7
T-110
Terminal
1
Preheater resistance wire terminal
J-7
T-111
Terminal
1
Start motor terminal B
K-7
T-112
Terminal
1
Alternator terminal B
K-6
T-135
Terminal
1
Start motor terminal S
K-7
T-202
Terminal
1
Chassis ground
W-6
K5
R
5
Horn relay
X-6
K2
R
5
Head lamp relay
X-6
K6
R
5
Work lamp relay
X-6
K4
R
5
Pilot valve relay
X-6
KB
—
5
Battery relay
M-2
K7
R
5
Start relay
X-6
KH
—
5
Preheater relay
Y-6
K3
R
5
Lockout relay
X-6
K9
R
5
Shutdown delay relay
X-6
CN-201F
A
2
Joint connector
W-6
CN-302F
A
3
Intermediate connector
R-6
F-501
Terminal
1
Intermediate connector
R-6
F-502
Terminal
1
Intermediate connector
R-6
司
公
销 营
Shop Manual - April 2014
7-9
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Type
Number of pins
Component
Stereogram
F-503
Terminal
1
Intermediate connector
R-6
F-504
Terminal
1
Intermediate connector
R-6
F-505
Terminal
1
Intermediate connector
R-6
F-506
Terminal
1
Intermediate connector
R-6
F-507
Terminal
1
Intermediate connector
R-6
F-508
Terminal
1
Intermediate connector
R-6
F-509
Terminal
1
Intermediate connector
R-6
CN-502F
D
12
Intermediate connector
R-5
In Ma t rk er n et a in ti o g n De al pt .
Connector No.
7-10
CN-1-110
D
6
Intermediate connector
AD-6
CN-1-112F
3
3
Intermediate connector
W-6
CN-1-111M
S
8
Intermediate connector
W-6
CN-142M
A
35
Monitor
P-5
CN-182P
S
6
Intermediate connector
I-7
CN-155M
S
6
Intermediate connector
J-7
CN-503F
A
2
Intermediate connector
W-6
CN-504F
A
2
Intermediate connector
X-6
CN-505F
A
2
Intermediate connector
X-6
CN-507F
A
2
Intermediate connector
X-6
CN-106M
A
2
Hyd oil temp sensor
I-7
CN-502F
D
8
Intermediate connector
W-6
CN-181M
L
6
Preheater controller
X-6
CN-506F
S
16
Intermediate connector
W-6
CN-180M
S
6
Parking relay
Y-6
CN-140M
DF
3
Front principal pressure sensor
I-7
CN-141M
DF
3
Rear principal pressure sensor
I-7
CN-129M
DF
3
Arm-in pilot sensor
I-6
CN-122M
DF
3
Arm-out pilot sensor
I-6
CN-126M
DF
3
Boom-up pilot sensor
I-6
CN-125M
DF
3
Boom-down pilot sensor
I-6
CN-124M
DF
3
Bucket-dig pilot sensor
I-6
CN-128M
DF
3
Bucket-dump pilot sensor
I-6
CN-123M
DF
3
Swing pilot sensor
I-6
CN-120M
DF
3
Left travel pilot sensor
I-6
CN-121M
DF
3
Right travel pilot sensor
I-6
CN-307M
H
8
Head lamp switch
R-5
司
公
销 营
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Type
Number of pins
Component
Stereogram
CN-303M
H
8
Work lamp switch
R-6
CN-305M
H
8
Washer switch
R-6
CN-304M
H
8
Wiper switch
R-6
CN-104M
A
2
Horn switch
R-6
CN-003F
S
12
Air conditioner
W-4
CN-150F
AMP
2
Front pump solenoid valve
I-7
CN-151F
AMP
2
Rear pump solenoid valve
I-7
CN-135F
AMP
2
Boom priority 2 solenoid valve
J-6
In Ma t rk er n et a in ti o g n De al pt .
Connector No.
CN-134F
AMP
2
Bucket confluence solenoid valve
J-6
CN-132F
AMP
2
Boom priority 1 solenoid valve
J-6
CN-136F
AMP
2
Pilot solenoid valve
J-6
CN-131F
AMP
2
High/low travel speed valve
J-6
CN-133F
AMP
2
Swing priority valve
J-6
CN-211M
AMP
2
Washer motor
K-5
F-300
Terminal
1
Coolant temp sensor
K-7
F-101
W
1
Right horn
I-6
F-100
W
1
Left horn
I-6
CN-140M
AMP
35
Controller
W-6
CN-141M
AMP
35
Controller
W-6
CN-800F
S
2
Alternator terminal L/R
K-7
F-103
S
3
Safety relay
X-6
CN-7-707
AMP
2
Cigar lighter
P-4
CN-150M
D
8
Intermediate connector
AE-3
CN-215F
HL
7
Radio
W-6
PF021
_
_
Fuse box
X-4
CN-1-001
AMP
2
Left speaker
AD-7
CN-1-002
AMP
2
Right speaker
AE-6
CN-1-003
AMP
2
Right head lamp
AB-5
CN-1-004
AMP
2
Left head lamp
AB-5
CN-1-005
AMP
2
Cab lamp
AE-7
司
公
销 营
Shop Manual - April 2014
7-11
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Description
S
SWP type, Yazaki
A/AMP
AMP, Japan
D
DT type, made in Japan
H
Hebi
HL
Hulane
L
Ling Xing
DF
Delphi, U.S.
W
AMP, Japan
Terminal
Round
In Ma t rk er n et a in ti o g n De al pt .
Connector No.
司
公
销 营
7-12
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3.1 Connector location layout
CN-105M
CN-104M
CN-102M
8
6
5
In Ma t rk er n et a in ti o g n De al pt .
7
司
CN-101M
公
销 营
Z
4
3
2
1 ZX305-1005001
A
B
C
D
E
F
Fig. 7-1 Shop Manual - April 2014
7-13
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
CN-111F
CN-113M
CN-155M T-111
CN-113F CN-115M
T-135
CN-116M T-110
CN-182P CN-120M
T-109
CN-121M
T-112
CN-122M CN-123M
CN-800F
In Ma t rk er n et a in ti o g n De al pt .
CN-124M
T-107
CN-125M
T-117
CN-126M
F-300
CN-128M
CN-129M
司
公
销 营
CN-211M
CN-131F
CN-132F
CN-133F
CN-134F
T-105 T-106
T-101
CN-135F
T-102
CN-136F
KB
F-100
T-104
F-101
T-103 T-118
Z
T-500
ZX305-1105041
Fig. 7-2 7-14
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
9
CN-303M
CN-304M
CN-305M CN-307M CN-502F
CN-302M CN-104M F-506 F-507
8
F-508 F-509
7
In Ma t rk er n et a in ti o g n De al pt .
F-501 F-502
F-503
F-504
6
F-505
司
公
销 营
5
4
3
CN-142M
CN-7-707
2
1 ZX305-1105042
N
O
P
Q
R
S
T
Fig. 7-3 Shop Manual - April 2014
7-15
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
CN-1-111M
CN-506F
CN-502F
T-202
F-103 K5
CN-1-112F
K6 K2
CN-503F
K4 CN-504M
K3 K7
CN-505F K9 CN-181M
In Ma t rk er n et a in ti o g n De al pt .
CN-507M
CN-615M
CN-180M KH
司
公
销 营
CN-616M
PF021
CN-215F CN-003F CN-201F
ZX305-1105043 T
U
V
W
X
Fig. 7-4 7-16
Shop Manual - April 2014
Y
Z
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
9
CN-303M
CN-304M
CN-305M CN-307M CN-502F
CN-302M CN-104M F-506 F-507
8
F-508 F-509 F-501
7
In Ma t rk er n et a in ti o g n De al pt .
F-502 F-503
F-504
6
5
4
3
2
F-505
CN-142M
司
公
销 营
CN-7-707
1 ZX305-1105042
N
O
P
Q
R
S
T
Fig. 7-5 Shop Manual - April 2014
7-17
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3.2 Diagram of system electrical elements
CN-7-707F (A-2)
29 1 22 2 3
CN-7-705M
9
1 2 3 4 5 6 7 8 9 10 11 12
CAN+ CAN-
24V 24V GND GND
00A 4 5 6 7 8 00# 9 60a 10 61a 11 12
CAN+ CAN-
1 29 2 22 3 4
22
Cigar lighter
CN-7-113M (D-12)
1
14 23
2
PF021 20
F1 20A F2 10A
13
F3 5A
20
24 F4 15A 25 F5 5A
00A
5 6 7 8 00# 9 10 60a 11 61a 12
21
20b F6 10A
21
26 F7 5A 38 F8 20A
21
20
10A 27 F9 5A 28 F10 29 F1120A
100
00#
CN-506F (S-16)
28 37 66 14 60 22
7 8 9 10 11 12 13 90 14
21 20 21
70 F125A 20A 90 F13 F145A
29 22 00#
64 1 63 2 65 3
21
21
1 64 2 63 3 65
7 8 9 10 11 12 13 14
28 37 66 14 22 90
21 20
10A F15
20
66 20b 38
8 CN-204F (D-12)
24 25 37 14 60 36 35H 33 35L
CN-203M (D-12) 1 2 3 4 5 6 7 8 9 10 11
69 62 61 22 13
1 2 3 4 5 6 50A 7 8 00A 9 70 10 72 11
6
CN-7-112F (D-3) CAN+
To controller circuit CN-112M
2
1 2
CAN-
1 2 57 3 00A 4 00# 5 6 7 8
S
1 2
60a 61a
CN-7-706M (S-2)
35L 35H 37 36 33 72 69 61 25 14
69 62 61 22 13
50A
57 00A
00A 70 72
00# 21 26 0# 24 23 70
1 2 3 57 4 00A 5 00# 6 7 8
司
Start relay
Pilot switch
4
Fuel control dial
公
60a 61a
6 14 5 60
14 6 60 5
CN-506M (D-8)
57 T-107
Compressor clutch
27
F-507 F-506
1 2 3
销 营
14 F-509 69 F-508
Preheat indicator
5
60 14 50A 1 506 2 00A 3 CN-501F (A-3)
CN-502M (D-12)
1
3
Sunlight sensor
Charging indicator
In Ma t rk er n et a in ti o g n De al pt .
7
24 25 37 14 60 36 35H 33 35L
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
Servce lamp
Lockout relay
Refuel
105
2
3 4 5
1
2
3 4 5
1
1
CN-205M (A-2)
1
105
0
11a
2
3 4 5
2
3 4 5
0
11b
11a
610
F-103
11b 60
3
Low-temp switch
Safety relay
0
F-104
21
F-105
12
2 2 CN-505F
F-105
66
T-101
TERMINAL
Start switch
BR ACC R1
B
R2
C
HEAT OFF ON
START
22 62 13
61 11
1 2
1 2
2
CN-504M
2 T-102 T-104 T-120
T-101 15
Start protection relay
1
2 3 45
1
2 3 45
11
0 11C
0
21
1
2
3 4 5
1
2
3 4 5
KB
T-116
T-135 T-102 21 12
14 60 21
B A P1P2
0
-
B
62 1
2
64 6365 3 45
1
0 2
3 45
24
T-500 T-501
Chassis ground
+ -
+
E
Start Chassis motor ground
C
E
E
Parking relay Chassis ground
Alternator
D
Fig. 7-6 7-18
22 646563
Battery relay
1 A
20
Shop Manual - April 2014
Parking motor
33 25 CN-503F (H-8)
Work lamp switch
37 CN-507F (H-8)
Washer switch
25
36 35L 35H
72
70
CN-505F (H-8)
CN-508F (H-8)
Wiper switch
Head lamp switch
ZX305-1105035
E
F
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
● This circuit diagram has been compiled by extracting the wiper system and the switch control systems from the general electrical circuit diagram. Preheat controller
Work lamp relay
Horn relay K5
CN-181M (D-6)
1 14
2 66
3
4
61
1
5 6
31
2
3 4 5
1
2
3 4 5
1 33
0 23 32
Preheater relay
K2
K6 1
Head lamp relay
1
KH
3 4 5
1
2 3 4 5 34 0 24
1 72
2
CN-124F (S-6) 50A 1
0 69
3
4 5
1
2 3 0 70
4 5
1 68
2
71
3
4 5
2 3 14 16
4 5 17
2
507 2
2
MT- 3
3
00A 5
5
MT+
6
Horn switch
6
1 2 3 5 6
Throttle motor AC-2000
31
23
In Ma t rk er n et a in ti o g n De al pt .
T-107
T-105
T-106
21
16
0
1
1
25
2
2
36 35H
61
3
3
4
4
5
5
35L
25 MT+ MT507 50A 00A
7 Wiper
M
6
CN-112M (A-2)
57 66 21
0
26 0#
司
公
销 营
24
CN-506F (S-16)
23 70
1
1
37 2
2
8
Preheater
CN-1-110M (D-6)
35L 35H 37 36 14 33 72 69
9
Washer motor
0
M
37
6 6
61a 60a 20b
0
38
71
0
71
R+ R-
L+ L-
0# 71 0
26
CN-150M (S-8)
1 2 3 4 5
1 2 3 4 5
6 7 8
6 7 8
1
1
2
2
1
1 2
2
Head lamp (R) 0 77
Head lamp (L) 0 77
F-104 (W-1)
32 34
CN-506M (D-16)
6
6
16
16
32
4
Horn
1
1
F-103 (W-1)
34
1
1
CN-101M (A-2)
1
20b
R+
L+ 0# 20b RL-
5
1 2 3 4 5 6 7
2
2
1
CN-104M (A-2) 1
2
2
Revolving frame work lamp
0
1
3
34
Left boom work lamp
0 34
CN-105M (A-2) 1
1
0
2
2
34
Right boom work lamp
2
CN-107M To radio control panel Radio speaker (R)
1
57
0 1
61a
4
60a
5 6
57 2
CN-109M
0#
Radio speaker (L)
0
7
38
26
8
38
1
1
2
2
0
Cab lamp
26
CN-207F
1
To A/C control panel
Fig. 7-7 G
ZX225-1105036
H
I
J Shop Manual - April 2014
K
L 7-19
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3.3 Diagram of electrical control system CN-502F (D-16)
CN-152M (AMP-2) 511 0
1 2
50
240Ω
00
9
4
4
13
13
CN-616M (AMP-81)
7
6
00# 42 509
108B 510 511 108A 508 200 204 207
50 00
202
200
502
201 202 203 204 208
00 00 50 CANCAN+ 11C 201
In Ma t rk er n et a in ti o g n De al pt .
8
1 2 5 11 13 15 19 30 31 34 38 48 L. travel pilot pressure 49 Bkt-dump pilot pressure 50 Boom-down pilot pressure 51 Arm-out pilot pressure 52 Rear pump main pressure53 54 55 56 58 60 65 R. travel pilot pressure 67 Swing pilot pressure 68 Bkt-dig pilot pressure 69 Boom-up pilot pressure 70 Arm-in pilot pressure 71 Front pump main pressure72 73 74 75 77 78 80
207
208 205
206
206
205 602
203 501
603
00
604
50 50
607 608 702 703
CAN+ CAN-
501 502 508 509 510 511 108A
CN-615M (AMP-40)
607
82 83 84 88 89 98 99 100 101 105 113 114 115 119 120 121
5
4
3
108B 27
610
611 702
0
司
公
703
销 营
608
42
604 602 603
00# 00# 42 42
TERMINAL B BRACCR1 R2 C HEAT OFF
27
ON START
22
42
13
2
T-101
T-102 T-104 T-103
13
0
1
2 3 45
1
2 3 45
20
21
KB
Battery relay
T-500
1
T-107
- +- +
A B C
A B
CN-112M (D-3)
GND
Battery
To monitor circuit
CN-115M (D-3)
120 Ω
ZX335-1105037
A
B
C
D
Fig. 7-8 7-20
Shop Manual - April 2014
E
F
G
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
● This circuit diagram has been compiled by extracting the pressure collecting system and the solenoid valve control systems from the general electrical circuit diagram.
50 00 200 50 00 201 50 00 202 50 00 203 50 00 204
50
50 00 208
00 200
50 00 207
B
B
C
C
B
R. travel pilot pressure sensor
B
C C CN-122M (DF-3) A A B
B
C
C
Arm-out pilot pressure sensor
CN-129M (DF-3) A A
B
B
C
C
Arm-in pilot pressure sensor
CN-128M (DF-3) A A
B
B
C
C
Bucket-dump pilot pressure sensor
CN-123M (DF-3) A A
B
B
C
C
50 00 206
50 00 205
207 206
50 00 501
205 501 502
50 00 502
602 603 604 607 608
Boom-down pilot pressure sensor
B C
CN-126M (DF-3) A A
B
B
C
C
Boom-up pilot pressure sensor
CN-124M (DF-3) A A
B
Bucket-dig pilot pressure sensor
B
C C CN-115M (DF-3) A A B
B
C
C
Front pump pressure sensor
CN-116M (DF-3) A A
B
B
C
C
8
Swing pilot pressure sensor
CN-125M (DF-3) A A
B C
9
L. travel pilot pressure sensor
CN-121M (DF-3) A A
In Ma t rk er n et a in ti o g n De al pt .
201 202 203 204 208
CN-120M (DF-3) A A
7
Rear pump pressure sensor
CN-132F (AMP-2)
602 0
603 0
702 703 508 510
1 2
1
1
Boom priority-1 -prptnl valve
2
2
1
1
Boom priority-2 -prptnl valve
2
2
1
1
2
2
High speed travel valve
司
公
销 营
CN-133F (AMP-2)
608 0
108B 27
1
2
2
Swing priority prptnl valve
CN-111F (AMP-2)
702 0
0
1
1
1
2
2
Front pump prptnl valve
CN-113F (AMP-2)
42
703 0
1
1
2
2
508
T-109
509
CN-101M
510
511 42
CN-113M (AMP-2) 1
2
CN-125F (S-2)
1
1
108A
2
2
108B
6
Bkt confluence -prptnl valve
CN-131F (AMP-2)
607 0
511 108A
2
CN-134F (AMP-2)
604 0
509
1
CN-135F (AMP-2)
5
Rear pump prptnl valve Engine oil prsur switch Fuel level
T-116
Coolant temp sensor
4
Hyd oil temp sensor Engine speed sensor
3
Pilot valve relay
Pilot switch
1
2
3
4
5
1
2
3
4
5
CN-205F (A-2) CN-136F (AMP-2)
1 2
2
1 2
Pilot valve
1 ZX225-1105038
H
I
J
K
L
M
Fig. 7-9 Shop Manual - April 2014
7-21
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3.4 SWP connectors Male (plug)
Female (socket)
7123-7414-40
(1 pin)
In Ma t rk er n et a in ti o g n De al pt .
7222-7414-40
7123-1424-40
(2 pins)
7222-7464-40
7123-7464-40
(6 pins)
7222-7484-40
7123-7484-40
(8 pins)
7222-1424-40
司
公
销 营
7222-7564-40
7123-7564-40
(16 pins) W365-130707
Fig. 7-10 7-22
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3.5 A/AMP connectors
Male (plug)
Female (socket)
Part No. ：282080-1 (2 pins)
In Ma t rk er n et a in ti o g n De al pt .
Part No. ：282104-1
282105-1
282087-1
(3 pins)
司
公
销 营
174354-2
174352-2
1473252-1
1473255-1
1473244-1
1473247-1
(2 pins)
(40 pins)
(81 pins) W365-130709
Fig. 7-11 Shop Manual - April 2014
7-23
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3.6 DT connectors Housing (plug)
Housing (socket) B
A
B
A
DT06-2S
DT04-2P
A
A
B
In Ma t rk er n et a in ti o g n De al pt .
B
C
C DT06-3S
DT04-3P (3 pins)
1
6
2
5
3
4
6
1
5
2
4
3
司
公
销 营
DT04-6P (6 pins) 8 5
DT06-6S
8
5
1
4
1 DT04-8P (8 pins) 4
DT06-8S
12
7
7
12
1
6
6
1
DT04-12P
DT06-12S
(12 pins) W365-130710
Fig. 7-12
7-24
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.4 Troubleshooting with an Event Code
In Ma t rk er n et a in ti o g n De al pt .
Information contained in troubleshooting table ............................................................. 7-26 E015 Power voltage abnormal ..................................................................................... 7-27 E212 Irregular throttle motor current or defective motor connection ............................ 7-28 E240 Hydraulic oil temperature abnormal .................................................................... 7-29 E320 Front pump output pressure abnormal ................................................................ 7-30 E321 Rear pump output pressure abnormal ................................................................ 7-31 E322 Bucket-dig pilot pressure abnormal..................................................................... 7-32 E323 Bucket-dump pilot pressure abnormal ................................................................ 7-33 E324 Arm-in pilot pressure abnormal ........................................................................... 7-34 E325 Arm-out pilot pressure abnormal ......................................................................... 7-35 E326 Boom-up pilot pressure abnormal ....................................................................... 7-36 E327 Boom-down pilot pressure abnormal .................................................................. 7-37 E328 Left travel pilot pressure abnormal ...................................................................... 7-38 E329 Right travel pilot pressure abnormal ................................................................... 7-39 E330 Swing pilot pressure abnormal ............................................................................ 7-40 E332 Motor built-in potentiometer irregular .................................................................. 7-41 E434 Front pump proportional solenoid current abnormal (A) ..................................... 7-42 E435 Rear pump proportional solenoid current abnormal (A) ...................................... 7-43 E436 Front pump proportional solenoid current abnormal (B) ..................................... 7-44 E437 Rear pump proportional solenoid current abnormal (B) ...................................... 7-45 E543 Engine speed abnormal ...................................................................................... 7-46 E244 Fuel control dial setting voltage abnormal .......................................................... 7-47 E145 CAN bus abnormal .............................................................................................. 7-48 司
公
销 营
Shop Manual - April 2014
7-25
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Information contained in troubleshooting table Failure code
Service Code
Code displayed
——
Failure information Controller reaction Machine reaction
Failure sympTitle of failure shown in failure history tom
Failure is described on the monitor display. When failure is detected, the controller has taken action to protect the affected system or equipment. Symptom that is shown on the machine due to action of controller.
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Cause
Possible causes and standard values
1 2
3
• Standard value under normal condition can be used to judge possible causes
4
• Reference for passing the above "Good" or "No Good" judgement Possible causes of trouble (Given numbers are ref- <Symptom of Wiring Harness Failure> erence numbers, which do not in- • Open circuit dicate priority) Faulty contact with connector or open circuit in wiring harness 司
公
销 营
5
• Faulty grounding
An ungrounded wiring is grounded.
• Short circuit
A wiring has mistaken contact with a 24 V electric circuit.
Related circuit diagram
This is part of the circuit diagram which shows the portion where the failure occurred. ● Connector No.: A connector number Indicates a connector. ● Arrow: An arrow roughly indicates the installing location.
7-26
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E015 Power voltage abnormal Failure code
Failure symptom
E015
Power voltage abnormal
Voltage of power supply is higher than 36V during machine operation.
Controller reaction
Driving of motor and solenoid valve is cut off automatically by the system.
Machine symptom
Engine fails to accelerate and machine moves slowly.
Cause
Standard values and troubleshooting references ★ Turn the start switch to the OFF position and leave it in the position for troublePower fail- shooting. ure Volt Under 25 V Check battery voltage. ★ Turn the start switch to the OFF position before proceeding. Turn the start Alternator switch to the START position for trouble shooting. abnormal Measure between alternator terminal B and ground. Volt Around 28 V
1
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Failure description
2
3 4
司
公
销 营
Start switch B
TERMINAL
BR ACC R1 R2 C
HEAT OFF ON
START
13
Charging indicator
G
14
-
+
-
+ Battery relay
0
B R
S
13 0
Delay relay
11b
E
L
B
E Alternator
Safety relay C
R
60
0
M Start motor
S E
0
0 ZX225-1105002
Fig. 7-13 Shop Manual - April 2014
7-27
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E212 Irregular throttle motor current or defective motor connection g Failure code
Failure symptom
E212
Throttle motor loading circuit is abnormal and the engine acceleration fails.
Failure description
Motor feedback voltage is lower than 0.25V or higher than 4.75V
Controller reaction
The controller stops the motor driving system when this failure is detected.
Symptom on machine
Engine acceleration fails and the machine acts slowly. . Standard values and troubleshooting references
Failure of throttle 1 motor coil
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
Between Ĺ and ļ of CN-124M
Resistance
12.2ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. 2 Open circuit of harKeep it in the OFF position while troubleshooting is performed. Unplug the controller and measure the resistance ness Resistance 12.2ȍ between the pins 32 and 33. Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
3
Short circuit of harUnplug the connector CN-124M and measure the ness (grounded) resistance between motor Ĺ ( ļ ) and the hous- Resistance Above 2Mȍ ing. 司
公
销 营
No troubleshooting can be done for failure occurs in the inner of controller. (Except for the above reasons, the controller must be replaced in case of failure.)
Internal failure of 4 controller 5
Controller
Throttle motor
CN-124M
50A#
Sensor
25
507#
Throttle feedback volt
7
MT-
33
GND
16
00A
MT+
32
MT+
MT-
1
1
2
2
3
3
4
4
5
5
6
6
Green White Red
M
Yellow Blue
Chassis harness
Operator station
ZX225-1105001
Fig. 7-14 7-28
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E240 Hydraulic oil temperature abnormal 0 yd au c o te pe atu e ab o a Failure code
Hydraulic oil temperature is abnormal. Only alarm output is effective.
Failure symptom
E240
Controller detects a temperature resistance of hydraulic oil that is lower than 10 ohms or higher than 120 ohms and it lasts more than 3s. Only alarm output is effective. The alarm resets automatically when conditions Controller reaction become normal. Symptom on machine —— Failure description
Cause
Standard values and troubleshooting references Ɣ Turn the start switch to the OFF position and then keep it in the ON position to perform troubleshooting.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
2
3
4
Failure of sensor
Open circuit of harness Short circuit of harness (grounded)
Failure of 24V power supply
Between CN-113M ķ and ground
Voltage
0.2-4.75V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-113M ķ and pin 21 of controller Resistance
Under 1 :
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Resistance Above 1M :
Between CN-113M ķ and ground 司
公
销 营
Ɣ Turn engine start switch to OFF position. Keep it at ON position to perform troubleshooting. Between CN-113M ĸ and ground
Voltage
About 24V
5
CN-115F
0#
1
1
240 ohms
Controller
2
2
CN-113M
Hyd oil temp sensor
511
21
1
1
2
2
Hyd oil temp sensor Signal
24V PWR
24V PWR
Operator station
Chassis harness
ZX225-1105016
Fig. 7-15
Shop Manual - April 2014
7-29
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E320 Front pump output pressure abnormal Failure code
Front pump output pressure is abnormal. Only alarm output is effective.
Failure symptom
E320 Failure description Controller reaction
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Symptom on machine
——
Cause Failure of 5V power supply
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the ON position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
Standard values and troubleshooting references
2
Between CN-151M A and B
Voltage
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of Between CN-151M C and pin 29 of controller signal line Between CN-115M B and ground
3
4
About 5V
Short circuit of signal line (grounded)
Failure of sensor
Under 1ȍ
Resistance
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. 司
Between CN-151M C and ground 公
销 营
Resistance
Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-151M C and ground
Voltage
0.5±0.2V
5
Controller
Front pump signal collecting port GND
5V PWR
Front pump press. sensor
CN-151M
29
501# 00#
23
12
50#
Operator station
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105003
Fig. 7-16
7-30
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E321 Rear pump output pressure abnormal p p p p Failure code
Reading of rear pump output pressure is abnormal. Only alarm output is effective. .
Failure symptom
E321 Failure description Controller reaction
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Symptom on machine
——
Cause
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position Failure of 5V while troubleshooting is performed. power supply Between CN-116M A and B Voltage About 5V
Possible causes and standard values
1
2
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of Between CN-116M C and pin 19 of controller signal line Between CN-116M B and ground
Under 1ȍ
Resistance
Under 1ȍ
3
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-116M C and ground Resistance Above 2Mȍ
4
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position Failure of senwhile troubleshooting is performed. sor Between CN-116M C and ground Voltage 0.5±0.2V
司
公
销 营
5
Controller
CN-116M
Rear pump signal collecting port
19
GND
20
5V PWR
12
502#
C
Signal
B
GND
A
5V
00#
Operator station
50#
Rear pump press. sensor
Chassis harness
ZX225-1105004
Fig. 7-17 Shop Manual - April 2014
7-31
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E322 Bucket-dig pilot pressure abnormal Failure code E322
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
The bucket-dig motion is slow.
Cause
Standard values and troubleshooting references
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of 5V troubleshooting is performed. power supply Between CN-124M A and B Voltage About 5V
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Bucket-dig pilot pressure is abnormal. Only alarm output is effective. .
Failure symptom
2
Open circuit of signal line
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-124M C and pin 10 of controller Between CN-124M B and ground
3
Under 1 :
Resistance
Under 1 :
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-124M C and ground Resistance Above 2M :
4
司
公
销 营
Failure of sensor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-124M C and ground
Voltage
0.5±0.2V
5
Controller
CN-124M
205#
Bucket-dig pilot press. 10 signal collecting port GND 5V PWR
00#
11
50#
12
Operator station
Bucket-dig pilot pressure sensor
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105005
Fig. 7-18
7-32
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E323 Bucket-dump pilot pressure abnormal Failure code
Reading of bucket-dump pilot pressure is abnormal. Only alarm output is effective.
Failure symptom
E323 Failure description
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on.
Controller reaction
Only alarm output is effective.
Symptom on machine
Bucket-dump motion is slow.
Cause
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of 5V troubleshooting is performed. power supply Between CN-128M A and B Voltage About 5V
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Standard values and troubleshooting references
2
Open circuit of signal line
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-128M C and pin 33 of controller Between CN-128M B and ground
Resistance
Under 1ȍ Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. . of signal line (grounded) Between CN-128M C and ground Resistance Above 2Mȍ 司
公
销 营
3
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of sen4 troubleshooting is performed. sor Between CN-128M C and ground Voltage 0.5±0.2V 5
Controller
Bucket-dump pilot press. signal collecting port
GND 5V PWR
CN-128M
204#
33
C
Signal
00#
11 12
Operator station
Bucket-dump pilot pressure sensor
B
GND
A
5V
50#
Chassis harness
ZX225-1105006
Fig. 7-19 Shop Manual - April 2014
7-33
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E324 Arm-in pilot pressure abnormal Failure code
Failure symptom
E324
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
Arm-in motion is slow.
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Cause
1
Possible causes and standard values
Reading of Arm-in pilot pressure is abnormal. Only alarm output is effective. .
Failure of 5V power supply
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-129M A and B
2
Open circuit of signal line
Voltage
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-129M C and controller pin 35 Between CN-129M B and ground
Resistance
司
公
销 营
3
Under 1ȍ
Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-129M C and ground Resistance Above 2Mȍ
4
Failure of sensor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-129M C and ground
Voltage
0.5±0.2V
5
Arm-in pilot pressure signal collecting port
Arm-in pilot press. sensor
CN-129M
Controller
203#
35
00#
GND
11
5V PWR
12
50#
Operator station
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105007
Fig. 7-20 7-34
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E325 Arm-out pilot pressure abnormal
Failure code
Reading of Arm-out pilot pressure is abnormal. Only alarm output is effective. .
Failure symptom
E325
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
Arm-out motion is slow.
Cause
Standard values and troubleshooting references Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Ɣ
Possible causes and standard values
1
Failure of 5V power supply
Between CN-122M A and B
Ɣ
2
Open circuit of signal line
Voltage
About 5V
Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Between CN-122M C and pin 22 of controller Between CN-122M B and ground
Under 1 :
Resistance
Under 1 :
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-122M C and ground Resistance Above 2M : 司
公
销 营
3
Ɣ
4
Failure of sensor
Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-122M C and ground
Voltage
0.5±0.2V
5
Controller
Arm-out pilot press. sensor
CN-122M
Arm-out pilot pressure 22 signal collecting port GND
11
5V PWR
12
202# 00# 50#
C
Signal
B
GND
A
5V
Operator station
Chassis harness
ZX225-1105008
Fig. 7-21 Shop Manual - April 2014
7-35
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E326 Boom-up pilot pressure abnormal Failure code
Failure symptom
E326
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
Boom-up motion is slow.
Cause
Standard values and troubleshooting references
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of 5V troubleshooting is performed. power supply Between CN-126M A and B Voltage About 5V
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Reading of boom-up pilot pressure is abnormal. Only alarm output is effective. .
2
Open circuit of signal line
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-126M C and controller pin 8. Between CN-126M B and ground
Resistance
Under 1ȍ
Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-126M C and ground Resistance Above 2Mȍ 司
公
销 营
3
4
Failure of sensor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-126M C and ground
Voltage
0.5±0.2V
5
Boom-up pilot press. sensor
Controller
Boom-up pilot pressure signal collecting port
GND 5V PWR
206#
8
00#
11
50#
12
Operator station
CN-126M C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105009
Fig. 7-22 7-36
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E327 Boom-down pilot pressure abnormal
Failure code
Reading of boom-down pilot pressure is abnormal. Only alarm output is effective. .
Failure symptom
E327
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
Boom-down motion is slow.
Cause
Standard values and troubleshooting references Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
Failure of 5V power supply
Between CN-125M A and B
2
Open circuit of signal line
Voltage
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-125M C and controller pin 9 Between CN-125M B and ground
Resistance
Under 1ȍ Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-125M C and ground Resistance Above 2Mȍ 司
公
销 营
3
4
Failure of sensor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-125M C and ground
Voltage
0.5±0.2V
5
Controller
Boom-down pilot pressure signal collecting port
GND 5V PWR
Boom-down pilot press. sensor
CN-125M
9
207# 00#
11 12
Operator station
50#
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105010
Fig. 7-23 Shop Manual - April 2014
7-37
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E328 Left travel pilot pressure abnormal Failure code E328
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
Left travel speed is low. Travel deviates.
Cause
Standard values and troubleshooting references
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of 5V troubleshooting is performed. power supply Between CN-120M A and B Voltage About 5V
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Reading of left travel pilot pressure is abnormal. Only alarm output is effective. .
Failure symptom
2
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of Between CN-120M C and pin 34 of controller signal line Between CN-120M B and ground
Resistance
Under 1ȍ
Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-120M C and ground Resistance Above 2Mȍ 司
公
销 营
3
Failure of sen4 sor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-120M C and ground
Voltage
0.5±0.2V
5
Controller
CN-120M
Left travel pilot press. signal collecting port GND 5V PWR
200#
34
00#
11
50#
12
Operator station
Left travel pilot pressure sensor
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105011
Fig. 7-24 7-38
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E329 Right travel pilot pressure abnormal Failure code E329
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
Right travel speed is low. Travel deviates.
Cause
Standard values and troubleshooting references
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of 5V troubleshooting is performed. power supply Between CN-121M A and B Voltage About 5V
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Reading of right travel pilot pressure is abnormal. Only alarm output is effective. .
Failure symptom
2
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of Between CN-121M C and pin 30 of controller signal line Between CN-121M B and ground
3
Resistance
Under 1ȍ Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-121M C and ground Resistance Above 2Mȍ 司
公
销 营
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of sen4 troubleshooting is performed. sor Between CN-121M C and ground Voltage 0.5±0.2V 5
Controller
CN-121M
Right travel pilot press. 30 signal collecting port
201# 00#
GND 5V PWR
11
12
Operator station
50#
Right travel pilot pressure sensor
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105012
Fig. 7-25
Shop Manual - April 2014
7-39
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E330 Swing pilot pressure abnormal Failure code
Reading of swing pilot pressure is abnormal. Only alarm output is effective. .
Failure symptom
E330 Failure description
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on.
Controller reaction
Only alarm output is effective.
Symptom on machine
Swinging motion is slow.
Cause
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of 5V troubleshooting is performed. power supply Between CN-123M A and B Voltage About 5V
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Standard values and troubleshooting references
2
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of Between CN-123M C and pin 18 of controller signal line Between CN-123M B and ground
Resistance
Under 1ȍ
Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-123M C and ground Resistance Above 2Mȍ 司
公
3
销 营
Failure of sen4 sor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-123M C and ground
Voltage
0.5±0.2V
5
Controller
CN-123M
Swing pilot pressure signal collecting port
208#
18
00#
GND
11
5V PWR
12
50#
Operator station
Swing pilot pressure sensor
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105013
Fig. 7-26 7-40
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E332 Motor built-in potentiometer irregular
Failure code
The potentiometer built in the motor is irregular. It returns to auto deceleration when time point is detected.
Failure symptom
E332
Controller reaction
When machine power is on, throttle position feedback has a voltage other than 0.25-4.75V lasting more 50 msec. Returns to auto deceleration.
Symptom on machine
The throttle fails to increase engine speed.
Failure description
Standard values and troubleshooting references
Failure of 5V power source
Ɣ Turn the start switch to the OFF position and then keep it in the ON position to perform troubleshooting.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Causes 1
2
3
Between CN-155M ķ and Ļ
Volt
About 5V
Ɣ Turn the start switch to the OFF position before troubleshooting. Kee the Open circuit switch in the OFF position to perform troubleshooting. of signal Between CN-155M ĸ and the controller port pin 7 Under 1ȍ line Resistance Between CN-155M Ļ and ground Under 1ȍ
Short cuit of Ɣ Turn the start switch to the OFF position before troubleshooting. Kee the switch in the OFF position to perform troubleshooting. signal line (grounded) Between CN-155M ĸ and ground Resistance Above 2Mȍ 司
公
销 营
Controller CN-142M Throttle position feedback
CN-502
CN-113
7
GND
16
Sensor 5V
25
507#
00A# 50A#
6
6
4
4
3
3
507#
00A# 50A#
7
7
4
4
6
6
Operator station
CN-155M
507#
00A# 50A#
2
2
5
5
1
1
507#
00A# 50A#
Throttle position Throttle position GND
5V
Chassis harness ZX225-1105045
Fig. 7-27
Shop Manual - April 2014
7-41
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E434 Front pump proportional solenoid current abnormal (A) Failure code
Front pump proportional solenoid current is abnormal. The system operates slowly.
Failure symptom
E434
Abnormality occurs in loaded circuit of proportional solenoid. Current which is above 1.3A lasts for 3 second. Differential current occurs in drive protection loop. Stop the solenoid when failure is detected. Power supply must be restored.
Failure description Controller reaction
Symptom on machine System operates slowly.
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
1
Open circuit of harness
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-111F ķ and pin 28 of controller Between CN-111F ĸ and ground
Short circuit 2 of harness (grounded)
Under 1ȍ
Resistance
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-111F ķ and wire 0#
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Failure of proKeep it in the OFF position while troubleshooting is performed. 3 portional valve Unplug the connector CN-111F, and measure the coil Resistance 17.5ȍ resistance between solenoid valve's ķ and ĸ 司
公
销 营
4
No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of troller this failure.)
5
Controller
CN-150F
Front pump SV signal output port GND
702#
28
0#
3
Operator station
Front pump SV
1
Signal
2
GND
Chassis harness
ZX225-1105014
Fig. 7-28
7-42
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E435 Rear pump proportional solenoid current abnormal (A)
Failure code
Rear pump proportional solenoid current is abnormal. The system operates slowly.
Failure symptom
E435
Abnormality occurs in loaded circuit of proportional solenoid. Current which is above 1.3A lasts for 3 second. Differential current occurs in drive protection loop. Stop the solenoid when failure is detected. Power supply must be restored.
Failure description Controller reaction
Symptom on machine System operates slowly.
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
1
Open circuit of harness
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-113F ķ and pin 17 of controller Between CN-113F ĸ and ground
2
Short circuit of harness (grounded)
Under 1ȍ
Resistance
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-113F ķ and wire 0#
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Failure of proKeep it in the OFF position while troubleshooting is performed. 3 portional valve Unplug the connector CN-113F, and measure the coil Resistance 17.5ȍ resistance between solenoid valve's ķ and ĸ . 司
公
销 营
4
No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of troller this failure.)
5
Controller
CN-151F
Rear pump SV signal output port GND
17
3
Operator station
703#
0#
Rear pump SV
1
Signal
2
GND
Chassis harness
ZX225-1105015
Fig. 7-29 Shop Manual - April 2014
7-43
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E436 Front pump proportional solenoid current abnormal (B) Failure code
Front pump proportional solenoid current is abnormal. The system operates slowly.
Failure symptom
E436
Abnormality occurs in loaded circuit of proportional solenoid. Current which is under 0.2 A lasts for 3 seconds and PWM output is greater than 10V. Stop the solenoid when failure is detected. Power supply must be restored.
Failure description Controller reaction
Symptom on machine System operates slowly.
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
1
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of Between CN-150F ķ and pin 28 of controller harness Between CN-150F ĸ and ground
2
Short circuit of harness (grounded)
Resistance
Under 1ȍ
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-150F ķ and wire 0#
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Failure of pro3 portional valve Unplug the connector CN-150F, and measure coil the resistance between solenoid valve's ķ and Resistance 17.5ȍ ĸ. 司
公
销 营
4
No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of troller this failure.)
5
Controller
CN-150F
Front pump SV signal output port GND
702#
28
0#
3
Operator station
Front pump SV
1
Signal
2
GND
Chassis harness
ZX225-1105014
Fig. 7-30
7-44
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E437 Rear pump proportional solenoid current abnormal (B)
Failure code
Rear pump proportional solenoid current is abnormal. The system operates slowly.
Failure symptom
E437
Abnormality occurs in loaded circuit of proportional solenoid. Current which is under 0.2 A lasts for 3 seconds and PWM output is greater than 10V. Stop the solenoid when failure is detected. Power supply must be restored.
Failure description Controller reaction
Symptom on machine System operates slowly.
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
1
Open circuit of harness
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-151F ķ and pin 17of controller Between CN-151F ĸ and ground
2
Short circuit of harness (grounded)
Resistance
Under 1ȍ Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-151F ķ and wire 0#
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Failure of pro3 portional valve Unplug the connector CN-151F, and measure coil the resistance between solenoid valve's ķ and Resistance 17.5ȍ ĸ 司
公
销 营
4
No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of troller this failure.)
5
Controller
CN-151F
Rear pump SV signal output port GND
17
3
Operator station
703#
0#
Rear pump SV
1
Signal
2
GND
Chassis harness
ZX225-1105015
Fig. 7-31
Shop Manual - April 2014
7-45
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E543 Engine speed abnormal Failure code
Failure symptom
E543
Engine speed is abnormal. Only alarm output is effective.
Failure description
CPU detects out that engine speed is too low (below 100 rpm). Only alarm output is effective. The alarm resets automatically when conditions Controller reaction become normal. Symptom on machine ——
Cause Normal condition
Code 43 will be displayed on the monitor when the engine start switch is turned from the OFF position to the ON position.
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Standard values and troubleshooting references
2
Open circuit of harness
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-125M ķ and pin 16 of controller Between CN-125M ĸ and pin 6 of controller
3
Short circuit of harness (grounded)
Under 1ȍ
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-125M ķ and ground 司
公
销 营
4
Resistance
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Failure of sensor Unplug the connector CN-125M, and measure the resistance between ķ and ĸ of the speed Resistance 2.3 r 0.2k : sensor.
5
Controller
CN-125M
Engine speed collection
16
GND
6
108A
108B
Operator station
Engine speed sensor
1
Signal
2
GND
Chassis harness
ZX225-1105017
Fig. 7-32
7-46
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E244 Fuel control dial setting voltage abnormal Failure code E544
Fuel control dial setting voltage is abnormal and engine returns auto deceleration.
Failure symptom
Failure description
When power is on, voltage of fuel control dial other than 0.25-4.75V lasts for over 200 msec.
Controller reaction
Throttle is moved to idle position.
Symptom on machine
Engine returns auto deceleration.
Causes 1
Possible causes and standard values
Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the ON position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
5V power failure
Standard values and troubleshooting references
2
3
CN-501F Ľ and Ŀ
Volt
About 5V
Open circuit Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line CN-501F ľ and controller pin19 Resistance Under 1ȍ Short cir- Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the cuit of OFF position while troubleshooting is performed. signal line CN-501F ľ and ground Resistance Above 2Mȍ (grounded) 司
公
销 营
4
5
Short circuit Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the ON position while troubleshooting is performed. of signal line (contact with CN-501F ľ and ground Volt Under 5V power supply) Dial failure
Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Unplug connector CN-501F and measure fuel conResistance trol dial Ľ and Ŀ .
CN-7-113M
CN-209F
Sensor 5V
25
3
3
3
3
GND
16
4
4
9
9
Fuel control dial setting voltage
19
5
5
2
2
5K±15%ȍ
CN-501F
50# 506# 0#
7
7
9
9
8
8
Yellow Red Blue
Fuel control dial
Operator station
ZX225-1105018
Fig. 7-33 Shop Manual - April 2014
7-47
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E145 CAN bus abnormal Failure code
Failure symptom
E145
Abnormality of CAN bus activates alarm.
Failure description
Time-out of CAN bus communication lasts for over 3s.
Controller reaction
Only alarm output is effective.
Symptom on machine
----
1
Standard values and troubleshooting references
CAN resistance failure
Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Causes
Between CN-7-709 A and B
Resistance
60ȍ
Between CN-185 A and B
Resistance
60ȍ
Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
2
Open circuit Unplug controller connector and measure pin of Harness 12 and CN-7-112 A. Unplug controller connector and measure pin 11 and CN-7-112 B.
Under 1ȍ
Resistance
Under 1ȍ
ControlNo troubleshooting can be done for failure occurs in the inner of controller. (Except ler internal for the above reasons, the controller must be replaced in case of this failure.) failure 司
公
销 营
CN-185M A B
Controller
CANH
12
CANL
11
F11 15A
F13 10A
CN-7-709M A
120 ohms
CN-7-112F A B
CN222F 4
7 CN-221M
CN-7-113M 1
2 9
120 ohms
B
CANH
CANL 42
35 12
5 43 24 0 11 0 31
Monitor
3
21 PWR
Operator station
PWR
Chassis harness ZX335-1005040
Fi 30 Fig. 77-34 7-48
20
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.5 Troubleshooting Electrical System (E-Mode)
In Ma t rk er n et a in ti o g n De al pt .
E-1 Engine does not crank .......................................................................................... 7-51 E-2 Engine runs rough or is unstable .......................................................................... 7-54 E-3 Power supply of machine cannot be cut off .......................................................... 7-55 E-4 Throttle motor not working .................................................................................... 7-56 E-5 Auto idle not functioning ........................................................................................ 7-57 E-6 Preheat function fails ............................................................................................ 7-59 E-7 All components not working .................................................................................. 7-60 E-8 Boom-up speed or power is low............................................................................ 7-61 E-9 Arm speed or power is low .................................................................................... 7-62 E-10 Bucket speed or power is low ............................................................................. 7-63 E-11 Travel speed or power is low............................................................................... 7-65 E-12 Blank monitor display .......................................................................................... 7-66 E-13 Monitor displays nothing ..................................................................................... 7-67 E-14 Dual speed travel not functioning........................................................................ 7-68 E-15 Incorrect engine coolant reading......................................................................... 7-69 E-16 Incorrect fuel level reading .................................................................................. 7-70 E-17 Wiper does not work ........................................................................................... 7-71 E-18 Incorrect arm-in pilot pressure reading ............................................................... 7-72 E-19 Incorrect arm-out pilot pressure reading ............................................................. 7-73 E-20 Incorrect boom-up pilot pressure reading ........................................................... 7-74 E-21 Incorrect boom-down pilot pressure reading....................................................... 7-75 E-22 Incorrect bucket-dig pilot pressure reading ......................................................... 7-76 E-23 Incorrect bucket-dump pilot pressure reading..................................................... 7-77 E-24 Incorrect swing pilot pressure reading ............................................................... 7-78 E-25 Left travel pilot pressure reading incorrect .......................................................... 7-79 E-26 Right travel pilot pressure reading incorrect ....................................................... 7-80 司
公
销 营
Shop Manual - April 2014
7-49
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Fuse box connection table ● This table gives all power supply units and rated currents of fuse box power supplies. ● If power supply is normal, check the fuse box and fuses when you perform troubleshooting of the electrical system. Information contained in troubleshooting table Failure information Related information
Symptom on machine Failure occurred and troubleshooting information Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Cause
Possible causes and standard values
● Standard value under normal condition can be used to judge possible causes ● Reference for passing the above "Good" or "No Good" judgement
Possible causes of trouble (Given numbers are refer- <Symptom of Wiring Harness Failure> ence numbers, which do not ● Open circuit indicate priority) Faulty contact with connector or open circuit in wiring harness 司
公
销 营
1
● Faulty grounding
An ungrounded wiring is grounded.
● Short circuit
A wiring has mistaken contact with a 24 V electric circuit.
7-50
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-1 Engine does not crank Trouble
Engine cannot be started.
Related information
Cause Low battery capacity
Battery voltage
Voltage
≥ 24V
Internal fail- ★ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. 2 ure of engine OFF position: between wire 22# and wire 11# Resistance ≥ 1M Ω start switch ★ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Failure of pilot Lockout control in unlocked position: between 3 ≤1 Ω switch 105 # and 27# wire Resistance Lockout control in locked position: between wire ≥1M Ω 105 # and wire 27# ★ Turn engine start switch to OFF position. Keep the engine running during troubleshooting. (When all power supplies, grounding, signal and engine inputs are normal except engine output, it is the failure of start motor) 4 Failure of Engine starting motor Start switch Voltage start motor Power supply: Terminal B and ground 20—30V Start Between start motor input terminal S and ground 20—30V ★ Turn engine start switch to OFF position before proceeding. Turn it to the ON position to perform troubleshooting. Open circuit ≤1 Ω Wire 21# and start motor terminal B 5 of harness Wire 12# and start motor terminal S Resistance ≤1 Ω
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
Standard values and troubleshooting references ★ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
司
公
销 营
Start relay terminal L and safety relay terminal S
Shop Manual - April 2014
≤1
Ω
7-51
Troubleshooting
Cause
Standard values and troubleshooting references
Failure of fuse Battery terminal "+" (wire 20#) and control dial F1 wire 22#
Short circuit 7 of harness (grounded)
≤1
Ω
★ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Start relay terminal S and ground ≥1M Start motor input terminal S and ground
Resistance
≥1M
Ω Ω
★ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Internal failure 8 troubleshooting is performed. of alternator Alternator terminal R and ground Voltage ≤ 1.5V 9 Start relay
10
★ Turn engine start switch to OFF position. Move it to ON position when performing troubleshooting. Between relay coils ≥ 300 Ω Resistance Between start relay terminal B and line 11# ≤1 Ω ★ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Check parking relay — Resistance Measure resistance of motor coil. Approx 63 Ω
Failure of parking unit
司
公
销 营
7-52
Resistance
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
6
SY365(B)H-9 Crawler Hydraulic Excavator
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
21
16 F13-160A 14
TERMINAL B BR ACC R1 R2 C HEAT OFF ON START S0 22 62 61 11
Start switch
897044-4180
61 66
1 3
4
2
6
0
1
4
3
17 GR-1 GLOW PLUG
Preheat relay
68 69 HL2
5
Low-temp switch
2
PReheat indicator
13
3
6 5
1
2
64 65
A
63
P2
E3
k7
P1
B E
0
Parking relay
HLR
Charging indicator
Parking motor
G
22
In Ma t rk er n et a in ti o g n De al pt .
14
14
P600G
F1-20A
F2-10A
B1
B2
Safety relay
+
-
+
11
k1
Battery relay
0
L
B
E
11a
11b
R
S
12 60
E
620
k3
Lockout relay
27
BAT-1 Battery
司
公
销 营
F7-10A
0
k3 Start relay
0
k11
606
60
Engine
M1
B
C
-
R
E2
21
20
R0
Preheater
Preheat controller
S
0
B
M E
Start motor
0
0
105
SQ1 Pilot switch
D-1 15 15a
22
D-10
0
K4 Pilot valve relay
0
VA7
Pilot solenoid valve
0
k-8 Shutdown relay
ZX225-1105020
Fig. 7-35
Shop Manual - April 2014
7-53
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-2 Engine runs rough or is unstable
Failure information
Engine Runs Rough or Is Unstable
Related information
Engine speed can be read on the monitor.
Standard values and troubleshooting references
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Open circuit of 1 harness Unplug the connector controller, and measure Resistance 2.3±0.2 Kȍ the resistance between pin 16 and pin 7. 2
Internal failure in sensor
Between CN-125M A and B
Resistance
2.3±0.2 Kȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of harness (grounded) Between CN-125M A and ground Resistance Above 1Mȍ
3
4
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
Internal failure No troubleshooting can be done due to internal failure. (Failure lies in the controller if the reasons above are ruled out) of controller 司
公
销 营
5
Controller
HCU_J1
RPM sensor input signal
GND
CN-125M （S-2）
RPM sensor
16
A
Signal
7
B
GND
Operator station
Chassis harness
ZX225-1105021
Fig. 7-36
7-54
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-3 Power supply of machine cannot be cut off Failure information
Engine cannot be stopped. Engine stalls when start switch it turned to OFF position. There is no time delay for power cutout.
Cause
Standard values and troubleshooting references
Failure of battery When the engine start switch is operated, if the operation of battery relay conrelay tact is heard, the battery is normal. Turn the start switch OFFĺONĺOFF.
1
Breakdown of surge diode
2
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between battery relay wire 20# and wire 21#
Resistance Above 1Mȍ
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
3
21
16
F13-160A 14
TERMINAL B BR ACC R1 R2 C HEAT OFF ON START S0 22 62 61 11
Start switch
897044-4180
61 66
司
公
销 营
1
3
4
2
6
0
1
4
3
17
GR-1 GLOW PLUG
Preheat relay
68 69 HL2
5
Low-temp switch
2
PReheat indicator
13
3
6 5
1
2
64 65
A
63
P2
E3
k7
P1
B
E
0
Parking relay
HLR
Charging indicator
Parking motor
G
22
F2-10A
B2
Safety relay B
C
-
+
-
+
11
k1 Battery relay
0
R
L
B
E
E2
21
20
B1
14
14
P600G
F1-20A
11a
11b
R
S
k3
Lockout relay
27
BAT-1 Battery
F7-10A
0
k3 Start relay
0
S
0
B
M E
Start motor
0
k11 606
60
Engine
M1
12 60
E
620
R0
Preheater
Preheat controller
0
105
SQ1 Pilot switch
D-1 15 15a
22
D-10
0
K4 Pilot valve relay
0
VA7 Pilot solenoid valve
0
k-8 Shutdown relay
ZX225-1105020
Fig. 7-37 Shop Manual - April 2014
7-55
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-4 Throttle motor not working Failure information Related information
Standard values and troubleshooting references
Preheat Ɣ Turn he start switch to the ON position and keep it in the ON position while troubleshooting is performed. 1 fuse failure. The monitor shows failure code 41. Coolant temperature and oil level are normal. Ɣ Turn he start switch to the ON position and keep it in the ON position while troubleSensor shooting is performed. 2 power Measure the voltage between motor plug, 50# wire abnormal Volt 5.0V and ground.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Causes
Engine speed does not increase or decrease. Turn the fuel control dial but engine speed does not change.
Unplug the connector of the harness between throttle motor and chassis.
3
Throttle motor failure
Measure the resistance between the blue and red wires. Measure the resistance between the yellow and green wires. 司
7-56
Resistance
5kȍ ± 10%
Throttle Ɣ Turn he start switch to the ON position and keep it in the ON position while troubleshooting is performed. motor failure The monitor shows failure codes 41, 12, 13, 14 and 32. 公
4
8~15ȍ
销 营
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-5 Auto idle not functioning Failure information Related information
Cause
1
Auto idle speed do not work Engine speed do not decrease wen the mode is auto idle speed and grip keeps still in NEUTRAL position
Standard values and troubleshooting references Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
Error of boomLevers in NEUTRAL, pressure signal transmitted up signal
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Lever in operation, pressure signal transmitted
Pressure
2
0-39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
Error of boomLevers in NEUTRAL, pressure signal transmitted down signal Lever in operation, pressure signal transmitted
3
0 KG
Pressure
0 KG 0-39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
Error of arm-in Levers in NEUTRAL, pressure signal transmitted signal Lever in operation, pressure signal transmitted
Pressure
0 KG 0-39 KG
司
公
销 营
4
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
Error of arm-out Levers in NEUTRAL, pressure signal transmitted signal Lever in operation, pressure signal transmitted
5
Pressure
0 KG 0-39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
Error of bucketLevers in NEUTRAL, pressure signal transmitted dig signal Lever in operation, pressure signal transmitted
Shop Manual - April 2014
Pressure
0 KG 0-39 KG
7-57
Troubleshooting
Cause
SY365(B)H-9 Crawler Hydraulic Excavator
Standard values and troubleshooting references Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
6
Error of Bucketdump signal
Levers in NEUTRAL, pressure signal transmitted
Pressure 0-39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. 7
Error of swing signal
Levers in NEUTRAL, pressure signal transmitted Lever in operation, pressure signal transmitted
0 KG Pressure 0-39 KG
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Lever in operation, pressure signal transmitted
0 KG
Ɣ urn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
8
Error of travel signal
Levers in NEUTRAL, pressure signal transmitted Lever in operation, pressure signal transmitted
0 KG
Pressure
0-39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. 司
9
Error of attachment signal
公
Levers in NEUTRAL, pressure signal transmitted 销 营
Lever in operation, pressure signal transmitted
10
7-58
0 KG
Pressure
0-39 KG
Failure of con- No troubleshooting can be done for it is internal failure. (If it is not caused troller by one of the factors listed above, it should be the failure of controller.)
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-6 Preheat function fails
Failure information
Engine does not preheat.
Related information
Cause
Standard values and troubleshooting references
2
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between wire 21# and preheat relay wire 16#
Resistance Under 1ȍ
When the preheat function is activated, if operation of the preheat relay contact is heard, the relay is normal. The start switch is to be switched HEATĺOFFĺHEAT.
Failure of preheat relay
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Failure of pre1 heat fuse
3
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep of harness it in the OFF position while troubleshooting is performed. (grounded) Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Between preheat controller pin 3# and start switch wire 61#
Failure of preBetween preheat controller pin 4# and preheat relay heat controlwire 68# ler Between preheat controller pin 1# and preheat relay wire 14#
Under 1ȍ
司
公
销 营
4
Between preheat controller pin 2# and low temp switch wire 66#
TERMINAL B BR ACC R1 R2 C HEAT OFF ON START
S0 Start switch 22 62 13
21n4-10430
61 11
21
16
F13-160A 14
61
66
Low temp SW
0
13
1
3
2
1
4
3
4
2
5
Under 1ȍ Under 1ȍ
GR-1 GLOW PLUG
P600G Preheater R0
20
Preheat indicator
Preheat controller
-
+
BAT-1
14 11
17
Preheat relay
68 6 69 HL2
Under 1ȍ
Resistance
F2-10A
-
21
+
Battery
k1 Batt. relay
F1-20A
0
20
Control switch harness
Cab harness
Chassis harness ZX225-1005039
Fig. 7-38
Shop Manual - April 2014
7-59
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-7 All components not working
Failure information
The machine is motionless while operated after starting.
Related information Cause
Standard values and troubleshooting references
Possible causes and standard values
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Failure of lockout switch
Item
Lockout control lever
Resistance
LOCK
Between wire 105# and wire 27#
Under 1ȍ
In Ma t rk er n et a in ti o g n De al pt .
1
2
3
Short circuit of wire (grounded) Failure of coil inside lockout solenoid valve
Between 105# and ground
Resistance
Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-136F 1 and 2
Resistance
About 34ȍ
司
公
销 营
0
Pilot switch
Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
4
105
FREE
CN-201F
CN-205F (D-12)
1
4
2
10
1
2
3
4
5
1
2
3
4
5
105 27
CN-302M CN-136F (D-12) (AMP-2) 606 1 606 1
0
8
0
2
27 +24V Cab harness
Chassis harness
ZX225-1005040
Fig. 7-39
7-60
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-8 Boom-up speed or power is low
Failure information
Boom-up speed or power is low. Pilot pressure of the boom in operation can be checked on the monitor.
Related information
1
Standard values and troubleshooting references
Failure of sensor
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Levers in NEUTRAL, boom-up pressure signal Lever in operation, boom-up pressure signal
2
Short circuit of harness (grounded)
Open circuit of 3 harness
4
Failure of controller
GND
5V PWR
0-39 KG
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between harness ( from controller pin 8 to CN126M A) and ground
Resistance
Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between controller pin 11 and CN-126M B
Resistance Under 1ȍ
No troubleshooting can be done due to internal failure. (Failure lies in the controller if the reasons above are ruled out) 司
公
销 营
Boom-up pilot press. sensor
Controller
Boom-up pilot pressure signal collecting port
0 KG
Pressure
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
8
206# 00#
11
12
50#
CN-126M C
Signal
B
GND
A
5V
Operator station
Chassis harness
ZX225-1105009
Fig. 7-40
Shop Manual - April 2014
7-61
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-9 Arm speed or power is low Failure information
Arm speed or power is low during operation. Pilot pressure of the arm in operation can be checked on the monitor.
Related information
1
Failure of sensor
Standard values and troubleshooting references Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Levers in NEUTRAL, arm-in and arm-out pressure signals
0 KG
Pressure
Levers in operation, arm-in and dump pressure signal
0-39 KG
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
2
3
Short circuit of harness Between harness (from controller pin 35 to CN129M A) and ground (grounded) Between harness (from controller pin 22 to CN122M A) and ground
Resistance
Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Open circuit of harness Between controller pin 11 and CN-129M B Resistance Under 1ȍ Between controller pin 11 and CN-122M B 司
公
销 营
4
Failure of controller
No troubleshooting can be done due to internal failure. (Failure lies in the controller if the reasons above are ruled out) CN-122M （DF-3）
Arm out press. sensor
A
Signal
B
GND
C
5V
Controller
Arm out press. sensor
Arm in press. sensor
22
CN-129M （DF-3）
Arm in press. sensor
35
A
Signal
Sensor GND
11
B
GND
Sensor 5V
12
C
5V
Operator Station
Chassis harness
ZX225-1105022
Fig. 7-41 7-62
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-10 Bucket speed or power is low Failure information Related information
Cause
Bucket speed or power is low during operation. Pilot pressure of the bucket can be checked on the monitor.
Standard values and troubleshooting references Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
Failure of sen- Levers in NEUTRAL, bucket-dig/dump pressure sor signals Levers in operation, bucket-dig/dump pressure signals
0 KG Pressure
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
2
3
Short circuit of harness (grounded)
Open circuit of harness
0-39 KG
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Between harness (from controller pin 10 to CN124M A) and ground Between harness (from controller pin 33 to CN128M A) and ground
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. 司
公
销 营
Between controller pin 11 and CN-124M B Between controller pin 11 and CN-128M B
Resistance Under 1ȍ
4
Defective buck- Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. et conÀuence solenoid valve Between CN-134F 1 and 2 Resistance About 34ȍ
5
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the troller controller if the reasons above are ruled out)
Shop Manual - April 2014
7-63
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
CN-128M （DF-3）
Bucket dump press. sensor
A
Signal
B
GND
C
5V
Controller
Bucket dump press. sensor
33
CN-124M （DF-3）
Bucket dig press. sensor
10
A
Signal
Sensor GND
11
B
GND
Sensor 5V
12
C
5V
Bucket confluence signal
27
In Ma t rk er n et a in ti o g n De al pt .
Bucket dig press. sensor
CN-134F （AMP-2）
Bucket confluence Proportional valve
1
Signal
2
GND
司
公
销 营
Chassis harness
Operator Station
ZX225-1105023
Fig. 7-42
7-64
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-11 Travel speed or power is low Failure information Related information
Cause
Travel speed or power is low during operation. Pilot pressure of travel operation can be checked on the monitor. Standard values and troubleshooting references
Possible causes and standard values
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. 1
Failure of sen- Levers in NEUTRAL, left and right travel pressure sor signals
In Ma t rk er n et a in ti o g n De al pt .
Levers in operation, left and right travel pressure signals
0 KG Pressure
2
Short circuit of harness (grounded)
0-39 KG
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between harness (from controller pin 34 to CN120M A) and ground Between harness (from controller pin 30 to CN121M A) and ground
Resistance
Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Open circuit of 3 harness Between controller pin 11 and CN-120M B Resistance Under 1ȍ Between controller pin 11 and CN-121M B 司
公
销 营
4
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the troller controller if the reasons above are ruled out) CN-121M （DF-3）
R. travel press. sensor
A
Signal
B
GND
C
5V
Controller
HCU_J2
R. travel press. sensor
30
CN-120M （DF-3）
L. travel press. sensor
34
A
Signal
Sensor grounding wire
11
B
GND
Sensor 5V
12
C
5V
L. travel press. sensor
HCU_J1 Operator station
Chassis harness
Fig. 7-39
ZX225-1105024
Fig. 7-43 Shop Manual - April 2014
7-65
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-12 Blank monitor display Failure information
Monitor display is blank after the machine is powered on.
Related information Standard values and troubleshooting references
1 Failure of fuse
Ɣ Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Between wire 42# and ground
About 24V
Voltage
Between wire 43# and ground
About 24V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
2
Open circuit of harness
Between CN-7-113M pin 1 and CN-222F pin 4 Between CN-7-113M pin 2 and CN-222F pin 7
Under 1ȍ
Resistance
Under 1ȍ
Between CN-7-113M pin 9# and ground
3
4
Short circuit of harness (grounded)
Failure of monitor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between harness (from CN-7-113M pin 1 to CN222F pin 4 and ground 司
公
销 营
Between harness (from CN-7-113M pin 2 to CN222F pin 7 and ground
Above 1Mȍ
Resistance
Above 1Mȍ
No troubleshooting can be done for it is internal failure. (If it is not caused by one of the factors listed above, it should be the failure of monitor.)
CN-7-709M
CN-185M A
A
120 ohms
Controller
Under 1ȍ
120 ohms
B
B
HCU-J2
CN-7-112F
12
A
CANL
11
B
F11 15A
F13 10A
4
7
CN-222F
CN-221M
CN-7-113M 1
2
9
CANH CANL
42
43
35 12
5
24
Monitor
CANH
0
11 0 31
21
PWR Operator station
20
PWR
Chassis harness
ZX335-1005050
Fig. 7-44 7-66
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-13 Monitor displays nothing Display of monitor is illuminated but no information is shown on the screen after machine is powered on.
Failure information Related information Cause Failure of resistance
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-1-185M A and B
Resistance
2
120 ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of harness Between CN-7-112F pin A and controller pin 12
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
Standard values and troubleshooting references
Between CN-7-112F pin B and controller pin 11
Resistance
Under 1ȍ Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
3
Short circuit Between harness (from CN-7-112F pin A to conof harness troller pin 12) and ground (grounded) Between harness (from CN-7-112F pin B to controller pin 11 and ground
Above 1Mȍ
Resistance
Above 1Mȍ
司
公
4
Failure of monitor or controller
销 营
No troubleshooting can be done for it is internal failure. (If it is not one of the failures stated above, it should be the failure of monitor or controller.)
CN-7-709M
CN-185M A
A
120 ohms
Controller
HCU-J2
120 ohms
B
B
CN-7-112F
12
A
CANL
11
B
F11 15A
F13 10A
4
7
CN-222F
CN-221M
CN-7-113M 1
2
9
CANH CANL
42
43
35 12
5
24
Monitor
CANH
0
11 0 31
21
PWR Operator station
20
PWR
Chassis harness
ZX335-1005050
Fig. 7-45 Shop Manual - April 2014
7-67
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-14 Dual speed travel not functioning Failure information
Only low speed travel is functioning during operation.
Related information
Press the Hi/Lo button on the monitor to change travel speed.
Possible causes and standard values
Cause
Failure of dual Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. speed travel solenoid valve Between CN-131F A and B Resistance About 34ȍ Open circuit of harness
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
1
Standard values and troubleshooting references
2
Between CN-131F pin A and controller pin 7
Between CN-131F pin B and controller pin 3
3
Resistance
Under 1ȍ
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Short circuit Keep it in the OFF position while troubleshooting is performed. of harness Between harness (from CN-131F pin A to con(grounded) Resistance Above 1Mȍ troller pin 7) and ground
4
司
公
销 营
Controller
CN-131F （AMP-2）
High speed travel solenoid valve
GND
High speed travel solenoid valve
7
A
Signal
3
B
GND
Operator Station
Chassis harness
ZX225-1105025
Fig. 7-46
7-68
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-15 Incorrect engine coolant reading Engine coolant temperature sensor cannot correctly reÀect current coolant temperature. Coolant temperature can be checked on the monitor.
Failure information Related information
Cause
Standard values and troubleshooting references
Possible causes and standard values
Standard values for engine coolant temperature sensor 50ć
130ȍ
80ć
48.5±4.2ȍ
100ć
26.7±2.5ȍ
In Ma t rk er n et a in ti o g n De al pt .
1
Failure of coolant temperature sensor
110ć
2
3
4
Open circuit of lead
Short circuit of lead (grounded) Lead short to 24V circuit
20ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between wire 510# and controller pin 32
Resistance
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between wire 510# and ground
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the ON position while troubleshooting is performed. 司
公
销 营
Wire 510# to ground
Voltage
Under 1V
Controller
Coolant temperature sensor
510
32
Operator Station
Chassis harness
ZX335-1005053
Fig. 7-47
Shop Manual - April 2014
7-69
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-16 Incorrect fuel level reading Failure information
Engine fuel level sensor cannot correctly reÀect current fuel level.
Related information
Fuel level can be checked on the monitor.
Cause
Standard values and troubleshooting references
Possible causes and standard values
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. 1
Fuel level sensor error
Pin
Resistance
FULL (Upper limit)
Approx. 10 ȍ
EMPTY (Lower limit)
85-95ȍ
In Ma t rk er n et a in ti o g n De al pt .
Between wire 509# and ground
Fuel level
Open circuit of 2 lead
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between wire 509# and controller pin 17
Resistance
Under 1ȍ
3
Short circuit of Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. lead (grounded) Between wire 509# and ground Resistance Above 1Mȍ
4
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Lead short to 24V Wire 509# grounded Voltage Under 1V 司
公
销 营
Controller
Fuel level sensor
17
Operator Station
509
Chassis harness
ZX335-1005054
Fig. 7-48
7-70
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-17 Wiper does not work Failure information
Wiper does not work.
Related information
Cause
Internal Fail- Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. ure of wiper motor Between wiper wire 25# and ground Resistance ˚ 10ȍ
1
Possible causes and standard values
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
2
Between CN-403F 1 and CN-1-110 2 Open circuit of Between wiper switch wire 35L# and lead CN-1-110M 5
Resistance
Between wiper switch wire 35L# and CN-1-110M 4
Under 1ȍ Under 1ȍ Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Short circuit of Keep it in the OFF position while troubleshooting is performed. 3 lead (groundHarness from CN-403F 1 to CN-1-110M ed) Resistance Above 1Mȍ 2 short to ground 司
公
销 营
4
Wiper switch
CN-401F （D-12）
2
F5 5A
25
CN-403M （D-12）
1
CN-204M （D-12）
6
6
7
2
6
7
36
CN-203F （D-12）
35L
35H
12
CN-1-110M （D-6） 2
2
3
3
4
4
5
5
25 36
35L
M
35H
21
PWR
Operator station
ZX225-1005049
Fig. 7-49
Shop Manual - April 2014
7-71
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-18 Incorrect arm-in pilot pressure reading Failure information
Reading of arm-in pilot pressure is incorrect.
Related information
Possible causes and standard values
Cause
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Failure of 5V power supply
1
Between CN-129M ķ and Ĺ
Open circuit of signal line
Voltage
Approx. 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
2
Standard values and troubleshooting references
3
4
Short circuit of signal line
Failure of sensor
Between CN-129M ĸ and controller pin 35
Resistance
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-129M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-129M ĸ and ground
5
Voltage
0.5V- 4.5V
司
公
销 营
Controller
CN-129M （DF-3）
Arm in pressure sensor
Arm in pressure sensor
35
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator Station
Chassis harness
ZX225-1105026
Fig. 7-50
7-72
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-19 Incorrect arm-out pilot pressure reading
Failure information
Reading of arm-out pilot pressure is incorrect.
Related information
Possible causes and standard values
Cause 1
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Failure of 5V power supply
Between CN-122M ķ and Ĺ
Open circuit of signal line
Voltage
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
2
Standard values and troubleshooting references
3
4
Short circuit of signal line
Failure of sensor
Between CN-122M ĸ and controller pin 22
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-122M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
5
Between CN-122M ĸ and ground
Voltage
0.5V- 4.5V
司
公
销 营
Controller
CN-122M （DF-3）
Arm out pressure sensor
Arm out pressure sensor
22
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator Station
Chassis harness
ZX225-1105027
Fig. 7-51
Shop Manual - April 2014
7-73
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-20 Incorrect boom-up pilot pressure reading Failure information
Incorrect Boom-up Pilot Pressure Reading
Related information Cause
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
1
Possible causes and standard values
Standard values and troubleshooting references
Between CN-126M ķ and Ĺ
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of signal line
In Ma t rk er n et a in ti o g n De al pt .
2
Voltage
3
4
Between CN-126M ĸ and controller pin 8
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Short circuit of signal line
Between CN-126M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position Failure of senwhile troubleshooting is performed. sor Between CN-126M ĸ and ground Voltage 0.5V- 4.5V 司
公
销 营
5
Controller
CN-126M （DF-3）
Boom up pressure sensor
Boom up pressure sensor
8
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator Station
Chassis harness
ZX225-1105028
Fig. 7-52
7-74
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-21 Incorrect boom-down pilot pressure reading Failure information
Boom-down pilot pressure reading is incorrect.
Related information
Cause
Possible causes and standard values
1
Standard values and troubleshooting references Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
Between CN-125M ķ and Ĺ
Voltage
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of signal line
In Ma t rk er n et a in ti o g n De al pt . 2
3
4
About 5V
Between CN-125M ĸ and controller pin 9
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Short circuit of signal line
Between CN-125M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of sensor
Between CN-125M ĸ and ground 司
公
销 营
Voltage
0.5V- 4.5V
5
Controller
CN-125M （DF-3）
Boom down pressure sensor
Boom down pressure sensor
9
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator Station
Chassis harness ZX225-1105029
Fig. 7-53
Shop Manual - April 2014
7-75
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-22 Incorrect bucket-dig pilot pressure reading Failure information
Bucket-dig pilot pressure reading is incorrect.
Related information
Possible causes and standard values
Cause
1
Standard values and troubleshooting references Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
Between CN-124M ķ and Ĺ
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Open circuit of signal line
Voltage
2
3
4
Short circuit of signal line
Failure of sensor
Between CN-124M ĸ and controller pin 10
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-124M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Between CN-124M ĸ and ground
Voltage
0.5V- 4.5V
司
公
销 营
5
Controller
CN-124M （DF-3）
Bucket dig pressure sensor
Bucket dig pressure sensor
10
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator Station
Chassis harness
ZX225-1105030
Fig. 7-54
7-76
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-23 Incorrect bucket-dump pilot pressure reading Failure information
Bucket-dump pilot pressure reading is incorrect.
Related information
1
Standard values and troubleshooting references Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
Between CN-128M ķ and Ĺ 2
Open circuit of signal line
Voltage
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
3
4
Short circuit of signal line
Failure of sensor
Between CN-128M ĸ and controller pin 33
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-128M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-128M ĸ and ground
Voltage
司
0.5V- 4.5V
公
销 营
5
Controller
CN-128M （DF-3）
Bucket dump pressure sensor
Bucket dump pressure sensor
33
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Chassis harness
Operator Station
ZX225-1105031
Fig. 7-55
Shop Manual - April 2014
7-77
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-24 Incorrect swing pilot pressure reading
Failure information
Swing pilot pressure reading is incorrect.
Related information
Cause
Possible causes and standard values
1
Standard values and troubleshooting references Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
Voltage
About 5V
In Ma t rk er n et a in ti o g n De al pt .
Between CN-123M ķ and Ĺ 2
3
4
Open circuit of signal line Short circuit of signal line
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-123M ĸ and controller pin 18
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-123M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position Failure of senwhile troubleshooting is performed. sor Between CN-123M ĸ and ground Voltage 0.5V- 4.5V 司
公
销 营
5
Controller
CN-123M （DF-3）
Swing pilot press. sensor
Swing pilot press. sensor
18
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator station
Chassis harness
ZX225-1105032
Fig. 7-56
7-78
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-25 Left travel pilot pressure reading incorrect
Failure information
Left Travel Pilot Pressure Reading is incorrect.
Related information
Cause
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
1
Possible causes and standard values
Standard values and troubleshooting references
Between CN-120M ķ and Ĺ
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Open circuit of signal line
Voltage
2
3
4
Short circuit of signal line
Failure of sensor
Between CN-120M ĸ and controller pin 34
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-120M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-120M ĸ and ground
Voltage
司
公
销 营
0.5V- 4.5V
5
Controller
CN-120M （DF-3）
Left travel pilot pressure sensor
Left travel pilot pressure sensor
34
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator Station
Chassis harness
ZX225-1105033
Fig. 7-57
Shop Manual - April 2014
7-79
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-26 Right travel pilot pressure reading incorrect Failure information
Right travel pilot pressure reading is incorrect.
Related information
Cause
Possible causes and standard values
1
Standard values and troubleshooting references Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
Between CN-121M ķ and Ĺ Open circuit of signal line
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
2
Voltage
3
4
Short circuit of signal line
Failure of sensor
Between CN-121M ĸ and controller pin 30
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-121M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-121M ĸ and ground
Voltage
司
0.5V- 4.5V
公
销 营
5
Controller
CN-121M （DF-3）
R. travel pilot press. sensor
R. travel pilot press. sensor
30
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator station
Chassis harness
ZX225-1105034
Fig. 7-58
7-80
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.6 Troubleshooting Hydraulic and Mechanical Systems (H-mode)
In Ma t rk er n et a in ti o g n De al pt .
A schematic of hydraulic and mechanical systems ...................................................... 7-82 Information contained in troubleshooting table ............................................................. 7-84 H-1 Work equipment speed slow, or swing and travel speeds slow ............................. 7-85 H-2 Engine speed drops sharply or engine stalls ......................................................... 7-86 H-3 Work equipment, swing, and travel systems do not work ...................................... 7-87 H-4 Abnormal noise in hydraulic pump ......................................................................... 7-88 H-5 Auto deceleration not functioning........................................................................... 7-88 H-6 Boom speed slow .................................................................................................. 7-89 H-7 Arm speed slow ..................................................................................................... 7-90 H-8 Bucket speed slow ................................................................................................. 7-91 H-9 Work equipment cylinders no response in separate operation ............................. 7-92 H-10 Work equipment drifts excessively ...................................................................... 7-93 H-11 Work equipment moves sluggishly ..................................................................... 7-96 H-12 Other work equipment moves while single oil circuit is relieved .......................... 7-96 H-13 Travel speed drops considerably while swinging and travelling .......................... 7-97 H-14 Machine deviates during travel ............................................................................ 7-98 H-15 Travel speed low .................................................................................................. 7-99 H-16 Machine not steered easily or steering power low ............................................. 7-100 H-17 Travel speed cannot be shifted .......................................................................... 7-101 H-18 Travel system fails (only at one side)................................................................. 7-102 H-19 Swing operation fails.......................................................................................... 7-103 H-20 Swing acceleration poor or swing speed low ..................................................... 7-105 H-21 Upper structure overrunning remarkably .......................................................... 7-107 H-22 Large shock produced upon swing stoppage .................................................... 7-108 H-23 High noise produced upon swing stoppage ....................................................... 7-109 H-24 Swing drift excessive ..........................................................................................7-110 司
公
销 营
Shop Manual - April 2014
7-81
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
A schematic of hydraulic and mechanical systems This diagram is a simpli¿cation of the diagram of the whole hydraulic system and can be referred to in troubleshooting the hydraulic and mechanical systems.
DIG
DUMP
DOWN
UP
BWD
Boom Bucket
FWD
L. travel R. travel BWD
RIGHT
LEFT
OUT
Swing
R. pilot valve
In Ma t rk er n et a in ti o g n De al pt .
IN
Arm
Travel pilot valve
FWD
L. pilot valve
Pilot valve
16
Boom priority
1
2
3
4
5
6
7
8
9
10 11 12
15
Bucket conflu.
14
Swing priority
Accumulator
13
Travel speed change
司
公
销 营
19
17
1 2 3
20
18
Regulator
Regulator Servo
Servo
P1
P2
M
FRONT
REAR
ZX225-1105039
Fig. 7-59 7-82
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
6D Safety valve Suction valve 6X 6 6 Safety & suction valve
Bucket Cylinder
1
11
S&S
Bucket valve
1
2
Arm 2 valve
S&S
Bucket confluence valve
15 regenerS&S Arm S&S ation valve
2
14
12
Arm cylinder
S&S
Standby valve
S&S
Standby actuating element
9
Boom Cylinder
S&S
S&S
9
Boom 2
10
L. travel valve
Su
3
6
Su
司
公
销 营
Left travel motor
8
13
Sa
R. travel valve
Sa
Su
Balance valve
Servo
Sa
7
Straight travel vavle
Su
4
Swing valve
Swing motor
Servo
Su
Sa
5
Anti-swing valve
Brake release valve
13
Balance valve
Boom valve
Sa
9
Su
In Ma t rk er n et a in ti o g n De al pt .
Boom retainer valve
10
Standby valve confluence
Anti-swing valve
Arm retainer valve
1
Right travel motor
1 2 3
ZX225-1105040
Fig. 7-60
Shop Manual - April 2014
7-83
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Information contained in troubleshooting table ● The following information is contained in the troubleshooting table and related electric circuit diagrams. Fully understand these information before carrying out troubleshooting. Failure information
Trouble which occurs on the machine
Related information
Information related to detected trouble or troubleshooting
7-84
Standard values and troubleshooting references
1
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
2
3 Possible causes of ● < Description > trouble (Given num● Standard value in normal state, which is used to judge possible 4 bers are reference causes that might be OK or N/G. numbers, which do not indicate priority) ● A reference value is used to determine OK or N/G. 司
公
销 营
5
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-1 Work equipment speed slow, or swing and travel speeds slow
Failure information Related information
Cause
● Work equipment speed is slow or the travel and swing speeds are slow. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Standard values and troubleshooting references
Defective adjustment or malfunction of main relief valve
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. 1
Control levers Arm IN
Main relief pressure 33~34.3 MPa
{337~350 kg/cm2}
If normal pressure cannot be restored after adjustment, it is possible the failure of main relief valve or internal defect. Check the valve directly.
2
Malfunction of pilot relief valve
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Control levers Pilot control pressure 司
公
销 营
All levers in NEUTRAL
3.9~4.1 MPa
{40~42 kg/cm2}
3
Malfunction of regulator
The regulator possibly fails. Check the servo mechanism of the regulator.
4
Malfunction of main pump
If the trouble is caused by other factors, it might be the main pump that has performance deterioration, malfunction or internal defect.
Shop Manual - April 2014
7-85
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-2 Engine speed drops sharply or engine stalls Failure information
● Engine speed drops sharply or engine stalls.
Related information
● Information concerned
1 2 3
Failure of injection pump Malfunction of regulator Clogging of oil filter element Carbon buildup at fuel injection nozzle Clogging of air cleaner Abnormal wear of engine
Standard values and troubleshooting references Injection pump may be defective. Check it directly. Regulator may have malfunction. Check its servo mechanism. Oil filter element may be clogged. Check the element directly.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
4 5 6
Carbon built up at fuel injection nozzle. Check it directly. Air cleaner may be clogged. Check it directly.
Engine may be worn abnormally. Check it directly.
7 Failure of oil pump Oil pump may be defective. Check it directly. 司
公
销 营
7-86
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-3 Work equipment, swing, and travel systems do not work Failure information Related information
Cause
Malfunction of pilot relief solenoid valve
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Pilot lockout control lever Pilot relief pressure LOCKED
0 {0}
Possible causes and standard values
In Ma t rk er n et a in ti o g n De al pt .
1
● Whole work equipment, swing, and travel systems do not work. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
FREE
3.9~4.1 MPa
{40~42 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Failure of relief valve Control lever Pilot relief pressure 2 (pilot pump) 3.9~4.1 MPa All levers in NEUTRAL {40~42 kg/cm2} The main pump may have malfunction or internal defect. Check it by following method. 司
公
销 营
3
Failure of hydraulic pump
4 Failure of coupling
● Remove the oil pressure measurement plug and start the engine. If oil flows out of the opening, the piston pump is in good condition. Internal failure of the coupling can stop rotation of the pump shaft. Check the coupling. ● Loosen the oil delivery line of the pilot pump. If no oil is seen, it is probably the failure of coupling.
Shop Manual - April 2014
7-87
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-4 Abnormal noise in hydraulic pump Failure information
● Abnormal noise is produced from the hydraulic pump
Related information
Standard values and troubleshooting references
1
Low level of hydraulic oil
Make a visual check.
2
Inferior hydraulic oil
Hydraulic oil probably contains air. Make a visual check.
Clogging of It is probably the clogging of the vent on top of the hydraulic tank that 3 vent on top of causes negative pressure in the hydraulic tank. Press the release button hydraulic tank of the breather valve to eliminate air. Check again if the noise disappears. Clogging of It is probably the clogging of hydraulic tank strainer that causes negative 4 hydraulic tank pressure in the oil suction line. Make a visual check. strainer
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
―
5
Failure of main pump
The main pump may have internal defect. Check the main pump. 司
公
销 营
H-5 Auto deceleration not functioning Failure information
Related information
Possible causes and standard values
Cause
7-88
1
Sensor failure
● Auto-deceleration is not functioning. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Standard values and troubleshooting references
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Control levers Pilot valve output pressure NEUTRAL
0 {0}
Operation
3.5~4.1MPa {36~42 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Failure of Control levers Pilot valve output pressure 2 NEUTRAL 0 {0} pilot valve 3.5~4.1MPa Operation {36~42 kg/cm2} Controller 3 Controller may be defective. Check it directly. failure
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-6 Boom speed slow Failure information
● The boom moves slowly.
Related information
● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Cause
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Boom control lever Pilot valve output pressure NEUTRAL
0 {0}
Boom UP Boom DOWN
≥ 3.5MPa {36 kg/cm2}
Possible causes and standard values
In Ma t rk er n et a in ti o g n De al pt .
Malfunction of right 1 pilot valve (boom circuit)
Standard values and troubleshooting references
2 3
Malfunction of boom Spool of boom control valve may have malfunction. Check it directly. control valve (spool) ● Stop the engine before troubleshooting. Perform troubleshooting Press sensor failure while the engine is running at high idle. Check the sensor by replacing it with a new one. Malfunction of boom Retaining valve of boom control valve may have malfunction. Check control valve (retainthe valve directly. ing valve) Malfunction or defective seal of boom The relief valve and makeup valve in boom control valve may have control valve malfunction or defective seal. Check the valves directly. (Relief valve and makeup valve) ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Charge the bucket with a load of approximate 1260 kg. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylFailure of boom inder from the main valve. Measure the displacement of piston for 15 cylinder minutes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure see "Hydraulic Drift of Work Equipment - Test" on page 6-34. 司
公
4
5
6
销 营
Shop Manual - April 2014
7-89
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-7 Arm speed slow Failure information Related information
Cause
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Arm control lever Pilot valve output pressure NEUTRAL
0 {0}
In Ma t rk er n et a in ti o g n De al pt .
Malfunction of left 1 pilot valve (arm circuit)
● The arm moves slowly. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Possible causes and standard values
Arm IN or Arm OUT
7-90
≥ 3.5MPa
{36 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. 2 Press sensor failure Check the sensor by replacing it with a new one. Malfunction of arm Spool of arm control valve may have malfunction. Check it directly. control valve (spool) Malfunction of arm Regeneration valve of arm control valve may have malfunction. 4 control valve (reCheck it directly. generation valve) Malfunction or defective seal of arm The relief valve or makeup valve inside the arm control valve may have 5 control valve (Relief malfunction or defective seal. Check the valves directly. valve and makeup valve) ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Cut off the oil passage to the high-pressure side of the cylinder. DisconFailure of arm cylin- nect the cylinder from the main valve. Measure the displacement of piston 6 for 15 minutes after the cylinder becomes stable. If the measured value is der greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure see "Hydraulic Drift of Work Equipment - Test" on page 6-34. 3
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Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-8 Bucket speed slow Failure information Related information
Cause
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Bucket control lever Pilot valve output pressure NEUTRAL
0 {0}
In Ma t rk er n et a in ti o g n De al pt .
Malfunction of right 1 pilot valve (bucket circuit)
● The bucket moves slowly. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Possible causes and standard values
Bucket DIG or Bucket DUMP
≥ 3.5MPa
{36 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. 2 Press sensor failure Check the sensor by replacing it with a new one. Malfunction of 3 bucket control valve Spool of bucket control valve may have malfunction. Check it directly. (spool) Malfunction or defective seal of Relief valve and makeup valve in bucket control valve may have mal4 bucket control valve function or defective seal. Check the valves directly. (relief valve and makeup valve) ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Charge the bucket with a load of approximate 1260 kg. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylFailure of bucket inder from the main valve. Measure the displacement of piston for 15 5 cylinder minutes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure see "Hydraulic Drift of Work Equipment - Test" on page 6-34. 司
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Shop Manual - April 2014
7-91
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-9 Work equipment cylinders no response in separate operation
● Boom cylinder gives no response in separate operation. ● Arm cylinder gives no response in separate operation.
Failure information
● Bucket cylinder gives no response in separate operation. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Related information
7-92
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Work equipment control lever Pilot valve output pressure
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
1
Malfunction of pilot valve
NEUTRAL
DIG or DUMP
0 {0}
≥ 3.5MPa
{36 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. 2 Press sensor failure Check the sensor by replacing it with a new one. 司
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3
Malfunction of conSpool of control valve may have malfunction. Check it directly. trol valve (spool)
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-10 Work equipment drifts excessively Failure information (1) Related information
Failure of boom cylinder
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Charge the bucket with a load of approximate 1260 kg. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylinder from the main valve. Measure the displacement of piston for 15 minutes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure see "Hydraulic Drift of Work Equipment - Test" on page 6-34. Boom retaining valve or pilot valve may be worn or sluggish. Check the valves.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
● The boom drifts at excessive speed. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
1
Failure of boom retaining valve Malfunction or defective seal of The relief valve and the makeup valve in the boom control valve may 3 boom control valve have a defective seal. Check the seals. (relief valve and makeup valve) 2
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4
Failure of boom valve spool
Spool of boom valve may be worn excessively. Check the spool.
Shop Manual - April 2014
7-93
Troubleshooting
Failure information (2) Related information
1
2
3
4
7-94
● The arm drifts excessively. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Standard values and troubleshooting references
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylinder from the main valve. Measure the displacement of pisFailure of arm ton for 15 minutes after the cylinder becomes stable. If the measured cylinder value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure see "Hydraulic Drift of Work Equipment - Test" on page 6-34. Relief valve or makeup valve of the arm control valve may be defective. Malfunction or defective seal of Check the valves directly. arm control valve ★ The performance of seal can be judged by replacing it with another (relief valve and relief valve or makeup valve.(Never replace it with the boom-down makeup valve) relief valve or makeup valve as their pressures are set differently.) Failure of arm Arm retaining valve or pilot valve may be worn or sluggish. Check the retaining valve valves. Failure of arm Arm valve (spool) may be worn excessively. Check it directly. valve (spool)
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
SY365(B)H-9 Crawler Hydraulic Excavator
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Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Failure information (3)
1
Cause
Standard values and troubleshooting references
Failure of bucket cylinder
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Bucket control levers Leakage from bucket cylinder Bucket-dig relief 20 ml/min Seal of relief valve or makeup valve of bucket control valve may be defective. Check it directly.
Defective seal of bucket control valve ★ The performance of seal can be judged by replacing it with anoth2 (relief valve and er relief valve or makeup valve. (Never replace it with the boommakeup valve) down relief valve or makeup valve as their pressures are set differently. ) Defective seal of Seal of bucket control valve spool may be defective. Check it direct3 bucket control valve ly. (spool)
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
● The bucket drifts excessively. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
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Shop Manual - April 2014
7-95
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-11 Work equipment moves sluggishly ● Work equipment moves sluggishly. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Failure information
Cause
Standard values and troubleshooting references
Malfunction of 1 arm regeneration valve
Regeneration valve of arm may have malfunction. Check it directly.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
Relief valve or makeup valve of control valve may have malfunction. Check it directly.
Malfunction of ● For arm and boom, whether a valve has malfunction can be judged control valve 2 (relief valve and by replacing it with another relief valve or makeup valve. makeup valve) (Never replace it with the boom-down relief valve or makeup valve as their pressures are set differently. )
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H-12 Other work equipment moves while single oil circuit is relieved
Failure information
Possible causes and standard values
Related information
7-96
Cause
1
● Other work equipment moves while single oil circuit of certain work equipment is relieved. ● Set the working mode to S to perform troubleshooting.
Standard values and troubleshooting references
Defective seal Seal of control valve may be defective. Check it directly. of control valve
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-13 Travel speed drops considerably while swinging and travelling Failure information
Cause
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
● Travel speed drops considerably in swinging plus travelling operation. ● If the travel speed is low in only travelling operation, check first according to H-15.
1
Failure of straight travel valve
The straight travel valve gives no response. Check the spool and the logic oil circuit drain port.
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Shop Manual - April 2014
7-97
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-14 Machine deviates during travel Failure information Related information
● Machine deviates during travel. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Cause
2 Possible causes and standard values
Malfunction of travel pilot valve
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure Forward
3.5~3.9 MPa
In Ma t rk er n et a in ti o g n De al pt .
1
Standard values and troubleshooting references
Malfunction of pilot relief valve
Reverse
{ 36~40 kg/cm2}
Difference occurs between 0.4 MPa {4 kg/cm2} left and right output ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Control lever Control circuit source pressure All levers in NEUTRAL
3.5~3.9 MPa
{ 36~40 kg/cm2}
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3
Failure of regulator
4
Sluggishness of proportional solenoid valve
Check the regulator by swapping the front and back regulators. ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel control lever Proportional valve output pressure Operate both control levers ≤ 0.1 MPa
5 6
7
Sluggishness of travel conCheck the valve spool to see whether it works well. trol valve (spool) Internal leakage of central Check it by swapping the lines. swivel joint ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Malfunction of travel motor Travel control lever Leakage of travel motor Travel relief 27.2 ml/min Final drive may have internal defect. Check it directly.
7-98
8
Failure of final drive
9
Failure of travel pilot pressure sensor
● Internal defect of the final drive can be determined through abnormal noise, abnormal heat, and metal powder or debris contained in the oil drained. Travel control levers Pilot valve output pressure The monitor reads: 3.5~3.9MPa Forward or backward
{ 36~40 kgf/cm2} Output difference between the left and the right Check it by swapping.
Shop Manual - April 2014
0.4 MPa {4 kgf/cm2}
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-15 Travel speed low Failure information Related information
Cause
Malfunction of travel pilot valve
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure 3.5~3.9 MPa { 36~40 kg/cm2}
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
● Machine travel speed is low. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
2
Malfunction of pilot relief valve
Forward or reverse
Difference occurs between front ≤ 0.4 MPa output and rear output ≤ {4 kg/cm2} ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Control lever Control circuit source pressure All levers in NEUTRAL 司
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3.5~3.9 MPa { 36~40 kg/cm2}
销 营
3
4 5
6
7
Sensor failure
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel speed Travel control 3.5~3.9 MPa Low Operation { 36~40 kgf/cm2} 3.5~3.9 MPa High Operation { 36~40 kgf/cm2} Check it by replacement.
Malfunction of travel Spool of travel control valve may have malfunction. Check it directly. control valve (spool) Malfunction of The makeup valve in travel control valve may have malfunction. Check it travel control valve directly. (makeup valve) ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Failure of travel moTravel control lever Oil leakage of travel motor tor
Travel relief 27.2 ml/min Final drive may have internal defect. Check it directly. ● Internal defect of the final drive can be determined through abnormal Failure of final drive noise, abnormal heat, and metal powder or debris contained in the oil drained.
Shop Manual - April 2014
7-99
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-16 Machine not steered easily or steering power low ● Machine is not steered well or steering power is low ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Failure information Related information
Cause
7-100
Malfunction of travel pilot valve
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure Both sides in NEUTRAL
0 {0} 3.5~3.9 MPa Either side operated { 36~40 kg/cm2} ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure Failure of travel pilot 3.5~3.9 MPa 2 Both sides operated pressure sensor { 36~40 kgf/cm2} 3.5~3.9 MPa Either side operated { 36~40 kg/cm2}
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
Standard values and troubleshooting references
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3
Malfunction of travel control valve (spool)
Spool of travel control valve may have malfunction. Check it directly.
Malfunction of travel The makeup valve in travel control valve may have malfunction. 4 control valve (makeup Check it directly. valve) Seal of relief valve in travel motor may be defective. Check it diFailure of travel motor rectly. 5 (relief valve) ● The failure of seal can be determined by swapping the front and back motors or the left and right motors. Seal of check valve in travel motor may be defective. Check it diFailure of travel motor rectly. 6 (check valve) ● The failure of seal can be determined by swapping the front and back motors or the left and right motors.
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-17 Travel speed cannot be shifted Failure information
Cause
Standard values and troubleshooting references
Malfunction of travel 1 speed shifting solenoid valve
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Solenoid valve output Travel speed Travel control lever pressure Lo Operated 0 {0}
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
● Travel speed cannot be shifted. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Hi
2
Operated
3.5~3.9 MPa
{ 36~40 kg/cm2}
Failure of travel mo- Speed shifting assembly of travel motor may have malfunction. tor (in speed change) Check it directly.
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Shop Manual - April 2014
7-101
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-18 Travel system fails (only at one side) ● One side of the tracks cannot make a turn. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Failure information Related information
7-102
Standard values and troubleshooting references
Defective seat of 1 travel control valve (makeup valve) Defective seat of 2 travel motor (relief valve) Defective seat of 3 travel motor valve (makeup valve)
Seat of makeup valve in travel control valve may have malfunction. Check it directly. Seat of relief valve in travel control valve may have malfunction.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
Check it directly.
Seat of check valve in travel motor valve may have malfunction. Check it directly.
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Speed of travel mo4 Travel control lever Leakage from travel motor tor drops. Travel relief 27.2 ml/min Final drive may have internal defect. Check it directly. 司
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● Internal defect of final drive can be determined with abnormal noise, overheat, and metal powder or debris contained in the oil drained. ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure The monitor read: 3.5~3.9 MPa Failure of pilot presForward or backward 6 sure sensor { 36~40 kgf/cm2} Output difference between the left 0.4 MPa {4 kgf/cm2} and the right Check it by swapping. 5 Failure of final drive
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-19 Swing operation fails Failure information (1) Related information
Cause
Standard values and troubleshooting references
Malfunction of swing motor (park- Parking brake of swing motor may have malfunction. Check it directly. ing brake) ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
● Upper structure fails to swing in either direction. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
2
Swing control lever Swing relief pressure Improper adjustment or malfunc25.5~28.5 MPa Swing relief tion of swing motor {260~291 kg/cm2} (relief valve) If oil pressure does not become normal after adjustment, swing motor relief valve may have malfunction or internal defect. Check the relief valve directly. ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Failure of swing Swing control lever Leakage from swing motor motor 司
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3
Swing relief ≥ 10 ml/min Swing mechanism may have internal defect. Check it directly.
4
Failure of swing mechanism
● Internal defect of swing mechanism can be determined with abnormal noise, overheat, and metal powder or debris contained in the oil drained.
Shop Manual - April 2014
7-103
Troubleshooting
Trouble (2)
Cause
● Upper structure only fails to swing in one direction. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle.
1
Malfunction of pilot valve
Malfunction of 2 swing control valve (spool) Defective seal 3 of swing motor (makeup valve)
Left control lever
Pilot valve output pressure
NEUTRAL
0 {0}
Swing
≥ 3.5MPa { ≥ 36 kg/cm2}
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
SY365(B)H-9 Crawler Hydraulic Excavator
Spool of swing control valve may have malfunction. Check it directly. Seal of makeup valve in swing motor may have defect. Check it directly. ● Failure of the seal can be determined by swapping the right and left makeup valves and check for any changes.
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7-104
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-20 Swing acceleration poor or swing speed low Failure information (1) Related information
Standard values and troubleshooting references
Malfunction of 1 swing motor (park- Parking brake of swing motor may have malfunction. Check it directly. ing brake) ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Swing control lever Swing relief valve Improper adjust-
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
● Swing acceleration is poor, or swing speed is low. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
ment or malfunc25.5~28.5 MPa Swing relief tion of swing motor {260~291 kg/cm2} (relief valve) If oil pressure does not become normal after adjustment, swing motor relief valve may have malfunction or internal defect. Check the relief valve directly. ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Failure of swing 3 Swing control lever Leakage from swing motor motor 2
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Swing relief
4
≤ 10 ml/min
Clogging of brake Disassemble, clean and check. control lines
Shop Manual - April 2014
7-105
Troubleshooting
Failure information (2) Related information
7-106
1
Malfunction of pilot valve
● Swing acceleration is only poor on one side, or swing speed is low. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Swing control lever Pilot valve output pressure NEUTRAL Left swing
0 {0} ≥ 3.5MPa { ≥ 36 kg/cm2}
Right swing Malfunction of swing motor Pressure compensation valve of swing motor may have malfunction. 2 (pressure com- Check it directly. pensation valve) Seal of makeup valve in swing motor may have defect. Check it directly. Defective seal 3 of swing motor ● Swap the left and right makeup valves and observe the result to de(makeup valve) termine whether the seal fails. ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. One-side leakSwing control lever Pilot valve output pressure age of swing pilot 4 pressure sensor NEUTRAL 0 {0} (shuttle valve) Left swing 3.5~3.9MPa {36~40 kg/cm2} Right swing
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
SY365(B)H-9 Crawler Hydraulic Excavator
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Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-21 Upper structure overrunning remarkably
Failure information (1) Related information
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Swing control lever Swing relief pressure
Improper adjustment or malfunc25.5~28.5 MPa 1 Swing relief tion of swing motor {260~291 kg/cm2} (relief valve) If oil pressure does not become normal after adjustment, swing motor relief valve may have malfunction or internal defect. Check the relief valve directly. ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Failure of swing 2 Control lever Leakage from swing motor motor
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
● Upper structure overruns remarkably when it stops swinging in both directions. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Swing relief 司
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Failure information (2) Related information
Possible causes and standard values
Cause
1
Malfunction of pilot valve
≤ 10 ml/min
● Swing acceleration is only poor on one side, or swing speed is low. ● Set the working mode at gear (10) of power mode (S) to perform troubleshooting.
Standard values and troubleshooting references
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Swing control lever Pilot valve output pressure NEUTRAL Left swing
0 {0}
≥ 3.5MPa { ≥ 36 kg/cm2}
Right swing Malfunction of swing 2 Spool of swing control valve may have malfunction. Check it directly. control valve (spool) Seal of makeup valve in swing motor may be defective. Check it diDefective seal of rectly. 3 swing motor (make● Swap the left and right makeup valves and observe the result to up valve) determine whether the seal fails.
Shop Manual - April 2014
7-107
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-22 Large shock produced upon swing stoppage ● Large shock is produced when upper structure stops swinging. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Failure information Related information
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle.
1
Malfunction of swing pilot valve
Swing control lever
Pilot valve output pressure
NEUTRAL
0 {0}
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
Left swing
≥ 3.5MPa { ≥ 36 kg/cm2} Right swing Reverse prevention valve of swing motor may have malfunction. Malfunction of swing Check it directly. 2 reverse prevention ● Replace the valve with a new on to determine whether the valve valve fails. 3
Malfunction of swing Swing relief valve may be worn or sluggish. relief valve 司
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7-108
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-23 High noise produced upon swing stoppage
Failure information Related information
Malfunction of 1 back pressure valve Malfunction of 2 swing motor (relief valve)
Standard values and troubleshooting references Back pressure valve may have malfunction. Check it directly.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
● High noise is produced when upper structure stops swinging. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Relief valve of swing motor may have malfunction. Check it directly.
Seal of makeup valve in swing motor may have malfunction. Check it diMalfunction of rectly. 3 swing motor ● Swap the left and right makeup valves and observe the result to deter(makeup valve) mine whether the seal fails. . The swing mechanism is suspected of an internal failure. Check the inside of the machinery itself. Failure of swing 4 ● Internal defect of swing mechanism can be determined with abnormechanism mal noise, overheat, and metal powder or debris contained in the oil drained. 司
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Shop Manual - April 2014
7-109
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-24 Swing drift excessive
Failure information (1)
Cause
Standard values and troubleshooting references
Failure of swing Swing holding brake control lines and holding brake pilot valve may be 1 holding brake defective. Check them directly. control lines
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
● Hydraulic drift of swing is large (when swing holding brake is applied). ● When swing lock switch is turned ON or when swing holding brake release switch is in normal position, swing holding brake operates and upper structure is fixed with disc brake.
Malfunction of 2 swing motor (parking brake)
Parking brake of swing motor may have malfunction. Check it directly.
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Failure information (2)
Possible causes and standard values
Related information
7-110
Cause
● Hydraulic drift of swing is large (when swing holding brake is released). ● When swing holding brake release switch is in release position, swing holding brake is released and upper structure is secured by only hydraulic pressure.
Standard values and troubleshooting references
Malfunction or deSwing control valve spool may have malfunction or defective seal. 1 fective seal of swing Check it directly. control valve (spool) 2
Failure of swing moSeal of relief valve in swing motor may be defective. Check it directly. tor (relief valve)
3
Failure of swing mo- Seal of makeup valve in swing motor may be defective. Check it ditor (makeup valve) rectly.
Shop Manual - April 2014
Troubleshooting
BLMaInt e r AkNe rn a tKi t i ng o PAD nal eGp tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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销 营
Shop Manual - April 2014
7-111
Troubleshooting
BLM In t aAr e kNe rn a tKi t i nP o gA n al DG ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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销 营
7-112
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Disassembly and Assembly 8 Disassembly and Assembly
8.1 How to Read This Manual ....................................................................................... 8-5 8.1.1 Removing and installing an assembly............................................................ 8-5 8.2 Operating Precautions ............................................................................................. 8-6 8.3 Start Motor AS ........................................................................................................ 8-9 8.3.1 Removal ......................................................................................................... 8-9 8.3.2 Installation ...................................................................................................... 8-9 8.4 Fuel Injection Pump AS ........................................................................................ 8-10 8.4.1 Removal ....................................................................................................... 8-10 8.4.2 Installation .................................................................................................... 8-12 8.5 Engine Front Oil Seal ............................................................................................ 8-13 8.5.1 Removal ....................................................................................................... 8-13 8.5.2 Installation .................................................................................................... 8-13 8.6 Engine Rear Oil Seal ............................................................................................ 8-14 8.6.1 Removal ....................................................................................................... 8-14 8.6.2 Installation .................................................................................................... 8-14 8.7 Cylinder Head AS .................................................................................................. 8-15 8.7.1 Removal ....................................................................................................... 8-15 8.7.2 Installation .................................................................................................... 8-19 8.8 Radiator AS ........................................................................................................... 8-20 8.8.1 Removal ....................................................................................................... 8-20 8.8.2 Installation .................................................................................................... 8-23 8.9 Engine and Hydraulic Pump AS ............................................................................ 8-24 8.9.1 Removal ....................................................................................................... 8-24 8.9.2 Installation .................................................................................................... 8-30 8.10 Final Drive AS ..................................................................................................... 8-31 司
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Shop Manual - April 2014
8-1
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
8.10.1 Removal ..................................................................................................... 8-31 8.10.2 Installation .................................................................................................. 8-32 8.11 Final Drive AS ...................................................................................................... 8-33 8.11.1 Disassembly ............................................................................................... 8-33 8.11.2 Assembly .................................................................................................... 8-36 8.12 Swing Motor and Swing Drive AS ....................................................................... 8-42 8.12.1 Removal ..................................................................................................... 8-42 8.12.2 Installation .................................................................................................. 8-43 8.13 Swing Motor and Swing Drive AS ....................................................................... 8-44 8.13.1 Disassembly............................................................................................... 8-44 8.13.2 Assembly.................................................................................................... 8-49 8.14 Idler AS ............................................................................................................... 8-54 8.14.1 Disassembly............................................................................................... 8-54 8.14.2 Assembly.................................................................................................... 8-55 8.15 Sprocket .............................................................................................................. 8-58 8.15.1 Removal ..................................................................................................... 8-58 8.15.2 Installation .................................................................................................. 8-58 8.16 Track AS ............................................................................................................. 8-59 8.16.1 Removal ..................................................................................................... 8-59 8.16.2 Installation .................................................................................................. 8-60 8.17 Swing Bearing AS ............................................................................................... 8-62 8.17.1 Removal ..................................................................................................... 8-62 8.17.2 Installation .................................................................................................. 8-63 8.18 Swing frame AS .................................................................................................. 8-64 8.18.1 Removal ..................................................................................................... 8-64 8.18.2 Installation .................................................................................................. 8-66 8.19 Swivel Joint AS .................................................................................................... 8-67 8.19.1 Removal ..................................................................................................... 8-67 8.19.2 Installation .................................................................................................. 8-69 8.20 Central Swivel Joint AS ....................................................................................... 8-70 8.20.1 Disassembly............................................................................................... 8-70 8.20.2 Assembly.................................................................................................... 8-70 8.21 Hydraulic Tank AS ............................................................................................... 8-71 8.21.1 Removal ..................................................................................................... 8-71 8.21.2 Installation .................................................................................................. 8-73 8.22 Control Valve AS .................................................................................................. 8-74 司
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8-2
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
8.22.1 Removal ..................................................................................................... 8-74 8.22.2 Installation .................................................................................................. 8-79 8.23 Hydraulic Pump AS ............................................................................................. 8-80 8.23.1 Removal ..................................................................................................... 8-80 8.23.2 Installation .................................................................................................. 8-83 8.24 Middle Oil Seal (Hydraulic Pump Input Shaft) ..................................................... 8-84 8.24.1 Removal ..................................................................................................... 8-84 8.24.2 Installation .................................................................................................. 8-84 8.25 Pilot Valve AS (Work Equipment) ....................................................................... 8-85 8.26 Travel Pilot Valve AS ........................................................................................... 8-86 8.27 Hydraulic Cylinder AS ......................................................................................... 8-87 8.27.1 Disassembly............................................................................................... 8-88 8.27.2 Assembly.................................................................................................... 8-92 8.28 Work Equipment AS ............................................................................................ 8-97 8.28.1 Removal ..................................................................................................... 8-97 8.28.2 Installation .................................................................................................. 8-99 8.29 Air Conditioner AS ............................................................................................. 8-100 8.29.1 Removal ................................................................................................... 8-100 8.29.2 Installation ................................................................................................ 8-103 8.30 Counterweight AS ............................................................................................. 8-104 8.30.1 Removal ................................................................................................... 8-104 8.30.2 Installation ................................................................................................ 8-105 8.31 Cab AS .............................................................................................................. 8-106 8.31.1 Removal ................................................................................................... 8-106 8.31.2 Installation ................................................................................................ 8-109 8.32 Cab Window Glass ............................................................................................8-110 8.32.1 Removal ....................................................................................................8-111 8.32.2 Installation .................................................................................................8-114 8.33 Front Window AS ............................................................................................... 8-126 8.33.1 Disassembly............................................................................................. 8-126 8.33.2 Assembly.................................................................................................. 8-129 8.34 Monitor - Remove and Install ............................................................................. 8-135 8.34.1 Removal ................................................................................................... 8-135 8.34.2 Installation ................................................................................................ 8-135 8.35 Controller AS ..................................................................................................... 8-136 8.35.1 Removal ................................................................................................... 8-136 司
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Shop Manual - April 2014
8-3
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
8.35.2 Installation ................................................................................................ 8-136 8.36 Radio ................................................................................................................. 8-137 8.36.1 Structure .................................................................................................. 8-137 8.36.2 Removal and installation .......................................................................... 8-139 8.36.3 Connector model and wiring .................................................................... 8-140 8.37 Battery ............................................................................................................... 8-141 8.37.1 Structure .................................................................................................. 8-141 8.37.2 Removal and installation .......................................................................... 8-142 8.37.3 Replacement ............................................................................................ 8-143 8.38 Start Switch........................................................................................................ 8-144 8.38.1 Structure ................................................................................................. 8-144 8.38.2 Removal ................................................................................................... 8-145 8.38.3 Working principle ..................................................................................... 8-146 8.38.4 Wiring ....................................................................................................... 8-146 8.39 Fuse Box............................................................................................................ 8-147 8.40 Wiper ................................................................................................................. 8-148 8.40.1 Structure .................................................................................................. 8-148 8.40.2 Working principle ..................................................................................... 8-149 8.40.3 Removal ................................................................................................... 8-150 8.40.4 Installation ................................................................................................ 8-150 8.40.5 Angle adjustment of wiper arm................................................................. 8-151 8.41 Relays ................................................................................................................ 8-152 8.41.1 Engine relays ........................................................................................... 8-152 8.41.2 Other relays ............................................................................................. 8-153 8.41.3 Removal and installation .......................................................................... 8-154 8.41.4 Relay connector and wiring...................................................................... 8-154 8.42 Sensors.............................................................................................................. 8-155 8.43 Connector Terminals ......................................................................................... 8-157 8.43.1 Insertion ................................................................................................... 8-157 8.43.2 Removal ................................................................................................... 8-158 司
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8-4
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8 DISASSEMBLY AND ASSEMBLY 8.1 How to Read This Manual 8.1.1 Removing and installing an assembly Special tools ● Special tools for parts removal and installation are listed. ● Necessary characteristics of the tools are noted in the list of special tools. ■ : Special tools that cannot be substituted and must be used.
In Ma t rk er n et a in ti o g n De al pt .
● : Very important tools, which can be substituted with commercially available ones. Removal of parts
● The "Removal" section contains procedure, precautions and the amount of oil or coolant to be discharged. ● The symbols used the in the "Removal" section are described below:
This symbol indicates that safety-related precautions must be observed when doing the job. This symbol is followed by instructions or precautions when performing a procedure. This symbol indicates related rules and precautions that must be obeyed when installing the pats. This symbol indicates the amount of oil or coolant to be discharged. 司
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★
Installation of parts
● Unless specified otherwise, installation of a part is to be performed in a reverse order of removing the part. ● The mark used in the "Installation" section indicates the rules and precautions related to parts installation. ● Symbols used in the "Installation" sections are shown below:
This symbol indicates that safety-related precautions must be observed when doing the job. ★
This symbol is followed by instructions or precautions when performing a procedure. This symbol indicates that specific coating agent must be used. This symbol indicates the lubricant required. This symbol indicates a torque specified. This symbol indicates the amount of oil or coolant to be added.
Shop Manual - April 2014
8-5
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.2 Operating Precautions Observe the following precautions before removing or installing (disassembling or assembling) a component. 1. Precautions to be observed prior to removal operation ● Dispose the engine coolant properly if antifreeze is used in the engine coolant. ● After disconnecting a hose or tube, seal the openings to prevent invasion of dirt or dust. ● Use a suitable container to contain oil drained.
In Ma t rk er n et a in ti o g n De al pt .
● Matching mark must be made at where is necessary before removing a part in order to avoid mistake during reinstallation. ● Do not pull the wire and avoid the wire coming off its contact. To avoid excessive force imposing on the wire, hold the connector when disconnecting a wire. ● Tag the wires and the hoses in order to ensure their connecting positions. By doing so, mistakes can be avoided during reinstallation. ● Count and check the number and thickness of the shims, and keep them in a safe place. ● When raising or lifting a component, be sure to use a proper lifting equipment of ample strength. 司
● When forcing screws are used to remove any components, tighten the screws evenly in turn. 公
销 营
● The surrounding area must be cleaned before removing a component. Cover the component after removal in order to prevent invasion of dirt or dust.
8-6
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Precautions to be observed when disassembling the lines The lines disassembled must be blinded with plugs. A. Thread-connected hoses Inner Diameter (mm)
Code
Description
Light Thread Connection B210780001189
Plug
8
B210780001190
Plug
10
B210780000077
Plug
12
B210780000078
Plug
In Ma t rk er n et a in ti o g n De al pt .
6
15
B210780000883
Plug
20
B210780000079
Plug
22
60056667
Plug
Heavy Thread Connection
12
B210780001142
Plug
16
60002397
Plug
20
B210780000080
25
B210780000081
Plug Plug
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B. Thread-connected adaptors (plug and nut used in combination) Inner Dia.(mm)
Code
Description
Code
Description
Light Thread Connection
6
B210780000903
Cone Plug
23002925
Nut
8
B210780001146
Plug
B210770000011
Nut
10
B210780000088
Plug
B210334000011
Nut
12
B210780000089
Plug
B210334000012
Nut
15
B210780000882
Plug
B210334000004
Nut
20
B210780000090
Plug
B210334000010
Nut
22
B210780000091
Plug
B210780000112
Nut
Heavy Thread Connection 12
B210780001143
Plug
B210780000406
Nut
16
A820205001523
Plug
B210780000405
Nut
20
B210780000902
Plug
B210780000904
Nut
25
B210780001172
Plug
B210334000006
Nut
Shop Manual - April 2014
8-7
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
performed as the following:
2. Precautions to be observed prior to installation
(1) Start the engine and run the engine at low idle. (2) Operate the work equipment control lever in order to cycle the movement of the hydraulic cylinder 4 or 5 times. Hold 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. (4) You can run the engine at normal speed after this operation.
● Tighten all the screws and nuts (sleeve nuts) to specified torques. ● Install the hoses without twisting or interference. ● Replace the gaskets, O-rings, cotter pins and lock plates with new ones. ● Bend the cotter pin or lock plate securely.
● This procedure is to be performed before using your machine for the first time after repair or long storage.
● Before applying the sealant to the gasket, clean the gasket surface of oil and dust. Check the gasket for contamination or damage. Apply the gasket sealant evenly.
3. Precautions to be observed upon completion of the operations
In Ma t rk er n et a in ti o g n De al pt .
● Before applying the adhesive, clean the parts of oil and dust. Apply 2 or 3 drops of adhesive to the threaded portion.
● Clean all parts, and correct any damage, dents, burrs, or rust. ● Apply engine oil to the moving parts.
● Before installing a snap ring, make sure that the snap ring is mounted properly in the circular groove.
● Before connecting the wiring connector, clean the wiring connector of oil, dirt or water. Make sure that the wiring connector is connected securely.
● Before using an eyebolt, check the eyebolt for deformation or deterioration. Screw on the eyebolt as far as possible and align it to the direction of the hook. ● Before tightening the half flanges, tighten it evenly in turn in order to prevent over tightening on one side.
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● Completely discharge the engine coolant, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Check the coolant level again. ● Add hydraulic oil to the specified level after disassembly and reinstallation of a hydraulic unit. Run the engine to circulate the hydraulic oil through the system. Check the oil level again. ● Purge the air from the system after removing and repairing the lines or hydraulic unit and reassembling the parts. ● To purge the air, see related information in “Testing and Adjusting”. ● Add the specified amount of grease (MoS2) to the work equipment related parts.
● After reassembling the hydraulic cylinder, main pump or other hydraulic equipment that has been disassembled and repaired, it is necessary to purge the air from the hydraulic cylinder prior to initial operation of the cylinder. The purging procedure is 8-8
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.3 Start Motor AS 8.3.1 Removal
NOTICE
In Ma t rk er n et a in ti o g n De al pt .
● Before removing the start motor assembly, disconnect the cable from the negative post (-) of the battery. Insulate the cable and negative post (-) with tape. 1. Open the engine hood.
2. Disconnect the Cables (2), (3) and (4).
3. Remove the start motor fixing bolt (1) in order to remove the start motor.
1
2
3
4
司
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ZXT335-1006001
Fig. 8-1
8.3.2 Installation
● Installation is performed in the reverse procedure of removal.
Shop Manual - April 2014
8-9
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.4 Fuel Injection Pump AS 8.4.1 Removal NOTICE ● Disconnect the negative (-) post of battery.
In Ma t rk er n et a in ti o g n De al pt .
1. Open the engine hood.
ZXT335-1006002
Fig. 8-2
2. Disconnect the air hoses (1) and (2) of the crankcase.
1 2
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ZXT335-1006003
Fig. 8-3
3. Remove the fuel return line (3), fuel delivery line (4), fuel supply line (5) and lubrication line (7).
3
● After disconnecting the hoses, cork them to prevent fuel leak.
4
5 6
7 ZXT335-1006004
Fig. 8-4 8-10
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. Remove the six (6) fuel delivery lines (8)
8
ZXT335-1006005
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-5
5. Remove the air hose (9).
6. Remove the bolt (10) fixing the electronic shutdown device and the bolt (11) of governor motor. 7. Remove the fuel injection pump mounting nut in order to remove the fuel injection pump assembly.
9
10
11
司
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ZXT335-1006006
Fig. 8-6
Shop Manual - April 2014
8-11
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.4.2 Installation ● Installation is performed in the reverse procedure of removal. Torques for: Fuel supply line connector bolt: 28-46 N•m Fuel return line nut: 28-46N•m Fuel delivery line nut: 28-32N•m Engine oil line nut: 16-25N•m ● Install the fuel injection pump as the following: A. Check the fuel injection timing.
In Ma t rk er n et a in ti o g n De al pt .
See “Fuel Injection Timing - Test and Adjust” on page 6-13.
B. Assemble the fuel injection pump assembly and tighten the nuts. Nut: 9.8±2 Nm {10±0.2 kgm}
● Purge the air.
Purge the air from the fuel injection system.
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8-12
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.5 Engine Front Oil Seal 8.5.1 Removal
3
1. Remove the radiator assembly. See “Radiator AS” on page 8-20.
2
2. Remove the engine fan (1), belt (2) and pulley (3).
1
In Ma t rk er n et a in ti o g n De al pt .
3. R e m o v e t h e b o l t ( 4 ) a n d t h e n t h e
ZX335-1006007
Fig. 8-7
crankshaft belt pulley (5).
4. Remove the front oil seal (6).
5
司
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6
4
ZX335-1006008
Fig. 8-8
8.5.2 Installation
● Installation is performed in the reverse procedure of removal.
Shop Manual - April 2014
8-13
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.6 Engine Rear Oil Seal 8.6.1 Removal 2
1. Remove the hydraulic pump assembly. See “Hydraulic Pump AS” on page 8-80. 2. Remove the flywheel (1).
In Ma t rk er n et a in ti o g n De al pt .
3. Remove the rear oil seal (2).
ZX335-10
Fig. 8-9
8.6.2 Installation
● Installation is performed in the reverse procedure of removal.
司
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Sealant
● Install the rear oil seal as the following:
A. Apply engine oil to the lip of rear oil seal.
ø2mm
B. Clean the seal surface.
C. Apply sealant along the sealing line continuously and uniformly.
Line
Sealant (Tianshan 1596)
D. Installation is to be performed within three (3) minutes after application of sealant. It is important to keep the applied sealant in proper area.
8-14
ZX335-1006010
Fig. 8-10
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.7 Cylinder Head AS 8.7.1 Removal NOTICE ● Disconnect the cable from the negative post (-) of the battery. 1. Drain coolant from the engine. Coolant: 26 L
In Ma t rk er n et a in ti o g n De al pt .
2. Open the engine hood.
ZXT335-1006011
Fig. 8-11
3. Remove the air intake hose (1).
1
司
公
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ZXT335-1006012
Fig. 8-12
4. Disconnect the lines (2) and (3) between the fuel filter and the fuel injection pump.
4
2
5. Remove the fuel filter bracket (4) and the fuel filter assembly (5).
5
3
ZXT335-1006013
Fig. 8-13 Shop Manual - April 2014
8-15
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Disconnect the six (6) fuel delivery lines (6).
6
ZXT335-1006014
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-14
7. Remove the cover (7) of exhaust muffler connector.
7
8. Disconnect the air intake hose (8).
9. Disconnect the air intake hose (9) and the crankcase breathing hose (10) between turbocharger and intercooler.
8
司
公
9
销 营
10
ZXT335-1006015
Fig. 8-15
8-16
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
10. Disconnect the oil delivery line (11) and the oil return line (12). 11. Remove the turbocharger system assembly.
In Ma t rk er n et a in ti o g n De al pt .
12. Remove the exhaust manifold (13).
司
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销 营
11
13
12
ZX335-1006016
Fig. 8-16 Shop Manual - April 2014
8-17
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
13. Remove the radiator inlet hose (14) and outlet hose (15).
14
15
ZXT335-1006017
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-17
14. Remove the six (6) nozzle seats (16).
16
司
公
销 营
ZXT335-1006018
Fig. 8-18
8-18
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
15. Remove the rocker arm cover (17). 16. Remove the camshaft assembly (18). 17. Remove the rocker arm assembly (19). 18. Remove the bolts of cylinder head and lift the cylinder head assembly in order to disassemble it.
In Ma t rk er n et a in ti o g n De al pt .
19. Remove the cylinder head gasket (21).
8.7.2 Installation
● Installation is performed in the reverse procedure of removal.
Rocker cover bolt:
7.8-9.8N.m{0.8-1.0kgf.m}
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Cylinder head bolt:
88N.m{9.0 kgf.m }+90°
Cylinder head bolt threads: engine oil Camshaft flange surface: engine oil
Camshaft journal circumference: engine oil
● Adjusting valve clearance
● See “Valve Clearance - Adjust” on page 6-7. ● Adding coolant
Add engine coolant to the specific level. Start the engine to circulate coolant in order to eliminate all foams. Check the coolant level again.
ZX335-1006019
Fig. 8-19
Shop Manual - April 2014
8-19
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.8 Radiator AS 8.8.1 Removal 1. Open the engine hood 2. Open the pressure cap (1). Drain engine coolant via the drain valve beneath the coolant tank. Coolant: Approx. 26 L
In Ma t rk er n et a in ti o g n De al pt .
1
ZXT335-1006020
Fig. 8-20
3. Disconnect the pipes from the hydraulic oil cooler delivery port (2) and supply port (3). Seal the ports in order to prevent the leakage of hydraulic oil in the hydraulic system.
司
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4. Drain hydraulic oil from the cooler and from radiator.
2
Hydraulic oil radiator: Approx. 8 L
3
ZXT335-1006021
Fig. 8-21
5. Remove hose (4) of coolant tank.
4
ZXT335-1006022
Fig. 8-22 8-20
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Remove the inlet and outlet houses (5) and (6) of the water cooler.
6
Hydraulic oil radiator: Approx. 5.6 L
5
ZXT335-1006023
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-23
7. Remove the inlet and outlet air hoses (7) and (8) of the intercooler.
8
7
司
公
销 营
ZXT335-1006024
Fig. 8-24
8. Remove the four bolts (9) of the A/C radiator. Remove the A/C radiator and put it in a suitable place.
9
ZXT335-1006025
Fig. 8-25
Shop Manual - April 2014
8-21
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
9. Remove the radiator fan guard (10).
10
ZXT335-1006026
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-26
10. Remove the four bolts (11) from the bottom of radiator.
司
公
销 营
11
11
ZXT335-1006027
Fig. 8-27
11. Remove the bolts (12) and (13) of both left and right brackets.
12 13
ZXT335-1006028
Fig. 8-28
8-22
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
12. Install eyebolts (14) on both sides of the radiator and lift the radiator assembly. ● Before lifting the radiator assembly, move the radiator assembly in axial direction until the fan is free from the fan guard.
14
ZXT335-1006029
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-29
8.8.2 Installation
● Installation is performed in the reverse procedure of removal.
● Adjust the clearance (a) between the fan and guard so that the clearance is uniform around the fan.
司
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● The clearance (a) should read as the following on the left, right, top and bottom points. ● Standard clearance (a) (around the fan): 10 mm ● Fan dia. (b): ø830 mm
● Guard inner dia. (c): ø850 mm
● Refilling engine coolant and hydraulic oil
Refill engine coolant and hydraulic oil to the specific levels. Start the engine to circulate the coolant and oil. Check the coolant level and oil level again. Engine coolant: Approx. 26 L. Hyd oil radiator: Approx. 8 L.
Shop Manual - April 2014
8-23
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.9 Engine and Hydraulic Pump AS 8.9.1 Removal Lower the work equipment to the ground in order to ensure safety. Stop the engine. Disconnect the cable from the battery negative (-) post. Loosen the butterfly nut on the breather valve and press the relief button to release internal pressure.
In Ma t rk er n et a in ti o g n De al pt .
● Mark the lines to avoid mistakes during reinstallation.
1. Remove the hydraulic tank suction filter and block the opening. 2. Discharge engine coolant.
Coolant: About 22.9 L
3. Open the engine hood.
ZXT335-1006030
司
公
销 营
Fig. 8-30
4. Disconnect lines (1), (2) and (3).
2
3
1
ZXT335-1006031
Fig. 8-31
8-24
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. D i s c o n n e c t h o s e s ( 4 ) , ( 6 ) a n d ( 7 ) . Disconnect the cables (5) and (8) of main pump pressure sensors.
6 5
7
4
8
ZXT335-1006032
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-32
6. Remove the hose (9) and the clamps (10).
9
10
司
公
销 营
10
ZXT335-1006033
Fig. 8-33
7. Remove the main pump negative feedback hoses (11) and (12).
12
11
ZXT335-1006034
Fig. 8-34
Shop Manual - April 2014
8-25
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8. Remove the main pump PSV hose (13), clamp (14) and cable (15).
13
15
14
ZXT335-1006035
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-35
9. Disconnect the engine fuel hoses (16) and (17) and the engine oil hoses (18) and (19).
21
20
22
10. Disconnect the engine speed sensor cables (20) and (21) as well as the clamp (22).
16
18
17
19
司
公
销 营
ZXT335-1006036
Fig. 8-36
11. Unscrew the throttle guy connecting bolt (23) and the electronic shutdown device connecting bolt (24).
24
23
ZXT335-1006037
Fig. 8-37
8-26
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
12. Remove the coolant temperature sensor, high temperature switch external cables (25) and (26) as well as the hose clamps (27). 25 26
27 ZXT335-1006038
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-38
13. Disconnect the compressor cables (28) and (29) as well as the hoses (30) and (31).
28
29
31
司
公
销 营
30
ZXT335-1006039
Fig. 8-39
14. Disconnect the external cable (32) of engine oil pressure sensor and the cable (33) of engine oil pressure sensor.
32
34
15. Remove the clamps (34).
16. Remove the starter main cable (35).
36
17. Disconnect the alternator cable (36). 35 33 ZXT335-1006040
Fig. 8-40
Shop Manual - April 2014
8-27
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
18. Remove the hose clamp (37). 37
ZXT335-1006041
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-41
19. Disconnect the hoses (38), (39) and (40) between the engine and the radiator. 20. Disconnect the air intake hose (41).
39
38
司
公
销 营
40
41
ZXT335-1006042
Fig. 8-42
21. Disconnect the hose (42) between the engine and the radiator.
42
ZXT335-1006043
Fig. 8-43
8-28
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
22. Disconnect the radiator fan guard (43).
43
In Ma t rk er n et a in ti o g n De al pt .
ZXT335-1006044
Fig. 8-44
23. Remove the fixing bolt (44) on each of the four (4) mounting plates of the damper. Lift the engine and main pump assembly.
44
Engine and hydraulic pump AS:
44
836 kg
司
公
销 营
ZXT335-1006045
Fig. 8-45
Shop Manual - April 2014
8-29
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.9.2 Installation ● Installation is performed in the reverse procedure of removal. ● Open the radiator tank cap to refill coolant. Add coolant to the coolant tank. Engine coolant:Approx. 26 L ● Refill the hydraulic tank with hydraulic oil. Hydraulic tank: Approx. 380 L
In Ma t rk er n et a in ti o g n De al pt .
● Start the engine to circulate the coolant in order release the foams, and check the coolant level again. ● Start the engine to circulate the hydraulic oil in the hydraulic system, and check the oil level again. ● Purging the air.
See “Air in Each Component - Purge” on page 6-41.
司
公
销 营
8-30
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.10 Final Drive AS 8.10.1 Removal 1. Remove the sprocket. See “Sprocket” on page 8-58.
WARNING ● Lower the work equipment to the ground in order to ensure safety. Stop the engine. Operate the breather valve to release internal pressure.
In Ma t rk er n et a in ti o g n De al pt .
1 ZX335-1006046
Fig. 8-46
2. Remove the motor cover plate (1).
3
3. Disconnect the four hoses (2) of the travel motor and the corresponding hose connectors. 4. Remove the 24 mounting bolts (3) connecting the final drive assembly with the sprocket. And the remove the sprocket.
司
公
销 营
2
5. Remove the bolts (4) connecting the final drive with the track frame. Lift the final drive (5) in order to disassemble it. ● Take care not to damage the surface of mounting seal installed on the hose base.
4
ZXT3355-1006247
Fig. 8-47
● Never use the threaded holes to lift the cover when lifting the final drive.
Number of Bolts Travel motor plus reducer
SY365(B)H-9 18 389 kg
3 2
4
ZX335-1006147
Fig. 8-48
Shop Manual - April 2014
8-31
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.10.2 Installation ● Installation is performed in the reverse procedure of removal.
Mounting bolts (final drive AS): 245~309 Nm {25~31 kgm} ● Refilling hydraulic oil. Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again. ● Purging the air.
In Ma t rk er n et a in ti o g n De al pt .
See “Air in Each Component - Purge” on page 6-41.
司
公
销 营
8-32
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.11 Final Drive AS 8.11.1 Disassembly 1. Discharging the oil Open the drain plug to discharge oil from the final drive tank. Final drive tank: About 4.0 L
2. Cover
①
In Ma t rk er n et a in ti o g n De al pt .
Unscrew the mounting bolts. Remove the cover (1) with the help of eyebolts ① .
1
司
公
销 营
ZX335-1006049
Fig. 8-49
3. Spacer
2
Remove the spacer (2).
ZX335-1006050
Fig. 8-50
Shop Manual - April 2014
8-33
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. No. 1 planetary carrier assembly 3
A. Remove No.1 planetary carrier assembly (3).
ZX335-1006051
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-51
B. Disassembling No.1 planetary carrier assembly.
9
7
a. Remove the screw (4). Remove the coverplate (5) from the planetary carrier (6).
b. Remove the thrust washer (7), gear (8), bearing (9), bearing inner race (10) and thrust washer (11).
5
4
10
8
司
公
销 营
11
6
ZX335-1006052
Fig. 8-52
5. No.1 sun gear shaft
12
Remove No.1 sun gear shaft (12).
ZX335-1006053
Fig. 8-53
8-34
Shop Manual - April 2014
SY365(B)H-9 Crawler Hydraulic Excavator
Disassembly and Assembly
6. Thrust washer.
13
14
Remove the thrust washer (13). 7. No.2 sun gear Remove No.2 sun gear (14).
ZX335-1006054
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-54
8. Disassembling No.2 planetary carrier assembly
18
A. Remove the screw (15). Remove the plate (16) and the planetary gear (17) from the carrier (22). B. Remove the bearing inner race (19) and outer race (18). Remove the plate (20).
19
15 16
17
20 21
23
司
公
销 营
C. Remove the screw (21) in order to take down the planetary carrier (22) and shims (23) from the body.
22
ZX335-1006055
Fig. 8-55
9. Boss assembly
②
A. Remove the boss assembly (24) from the travel motor with the help eyebolts ②.
24
ZX335-1006056
Fig. 8-56
Shop Manual - April 2014
8-35
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
B. Disassemble the boss assembly as the following.
27
26
a. Remove the floating seal (25). b. Remove the bearings (26) and (27) from the boss (28). ● Take care not to damage the bearing retainer while disassembling the bearing (26). 25
28 ZX335-1006057
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-57
C. Remove the floating seal (29) from the travel motor (30).
29
司
公
销 营
30
ZX335-1006058
Fig. 8-58
8.11.2 Assembly
26
● Clean all the parts. Make sure that these parts are free from contamination or damage. Apply some engine oil to the sliding surfaces prior to installation.
27
1. Boss assembly
A. Install the bearings (26) and (27) by pressing them onto the boss (28). 25
B. Install the floating seals (25).
28 ZX335-1006057
Fig. 8-59
8-36
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Remove any oil or dust from the O-ring or O-ring contact surfaces. Dry the parts before installing the floating seals. ● After installing the floating seal, make sure that the angle of floating seal is within 1 mm. ● Apply a thin layer of engine oil to the sliding surface after the floating seal has been installed.
ZX335-1006059
Fig. 8-60
In Ma t rk er n et a in ti o g n De al pt .
C. Install the floating seal (29) on the travel motor (30). ● See the above step 2 for the installation procedure.
29
司
公
销 营
30
ZX335-1006058
Fig. 8-61
D. Place the boss assembly (24) on the travel motor with the help of eyebolts ② . Carefully tap the bearing to pressfit it.
②
24
ZX335-1006056
Fig. 8-62
Shop Manual - April 2014
8-37
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
2. Calculation of shim thickness A. Measure the thickness (H) of the raised part of No.2 planetary carrier (22).
22
H
ZX335-1006060
B. Measurement of raised thickness
Fig. 8-63
In Ma t rk er n et a in ti o g n De al pt .
Apply 3000 Kg load to the bearing and measure the value (H) of the raised part of bearing. ● Turn the boss 2-3 times before applying a pushing force.
● Do not use a spray gun to cushion the bearing.
Load 3000Kg
h
● Do not push or strike the retaining valve. C. Shim thickness calculation: C=H-h.
司
公
销 营
ZX335-1006061
Fig. 8-64
D. Place the shims on the body and insert the dowel pin. Press the carrier assembly onto the dowel pin and tighten it with screw (21). Apply locking adhesive to the threads.
Tensiometer
Screw-locking adhesive:
(Kesaixin 1277)
Screw (21): 539±28 Nm {55±2.9 kgm} ● Use a tensiometer to measure the tangential force of boss to motor case rotation.
ZX335-1006062
Fig. 8-65
Tangential force: Max. 294N {30 kg} Maximum tangential force occurs at the beginning of direction change.
8-38
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
3. Assembly of No.2 planetary carrier assembly
18
19
15 16
Assemble the No.2 planetary carrier assembly through to the following steps.
17 20
● Replace the plates (20) and (16) with new ones.
23
21
A. Assemble the bearings (18) and (19) on the gear (17). Assemble the top and bottom plates (16) and (20), and place the gear assembly into the planetary carrier (22).
22
ZX335-1006055
Fig. 8-66
In Ma t rk er n et a in ti o g n De al pt .
B. Lock it with screw (15). Screw (15):
13
14
539±28 Nm {55±2.9 kgm}
● Check the flexibility of gear (17) after assembling the planetary carrier assembly. 4. Thrust washer
Install the thrust washer (13).
司
公
销 营
5. No.2 sun gear
Install No.2 sun gear (14).
ZX335-1006054
Fig. 8-67
6. No.1 sun gear shaft
12
Install No.1 sun gear shaft (12).
ZX335-1006053
Fig. 8-68
Shop Manual - April 2014
8-39
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
7. No.1 planetary carrier assembly A. Install No.1 planetary carrier assembly as the following.
9
7
5
4
10
8
● Replace the thrust washers (7) and (11) with new ones. a. Assemble bearings (9,10) on gear (8). Assemble the top washer (7) and the bottom washer (11). Place the gear assembly in the carrier assembly (6).
11
6 ZX335-1006052
Fig. 8-69
In Ma t rk er n et a in ti o g n De al pt .
b. Secure the coverplate (5) to the planetary carrier (6) with screw (4). B. Install No.1 planetary carrier assembly (3).
3
司
公
销 营
ZX335-1006051
Fig. 8-70
8. Spacer
2
Install the spacer (2).
ZX335-1006050
Fig. 8-71
8-40
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
9. Cover
①
Assemble the cover (1) with the help of eyebolts ① . Use a torque wrench to tighten the bolts. Bolts: 73.4±3.63 Nm {7.5±0.4 kgm}
1 ZX335-1006049
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-72
司
公
销 营
Torque wrench
ZX335-1006063
Fig. 8-73
10. Refilling the oil
Tighten the drain plug and refill engine oil through a filler. Final drive case: About 4.7 L
● After the final drive has been successfully installed to the chassis, check the oil to see if it has reached the specified level.
Shop Manual - April 2014
8-41
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.12 Swing Motor and Swing Drive AS 8.12.1 Removal Release the remaining pressure in the hydraulic return circuit. See “Remaining Pressure in Hydraulic Lines - Relieve” on page 6-36. Lower the work equipment to the ground in order to ensure safety. Stop the engine. Press the release button of the breather valve to release remaining pressure in the hydraulic tank. Place the hydraulic lockout control in the locked position.
4
3
In Ma t rk er n et a in ti o g n De al pt .
6
1. Disconnect the hose (1) through the hose (9).
2
7
(1): Between oil tank and swing motor (port Dr)
5
1
(2): Between central swivel joint and swing motor (port Dr) (3): Between swing motor and main valve (port M) (4): Between swing motor and main valve port Px (port A)
司
公
销 营
ZXT335-1006064
Fig. 8-74
(5): Between swing motor and main valve (port B) (6): Between swing motor and main valve port Px (port SH)
(7): Between swing motor and solenoid valve block (port PG)
9
2. Remove the 14 fixing bolts (8).
3. Lift the swing motor and swing mechanism assembly (9) in order to disassemble it.
8
Slowly lift the swing motor and swing mechanism assembly in order to avoid damaging the hoses and other parts. Swing motor and swing drive AS: 425.5 kg
8-42
ZXT335-1006065
Fig. 8-75
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.12.2 Installation ● Installation is performed in the reverse procedure of removal.
Mounting bolts (swing motor and swing mechanism AS): 490~608 Nm {50~62 kgm} ● Refilling of hydraulic oil
In Ma t rk er n et a in ti o g n De al pt .
Refill hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again. ● Purging of air
See “Air in Each Component - Purge” on page 6-41.
司
公
销 营
Shop Manual - April 2014
8-43
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.13 Swing Motor and Swing Drive AS 8.13.1 Disassembly 1. Draining of oil 2
Open the drain plug to drain the oil from the swing mechanism. 1
Swing drive case: Approx. 10.5 L 2. Swing motor assembly
In Ma t rk er n et a in ti o g n De al pt .
A. Place the swing motor and swing mechanism assembly on a suitable cribbing. Take care not to damage the drive gear or let it contact the ground. B. Unscrew the four(4) bolts (1) in order to remove the swing motor assembly (2).
ZXT335-1006066
Fig. 8-76
Swing motor assembly: 67.5 kg
3. No.1 sun gear
司
公
销 营
2
Remove No.1 sun gear (2).
ZX335-1006067
Fig. 8-77
8-44
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. No.1 planetary carrier assembly
4
3
In Ma t rk er n et a in ti o g n De al pt .
A. Remove No.1 carrier assembly (3) and the plate (4).
ZX335-1006068
Fig. 8-78
B. Disassemble No.1 carrier assembly.
Cut the rivets on the shaft (8) to remove the shaft (8), and remove in turn the gear (6), bearing (9) and plate (7).
6
5
7
8
9
司
公
销 营
ZX335-1006069
Fig. 8-79
5. Gear ring
10
Unscrew the mounting bolts to remove the gear ring (10).
ZX335-1006070
Fig. 8-80 Shop Manual - April 2014
8-45
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. No.2 sun gear
11
In Ma t rk er n et a in ti o g n De al pt .
Remove No.2 sun gear (11).
ZX335-1006071
Fig. 8-81
7. No.2 planetary carrier assembly
12
A. Remove No.2 carrier assembly (12).
司
公
销 营
ZX335-1006072
Fig. 8-82
8-46
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
B. Disassemble No.2 carrier assembly with hands through the following steps. a. Hammer the pin (13) in the shaft (14) in order to push the shaft (14) out of the carrier assembly (19).
19
16
15
18 17
● Hammer out the pin (13) after removing the shaft.
14 13
b. Remove the thrust washer (16) and gear (17). c. Insert the pin (15) to remove the bearing (18) from the shaft. Remove the pin (15).
ZX335-1006073
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-83
8. Snap ring
20
Remove the snap ring (20).
司
公
销 营
ZX335-1006074
Fig. 8-84
9. Disassembling the main shaft
Push
21
22
A. Place the shaft housing assembly on a press and push the shaft assembly (21) out of the shaft housing assembly (22).
ZX335-1006075
Fig. 8-85 Shop Manual - April 2014
8-47
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
B. Disassemble the shaft assembly in the following procedure.
Push
Remove the bearing (23) from the shaft (24).
23
In Ma t rk er n et a in ti o g n De al pt .
24
ZX335-1006076
Fig. 8-86
10. Bearing
26
Remove the bearing (25) and the oil seal (26) from the housing (27).
27
司
公
销 营
25
Fig. 8-87
8-48
Shop Manual - April 2014
ZX335-1006077
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.13.2 Assembly
23
● Clean all the parts and check for any contamination or damage. Apply engine oil to the sliding surfaces of the parts. 1. Bearing Press the bearing (23) into the housing (27).
27
ZX335-1006078
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-88
2. Oil seal
27
Press the oil seal (26) into the housing (27).
26
Oil seal mounting surface: gasket sealant (Loctite 515)
司
公
销 营
ZX335-1006079
Fig. 8-89
3. Housing assembly
24
A. Position the plate (28) on the shaft (24). B. Position the housing assembly (22) on the shaft (24). Press to fit the bearing.
22
28
ZX335-1006080
Fig. 8-90
Shop Manual - April 2014
8-49
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. Bearing
22
25
Press to fit the bearing (25). ● When press-fitting the bearing, press the bearing inner race and outer race simultaneously. Never press only the inner race. ● After assembling the bearing, check if the housing rotates freely.
In Ma t rk er n et a in ti o g n De al pt .
ZX335-1006081
Fig. 8-91
5. No.2 Planetary carrier assembly
Reassemble No.2 carrier assembly through the following steps.
19
A. Assemble the plate (16) in the carrier assembly (19).
16
15
18 17
司
公
销 营
B. Assemble the gear (17) in the carrier assembly (19). Put the bearing (18) on the shaft (14). Slightly tap the pin (15) into the bore after alignment. Use a rubber hammer to tap the pin. Make sure that the pin (15) must not be higher than the bearing (18).
13
ZX335-1006073
Fig. 8-92
C. Push the shaft assembly into the carrier assembly (19). Be careful not to damage the gear and the plate. Align the pin hole of the shaft with that of the carrier assembly, and install the pin (13). Carefully tap the pin with a rubber hammer during installation. ● Installation of the shaft requires rotating the planetary gear. Take care not to damage the thrust washer.
8-50
14
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Assemble in turn the snap ring (20), No.2 carrier assembly and No.2 sun gear (11).
11
No.2 planetary carrier
20
In Ma t rk er n et a in ti o g n De al pt .
ZX335-1006082
Fig. 8-93
7. Installation of gear ring
10
Apply sealant on the mating surface indicated by (C) and tighten it with screws. Never get the sealant onto the gear ring (10). Mating surface: Sealant (Loctite 515)
c
司
公
销 营
ZX335-1006083
Fig. 8-94
8. No.1 planetary carrier assembly
A. No.1 carrier assembly is assembled as the following.
a. Install the plate (7) on the carrier assembly (5).
5
6
7
8
9
b. Install the gear (6) onto the plate after installing the bearing (9) into the gear. c. Press the shaft (8) into the gear (6) and the carrier assembly (5). Rivet one end of the shaft. ● Check if the gear rotates freely.
ZX335-1006069
Fig. 8-95
Shop Manual - April 2014
8-51
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
B. Install No.1 carrier assembly (3) and the plate (4).
4
In Ma t rk er n et a in ti o g n De al pt .
3
ZX335-1006068
Fig. 8-96
9. No.1 sun gear assembly
2
Install No.1 sun gear (2).
司
公
销 营
ZX335-1006067
Fig. 8-97
8-52
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
10. Installation of swing motor assembly Install the swing motor assembly after applying sealant to the mating surfaces of the gear ring and the motor cover. Mating surface: sealant (Loctite 515) Swing motor assembly: 55 kg Mounting bolts (swing motor): 156±5 Nm {16±0.5 kg}
In Ma t rk er n et a in ti o g n De al pt .
● The 14 bolt holes of the swing motor and swing drive assembly are distributed nonuniform. The mating direction of each hole is exclusive, as shown in the illustration on the right. The installation of swing motor requires proper alignment of the bolt holes in order to ensure the installation orientation. 11. Refilling of lubricant
Screw on the drain plug and refill lubricant through the filler to the specified level (the upper mark of oil stick).
司
公
销 营
ZX335-1006084
Fig. 8-98
Swing drive case: About 4 L
Shop Manual - April 2014
8-53
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.14 Idler AS 8.14.1 Disassembly
7
8
1. Remove the dowel pin (1) and the support (2).
6 13
12
10
2. Remove the floating seals (3) from the support (2) and the idler (4).
5
3. Remove the O-ring (11). Remove the idler (4) from the shaft (5) and the support assembly (7).
9
3
1
In Ma t rk er n et a in ti o g n De al pt .
● The idler contains 80 ml oil, which should be drained completely before disassembling. Spread a cloth on the floor to prevent smearing of the floor by the oil.
11
4
2
ZX335-1006085
Fig. 8-99
4. Remove the floating seals (6) on the other side from the idler (4), shaft (5) and support assembly (7).
司
公
4
6
销 营
6
5
7
ZX335-1006086
Fig. 8-100
5. Remove the dowel pin (8) in order to remove the support (7) from the shaft (5).
9，10
6. Remove the bushings (9) and (10) from the idler (4).
5
4
7
8 ZX335-1006087
Fig. 8-101 8-54
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.14.2 Assembly 1. Install the bushings (9) and (10) in the idler (4). 9
10
4
4
ZX335-1006088
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-102
2. Assemble the O-ring. Use the dowel pin (8) to install the support (7) on the shaft (5).
9，10
5
4
司
公
销 营
7
8 ZX335-1006087
Fig. 8-103
3. Install the floating seals (6) on the idler (4), shaft (5) and support (7) assembly. ● Floating seals
Completely remove the grease from the contact surfaces (hatched area in the illustration on the right) of O-ring and floating seal before installing the floating seal. In addition, care must be taken to keep the contact surface of floating seal free from dust.
6
ZX335-1006089
Fig. 8-104
Shop Manual - April 2014
8-55
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● After installation of the floating seals, check that the sealing inclination should be less than 1 mm and the seal protrusion be within a range of 5-7 mm.
a
ZX335-1006090
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-105
4. Install the shaft (5) and support (7) assembly to the idler (4).
7
5
4
司
公
销 营
ZX335-1006091
Fig. 8-106
8-56
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. Install the floating seal (3) to the idler (4) and support (2). 4
● Apply oil to the sliding surface of floating seal. Care must be taken to keep the sliding surface from any contaminants or dust.
3 2
3
● Remove the oil and dust from the contact surfaces of the O-ring and floating seal. ZX335-1006092
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-107
3
司
公
销 营
ZX335-1006093
Fig. 8-108
6. Install the O-ring. Use the dowel pin (1) to install the support (2).
7
8
6
13
7. Refill oil and screw on the plug.
12
10
Oil: About 80 ml (No.18 hyperbola gear oil)
5
Plug: 205.8±49 Nm {21±5 kgm}
9
4
11
3
2
1
ZX335-1006085
Fig. 8-109
Shop Manual - April 2014
8-57
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.15 Sprocket 8.15.1 Removal
1
1. Remove the track assembly. For more information see “Track AS” on page 8-59. 2. Swing the work equipment 90° and lift the chassis with the help of the work equipment. Place a block ① between the track frame and the track shoe.
①
3. Remove the sprocket (1).
In Ma t rk er n et a in ti o g n De al pt .
Sprocket: 98.4 kg
ZX335-1006094
Fig. 8-110
8.15.2 Installation
● Installation is performed in the reverse procedure of removal.
司
公
销 营
Threads (bolt - sprocket):
Thread sealant (Kesaixin 1277).
Bolts (sprocket):
927±103 N·m {94.6±10.5 kgf·m}
8-58
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.16 Track AS Special tools Mark
Part Name
Necessity
Qty
M
Manual/electric hydraulic track removing/installing machine
●
1
8.16.1 Removal
In Ma t rk er n et a in ti o g n De al pt .
1. Choose a place that has enough space to spread the track. Park the machine when the master pin is between the idler and the carrier roller.
2. Lower the work equipment. Loosen the grease fitting (1) and release the track tension.
1
WARNING
司
公
销 营
● The adjustment cylinder is under extremely high pressure. Never loosen the grease fitting by more than one turn. Move the machine back and forth if no grease is seen.
ZXT335-1006095
Fig. 8-111
3. Pull out the master pin (2) with the tool (M).
2
M
ZX335-1006096
Fig. 8-112
Shop Manual - April 2014
8-59
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. Remove the tool (M). Move the machine forward so that the temporary pin ② is in front of the idler. Place the block ① . 5. Remove the temporary pin ② and the dust seal. Move the machine backward to spread the track (3).
②
3
① ZX335-1006097
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-113
8.16.2 Installation
● Installation is performed in the reverse procedure of removal.
Corner
Track shoe nut (Square)
See “Track Tensioner - Test and Adjust” on page 6-21.
R
司
公
● Installation procedure of track shoe bolts and nuts
销 营
Corner
A. Bring the R side of the track shoe nut (1) to the link seat surface. Both seat surfaces should be in close contact when assembling the track shoe. ● If the track shoe bolts are installed from the other side, the corner of nut will interfere with the link seat surface, causing the nut to raise and the bolt to loosen.
R
R
Corner
Seat surface Must be in Close contact.
B. Tighten the bolts of track shoe to the torque below. Track shoe bolts: 1029±60 Nm {105±6 kgm}
ZX335-1006098
Fig. 8-114
8-60
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Use the tool (M) to press the master pin. Make sure that the protrusion of master pin meets the size (a). Master pin protrusion (a): 4.2±2mm
a
ZX335-1006099
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-115
● Before installing the dust seal, apply grease (G2-LI) to its contact surface with the bushing.
司
公
销 营
Shop Manual - April 2014
8-61
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.17 Swing Bearing AS 8.17.1 Removal 1. Remove the swing frame assembly. For more information See “Swing frame AS” on page 8-64. 2. Remove the 36 bolts (1) in order to take off the swing bearing assembly. 3. Lift the swing bearing assembly (2).
1
In Ma t rk er n et a in ti o g n De al pt .
ZXT335-1006100
Fig. 8-116
Swing bearing assembly; 526 kg
2
司
公
销 营
ZXT335-1006101
Fig. 8-117
8-62
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.17.2 Installation ● Installation is performed in the reverse procedure of removal. Threads (bolt - swing bearing): Thread adhesive (Tianshan 1277) Mounting bolts (swing bearing): Step 1:
In Ma t rk er n et a in ti o g n De al pt .
Use a pneumatic spanner to tighten the bolts. Step 2:
Tightened to:
927±103 Nm {94.6±10.5 kgm}
A. When a torque wrench is used to tighten the bolts, tighten first the four corners and then mark them. B. Other bolts will be tightened clockwise or counterclockwise. After one bolt is tightened, tighten the next one on the diagonal position and make a mark.
司
公
销 营
C. Tighten the rest bolts in the same way.
● Let the S mark in the soft zone of the inner race of the inner ring face the right side, as shown in the photo, and install the swing bearing to the track frame.
Inner race soft zone
● Apply grease to the inside of the gear ring of the swing bearing.
All gear teeth must be covered by grease . Swing bearing: Grease(MoS2 G2-LI):15 L
ZXT335-1006102
Fig. 8-118
Shop Manual - April 2014
8-63
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.18 Swing frame AS 8.18.1 Removal Fully extend the arm and the bucket. Lower the work equipment to the ground and engage the hydraulic lockout control. 1. Disassemble the work equipment assembly. See “Work Equipment AS” on page 8-97. 2. Remove the counterweight assembly. See “Counterweight AS” on page 8-104.
1
In Ma t rk er n et a in ti o g n De al pt .
3. Remove the four (4) hoses (1) of boom cylinder. Cork the hoses to stop oil flowing out.
ZXT335-1006103
4. Lift the boom cylinder assembly (2).
Fig. 8-119
5. Remove the plate (3) and the pin (4). Lift
司
公
销 营
2
ZXT335-1006104
Fig. 8-120
8-64
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
the boom cylinder assembly (2) in order to disassemble it. Remove the boom cylinder assembly on the other side in the same way.
4
Boom cylinder AS: 264 kg 6. Remove the plate (5), air intake hose (6)
3
ZXT335-1006105
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-121
and fan guard (7).
Removal of the swing frame requires removing other parts that interfere with the lifting of swing frame. 7. Disconnect the six (6) hoses over the
司
公
销 营
rotary joint assembly on the side of swivel joint.
7
6
5
ZXT335-1006106
Fig. 8-122
(8): Central swivel joint (port A)-
Left travel control valve (port BTL)
(9): Central swivel joint (port C)-
Left travel control valve (port ATL)
(10): Central swivel joint (port F)-
Solenoid valve
(11): Central swivel joint (port G)Swing motor (port T) (12): Central swivel joint (port D)Right travel control valve (port ATR) (13): Central swivel joint (port B)-
8
9
10
11
12
13
ZXT335-1006107
Fig. 8-123
Right travel control valve (port BTR) 8. Remove the bolt (14). 9. Unscrew the 32 swing frame mounting Shop Manual - April 2014
8-65
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
bolts in order to remove the swing frame assembly (15). Lift the swing frame assembly off the machine.
15
● Remove the front and rear mounting bolts of the platform. Use a lever block to adjust the swing frame so that the platform can reach a balance both longitudinally and laterally. Remove the last two bolts finally. Take care not to damage the central swivel joint assembly while removing the swing frame assembly.
In Ma t rk er n et a in ti o g n De al pt .
ZXT335-1006108
Swing frame assembly:
Model
Assembly (kg)
SY365(B)H-9
14,755
Only swing frame (kg) 3,040
司
公
8.18.2 Installation
销 营
● Installation is performed in the reverse procedure of removal.
Clamping screws (air intake hose): 5.4~6.4 Nm {0.55~0.65 kgm}
Mating surface (swing bearing): Flat surface sealant (Tianshan 1596)
Threads (bolt - swing frame): Thread adhesive: (Tianshan 1277) Mounting bolts (swing frame):
Step 1: Tighten the bolts with a pneumatic spanner. Step 2: tighten them again.
490~608 Nm {50~62 kgm}
● Refilling of hydraulic oil Refill through the filler opening the hydraulic oil to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again. ● Purging the air Purge the air from the travel motor. See “Air in Each Component - Purge” on page 6-41.
8-66
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.19 Swivel Joint AS 8.19.1 Removal Release remaining pressure in the hydraulic return circuit. See “Remaining Pressure in Hydraulic Lines - Relieve” on page 6-36. ● Tag each line so as to ensure correct reinstallation. 1. Disconnect the hoses (1) through (8) on the central swivel joint of the travel motor.
1
In Ma t rk er n et a in ti o g n De al pt .
(1): Central swivel joint (port T) -
2
Left travel motor (port T)
(2): Central swivel joint (port T) -
Right travel motor (port T)
ZXT335-1006109
Fig. 8-124
(3): Central swivel joint (port B) -
Left travel motor (port PA)
(4): Central swivel joint (port D) -
3
司
公
销 营
Right travel motor (port PB)
(5): Central swivel joint (port A) -
8
4
5
Left travel motor (port PB)
(6): Central swivel joint (port C) -
6
7
Right travel motor (port PA)
(7): Central swivel joint (port E)-
Left travel motor (port X)
ZXT335-1006110
Fig. 8-125
(8): Central swivel joint (port E) -
Right travel motor (port X)
Shop Manual - April 2014
8-67
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
2. Disconnect the hoses (7) through (12) between: (9): Central swivel joint (port T) -
14
Swing motor (port Dr)
13
(10): Central swivel joint (port E) Solenoid valve (port PT)
12
11
(11): Central swivel joint (port C) Left travel control valve (port BTL)
9 10
(12): Central swivel joint (port A) -
In Ma t rk er n et a in ti o g n De al pt .
Right travel control valve (port ATL)
(13): Central swivel joint (port D) -
ZXT365-1308111
Fig. 8-126
Left travel control valve (port BTR)
(14) Central swivel joint (port B) -
Right travel control valve (port ATR)
3. Remove the two(2) pin rolls (16) in order to remove the plate (15).
司
公
销 营
4. Remove the four bolts (a) in order to remove the plate (b).
16
b
15
a
16
ZXT335-1006112
Fig. 8-127
5. Remove the four mounting bolts (17).
17
ZXT335-1006113
Fig. 8-128 8-68
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Remove the swivel joint assembly (18). Central swivel joint: 45 kg 18
ZXT335-1006114
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-129
8.19.2 Installation
● Installation is performed in the reverse procedure of removal. Install the central swivel joint facing the direction indicated in the illustration.
B D
司
公
销 营
(In the illustration, the machine is viewed from the above.)
Central swivel joint
Sprocket
● Refilling of oil (hydraulic tank)
Refill through the filler opening the hydraulic oil to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again. ● Purging the air
Purge the air from the travel motor. See “Air in Each Component - Purge” on page 6-41.
A C
ZX335-1006115
Fig. 8-130
Shop Manual - April 2014
8-69
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.20 Central Swivel Joint AS 8.20.1 Disassembly 1
1. Remove the fixing bolt (1).
2
2. Remove the cover (2).
3 4 5
3. Remove the rotor (12) from the housing (6). ● Take care not to damage the sliding surface of the seal of the rotor (12). 4. Remove the O-ring (3), oil seal (8) and retainer (7) from the housing (6).
In Ma t rk er n et a in ti o g n De al pt .
6
5. Remove the rotary seal (9) and O-ring (10) from the housing (6).
7 8 9
6. Remove the oil seal (11) from the rotor (12).
10
11
8.20.2 Assembly
1. Install the oil seal (11) on the rotor (12).
司
公
销 营
12
● Let the lip face the dust ring of housing.
2. Install the O-ring (10), rotary seal (9) in the housing (6). 3. Fix the rotor (12) on a work bench. Install the housing (6) on the rotor (12).
The clearance between the housing (6) and the rotor (12) approximates 0.1 mm, so the rotor must be inserted slowly in the axial direction. Take care not to damage the rotary seal and the O-ring.
13
ZX335-1006116
Fig. 8-131
Dust ring
4. Use a rubber hammer to tap the housing (6) in order to match the rotor (12) properly.
Lip
5. Install the O-ring (3) and retainer (7) on the rotor (12). Housing
6. Install the cover (2) and tighten the bolts (1). Fixing bolts: 49 Nm {5 kgm}
8-70
ZX335-1006117
Fig. 8-132
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.21 Hydraulic Tank AS 8.21.1 Removal 1. Drain oil from the hydraulic tank.
1
Hydraulic oil: About 260 L 2. Open the engine hood.
2
3. Remove the engine hood (1), beam (2) and control valve cover (3).
In Ma t rk er n et a in ti o g n De al pt .
3
ZXT335-1006118
Fig. 8-133
4. Remove the covering (4) and the main pump partition (5). 5. Remove the engine partition (6) and the bracket (7) at the hydraulic tank side.
4
6
司
公
销 营
5
7
ZXT335-1006119
Fig. 8-134
6. Remove the two(2) oil return tubes (8) and (9) of the hydraulic tank.
8
9
ZXT335-1006120
Fig. 8-135 Shop Manual - April 2014
8-71
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
7. Remove the six hoses. (10): Oil return (T-block, pilot) (11): Oil return D2 (main valve)
14
15
16
(12) & (13): Oil return (leak of main pump) (14): Oil return (solenoid valve)
13
(15): Oil return D1/D3 (main valve) (16): Oil return (swing motor)
12
● Tag the hoses for identification.
11
10
● Use socket nuts to protect the hose connectors and cone seals against damage.
ZXT335-1006121
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-136
8. Disconnect the oil suction tube (17) from the bottom of hydraulic tank and the oil suction hose (18) connected with the oil suction tube of the main pump. 9. Remove the six (6) mounting bolts (19) from the bottom of hydraulic tank. Lift the hydraulic tank assembly.
17
19
司
公
销 营
10. Move the hydraulic tank assembly away in order to disassemble it. Hydraulic tank AS: 234 kg
8-72
18
ZXT335-1006122
Fig. 8-137
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.21.2 Installation ● Installation is performed in the reverse procedure of removal.
Drain plug (hydraulic tank): 58.8~78.5 Nm {6.0~8.0 kgm}
Screw
● After tightening the hose clamping screw, check that the screw should be in the range indicated in the illustration.
Upper side
In Ma t rk er n et a in ti o g n De al pt .
Lower side
Screw (hose clamp):
8.8±0.5 Nm {0.9±0.05 kgm}
ZX335-1006123
Fig. 8-138
● Install the hose clamp and tighten the screw according to the illustration on the right.
司
公
销 营
Tube
Hose
Bolt:
245.2~308.9 Nm {25~31.5 kgm}
O-ring seal 2
O-ring seal 1
● Refilling the oil (to hydraulic tank)
Refill hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.
Clamp 2
Clamp 1
ZX335-1006124
Fig. 8-139
● Purging the air
See “Air in Each Component - Purge” on page 6-41.
Shop Manual - April 2014
8-73
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.22 Control Valve AS 8.22.1 Removal Lower the work equipment to the ground in order to ensure safety. Stop the engine. Power on the machine and relieve system pressure. Use the breather valve to release the pressure in the hydraulic tank. Place the hydraulic lockout control in the LOCK position.
1 2
In Ma t rk er n et a in ti o g n De al pt .
● Tag each line so as to ensure correction reinstallation. 1. Remove the engine hood (1).
2. Remove the coverplate (2) on the control valve.
ZXT335-1006125
Fig. 8-140
3. Remove the engine partition (3).
司
公
销 营
3
ZXT335-1006900
Fig. 8-141
4. Remove the pressure sensor guard (4).
4
ZXT335-1006901
Fig. 8-142 8-74
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. Remove the ten (10) pilot hoses (from left to right) and tag them properly. The hoses are for: (5) Left travel (6) Right travel
5 6 7
8 9
10 11
14 12 13
(7) Arm OUT (8) Left swing (9) Bucket DIG (10) Boom DOWN
ZXT335-1006902 ZXT335-1006902
(11) Boom UP
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-143
(12) Right swing
(13) Bucket DUMP (14) Arm IN
6. Remove the two(2) pilot hoses on the control valve and tag them properly. The hoses for:
16
15
(15): Right travel forward
司
公
销 营
(16): Left travel forward
ZXT335-1006903
Fig. 8-144
7. Remove the pressure sensor harness (17).
17
ZXT335-1006904
Fig. 8-145
Shop Manual - April 2014
8-75
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8. Remove the clamp (18) fixing the harness of solenoid valve.
18
ZXT335-1006905
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-146
9. Disconnect the hoses (19) and (20) from the check valve block to the pilot pump and swing motor port (PG).
司
公
销 营
19
20
ZXT335-1006906
Fig. 8-147
23
10. Remove the boom tube clamp (21) on the main valve.
22
11. Remove the tubes (22) and (23) from the main valve to boom cylinder. Seal the ports properly.
21 ZXT335-1006907
Fig. 8-148
8-76
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
12. Disconnect the bucket hoses (24) and (25). Seal the ports properly. 13. Disconnect the arm hoses (26) and (27). Seal the ports properly.
24
25 26
27
ZXT335-1006908
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-149 14. Disconnect the hoses (28), (29), (30) and (31) between the central swivel joint and the main valve. Seal the ports properly.
29
30
28
31
15. Disconnect the swing motor hoses (32) and (33). Seal the ports properly.
16. Disconnect the hose (34) between control valve and swing motor port (M) and the hose (35) between control valve and swivel joint.
35
34
32 33
司
公
销 营
ZXT335-1006909
Fig. 8-150
17. Disconnect the tube or hose (36) of radiator and the oil return tube (37) of hydraulic tank. Seal the ports properly.
37
36
ZXT335-1006137
Fig. 8-151
Shop Manual - April 2014
8-77
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
18. Disconnect the hydraulic pump hoses (38) and (39). 39
38
ZXT335-1006138
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-152
19. Remove the two pilot hoses under the control valve and tag them properly. (40) Right travel backward
41
40
(41) Left travel backward
司
公
销 营
ZXT335-1006139
Fig. 8-153
20. Remove the harness and hoses of the solenoid valve and tag them properly.
42
43
(42) Oil return hose (43) Harness
(44) Negative feedback hose from solenoid valve to front pump
44
(45) Negative feedback hose from solenoid valve to rear pump (46) Oil feed hose from solenoid valve to PT block
8-78
45
46
ZXT335-1006140
Fig. 8-154
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
21. Remove the bolts (48) of the control valve assembly. Lift the control valve assembly in order to dissemble it. Control valve AS: 380 kg 47
ZXT335-1006141
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-155
8.22.2 Installation
● Installation is performed in the reverse procedure of removal. ● Refilling the oil (to hydraulic tank)
Refill hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.
司
公
销 营
● Purging the air
See “Air in Each Component - Purge” on page 6-41.
Shop Manual - April 2014
8-79
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.23 Hydraulic Pump AS 8.23.1 Removal Lower the work equipment to the ground in order to ensure safety. Stop the engine. Press the release button of the breather valve to release remaining pressure in the hydraulic tank. Disconnect the cable from the negative (-) post of the battery before performing the job.
Oil stopper
In Ma t rk er n et a in ti o g n De al pt .
● Tag each line so as to ensure correction reinstallation.
1. Remove the oil inlet filter element from the hydraulic tank and stop oil outflow with an oil stopper.
ZX335-1006142
Fig. 8-156
If no oil stopper is used, remove the drain plug and drain the oil from the hydraulic tank and the lines.
1
Hydraulic oil tank: About 340 L
司
公
销 营
2. Remove the engine hood (1)
WT365081301
Fig. 8-157
3. Remove the rod (2) and bolts (3). Lift the engine hood.
2 ZXT335-1006144
Fig. 8-158
8-80
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. Remove the upper right coverplate (4). 3
4
ZXT335-1006145
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-159
5. Disconnect the hose (5) supplying oil to the lower proportional valve and the hose (6) delivering oil from the pilot pump. Seal the ports properly.
5
6
司
公
销 营
ZXT335-1006146
Fig. 8-160
6. Remove the shutdown device line (7).
7 ZXT335-1006147
Fig. 8-161
Shop Manual - April 2014
8-81
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
7. Remove the right door (8). 8. Remove the hydraulic pump cover (9).
8
9
ZXT335-1006148
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-162
9. Disconnect the oil drain hose (10) and seal the ports properly.
13
10. Disconnect the high-pressure hoses (11) and (12) connected to the control valve, and seal the port properly.
11. Disconnect the harness (13) of the pressure transducer.
11
12. Disconnect the pilot pump oil suction hose (14) and seal the port properly. 13. Disconnect the hydraulic pump oil suction tube (15) and seal the port properly.
12
司
公
销 营
10
14
15
ZXT335-1006149
Fig. 8-163
14. Disconnect the solenoid valve harnesses (16) and (17).
16
17
ZXT335-1006150
Fig. 8-164
8-82
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
15. Remove the four bolts (18) of the hydraulic pump. Lift the hydraulic pump assembly (19) in order to disassemble it.
19
Hydraulic pump assembly: 186 kg
18 ZXT335-1006151
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-165
8.23.2 Installation
● Installation is performed in the reverse procedure of removal.
● After tightening the hose clamping screw, check that the screw should be in the range indicated on the right illustration.
Screw
Upper side Lower side
司
公
销 营
Screw (suction hose clamp):
10~13 N·m {1.0~1.3 kgf·m}
● Install the hose clamp and tighten the screw according to the illustration on the right.
ZX335-1006123
Fig. 8-166
Mating surface (hydraulic pump housing): Gasket sealant: (Loctite 515)
Tube
Hose
● Refilling the oil (to hydraulic tank)
Refill hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.
O-ring seal 2
Clamp 2
Hydraulic tank: About 340 L
O-ring seal 1
Clamp 1 ZX335-1006124
Fig. 8-167
● Purging the air See “Air in Each Component - Purge” on page 6-41.
Shop Manual - April 2014
8-83
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft) 8.24.1 Removal 1. Remove the hydraulic pump assembly (1). See “Hydraulic Pump AS” on page 8-80.
1
2. Remove the screw (2). Remove the bearing cover (3).
2 3 4
3. Pry the oil seal (4) out with a screwdriver.
In Ma t rk er n et a in ti o g n De al pt .
● Take care not to damage the shaft while prying the oil seal.
8.24.2 Installation
ZX335-1006152
Fig. 8-168
● Installation is performed in the reverse procedure of removal.
司
公
销 营
4
Seal lip: grease (No.1 Calcium base grease) Seal circumference: grease (No.1 Calcium base grease)
● Apply a thin layer of grease to the oil seal circumference.
ZX335-1006153
Fig. 8-169
8-84
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.25 Pilot Valve AS (Work Equipment) ● This section discusses only the precautions when reassembling the work equipment pilot valve assembly. 8 2
3
4
5
6
7
10
In Ma t rk er n et a in ti o g n De al pt .
1
9
ZXT335-1006154
Fig. 8-170
● Reassembly of the work equipment pilot valve assembly 1. Install the plate (9) in the valve body (8) with O-ring seal. Tighten the socketheaded screw (10).
司
公
销 营
Screw (socket head): 25~33 Nm {2.55~3.36 kgm} 2. Insert the spring (7) into the spool hole in the valve body (8). Put the spool (6) in the spring. Install the plug (5) on the spool. Push the plug (5) to the spool hole.
Apply the thread adhesive (Tianshan 1277) to two points on the inner threads, as indicated in the illustration on the right. The amount of application is approximately 0.02 g. U-joint (3): 98~133 Nm {10~13.5
kgm}
● Tightening is to be made to the specified torque.
5~7 mm
3. Install the plate (4) on the plug (5). Tighten the U-joint (3).
4. Install the plate (2). Align the position of the plate (2) and tighten the nut (1). Nut: 98~133 Nm {10~13.5 kgm}
● Location of each oil port is stamped on the bottom of valve body. Plug (5) circumference: Grease (No.1 Calcium base grease) U-joint working surface: Grease (No.1 Calcium base grease) Threads in valve body: Thread adhesive (Tianshan 1277)
ZX335-1006155
Fig. 8-171 Contact surface between plug (5) and plate (2): Grease 0.3~0.8cc (G2-L1) ● After assembling plate (2) see “Work Equipment and Swing Pilot Valves Adjust” on page 6-33.
Shop Manual - April 2014
8-85
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.26 Travel Pilot Valve AS ● This section discusses only the precautions when reassembling the travel pilot valve assembly.
In Ma t rk er n et a in ti o g n De al pt .
Pushrod
9
8
7
6
4
3
2
5
1
ZXT335-1006156
Fig. 8-172
● Reassembly of pedal pilot valve assembly
司
公
销 营
1. Install the spring (8) into the spool installation hole in the body assembly (9). Install the spool (7). Place the cover assembly (6) on the spool and press the cover assembly (6) with a hand. 2. Install the cover (4) after aligning the holes. Tighten the socket-headed bolts (1). Bolt (socket head): 98~114 Nm {10~11.6 kgm}
3. Install the dust ring (3) on the plug. Install the cover (2) and fix the cover (2) with the camshaft (5). Contact surface between the plug and the dust ring (3): Grease (No.1 Calcium base grease)
8-86
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.27 Hydraulic Cylinder AS Special tools Tool Description
Sketches
Necessity
For pulling out/ pushing in the bushing
■
Quantity
1
In Ma t rk er n et a in ti o g n De al pt .
For press fitting the dust ring
■
1
■
1
■
1
■
1
For O-ring seal correction
司
公
销 营
For insertion
For inserting the cylinder head
For correction
For inserting the piston
Shop Manual - April 2014
8-87
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.27.1 Disassembly 1. Drain the oil and remove the tubing. 2. Fix the cylinder. ● Fix the cylinder in a vertical or level manner. A vertically fixed cylinder can be disassembled and assembled easily.
In Ma t rk er n et a in ti o g n De al pt .
● The pin hole in the head end can be used for fixing of the cylinder. The pin roll can prevent the cylinder from turning. ● Remove the tubing in case of tubing interference while fixing the cylinder.
Secure the cylinder
司
公
销 营
ZX335-1006162
Fig. 8-173
3. Removal of cylinder head
Approx 1.5 m
● Unscrew the bolts with Allen Wrench.
● Using an extension rod, as shown in the illustration on the right, will make the work easy.
ZX335-1006163
Fig. 8-174 8-88
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. Pulling out the piston rod ● Be sure to have removed the tubing cover. ● Prepare a suitable container to collect oil coming out of the oil port.
1
● After pulling out the piston rod (1) to its limit, slowly loosen the cylinder head and pull it out.
2
Sleeper
● Remove piston rod (1) with cylinder head (2) and place them on a wooden sleeper.
ZX335-1006164
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-175
5. Securing the piston rod
Secure
● Pin hole on the rod end or the flat part of the ear can be used to fix the piston rod and prevent it from turning.
5
司
公
销 营
ZX335-1006165
Fig. 8-176
6. Remove of piston nut (5)
A. Remove the fixing screw (3) from the piston nut (5).
Drill bit
3
● Around the fixing screw there are two points that have been punched against loosening. After removing the riveted part with a hand drill, loosen and remove the fixing screw (3). B. Remove the steel ball (4) inside the fixing screw.
4
ZX335-1006166
Fig. 8-177
Shop Manual - April 2014
8-89
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
C. Remove the piston nut (5).
5
● The piston nut (5) is very tight. To loosen the piston nut (5), prepare a hydraulic jack or a spanner powered by hydraulic cylinder. An extension rod should be ready when removing the piston nut (5) manually.
Hydraulic jack Hydraulic cylinder ZX335-1006167
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-178
7. Removal of piston assembly
Remove in turn the piston (7), buffer sleeve (6) and cylinder head (2).
2
6
7
ZX335-1006168
司
公
销 营
8. Removal of the buffer sleeve (8) on the head end
Fig. 8-179
Threads
A. Remove first the piston nut (5).
B. Use a tool like rubber hammer to tap the piston nut (5) slightly in order to remove it. The piston rod and the buffer sleeve (8) should be kept intact. Remove the elastic retainer (9).
Piston rod
C. Slide the buffer sleeve (8) toward the piston threads in order to remove the two-piece stopper ring. D. Remove the buffer sleeve (8).
9
8
11
(two-piece type) ZX335-1006169
Fig. 8-180
E. There is an opening in the buffer seal (10). Take advantage of this opening to remove the buffer seal (10).
8-90
10
With one opening
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
9. Removal of piston seal
Screwdriver
A. The slide ring (12) and the guard ring (13) can be simply removed with hands. B. The seal (14) can be removed with a hammer and a flat-head screwdriver.
12
14
Piston
Bench clamp
C. Remove the O-ring seal (15) with a pry bar. ● The removed seals should not be reused.
15
13
ZX335-1006170
Fig. 8-181
In Ma t rk er n et a in ti o g n De al pt .
10. Removal of buffer ring (16)
● The buffer ring (16) is installed in the inner groove in the cylinder head. Use a tool with sharp end to pry it out and remove it with a scraper.
18
11. Removal of the U-ring (17) and the dust ring (18).
A. Remove the U-ring (17) with a tool such as screwdriver.
司
公
销 营
B. Press a tool (such as a screwdriver) against the dust ring (18) and hammer the screwdriver to remove the dust ring (18).
17
16
19
20
ZX335-1006171
Fig. 8-182
● The removed seals should not be reused.
Press
12. Removal of bushing (19)
A. Remove the elastic ring (20) from the cylinder head (2) with a screwdriver. B. Push the bushing (19) out with the help of clamps and press.
Block
13. Removal of pin bushing (21) 21
A. Remove the dust ring (22) on the side of cylinder barrel and piston rod with a tool such as screwdriver. B. Remove the bushing (21) with the help of a suitable cushion block.
Support ZX335-1006172
Fig. 8-183
Shop Manual - April 2014
8-91
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.27.2 Assembly Press
1. Installation of bushing (21)
Installation tool
A. Use an installation tool to press the bushing (21) into the bushing (lubricated with hydraulic oil) on the side of piston rod and cylinder barrel.
Block
Piston rod
21
22 21
B. Install the dust ring (22) with the help of a suitable cushion block.
ZX335-1006173
Fig. 8-184
In Ma t rk er n et a in ti o g n De al pt .
2. Assembly of cylinder head (2)
Hydraulic press
A. Use the press to push in the bushing (19).
● Apply hydraulic oil to the inside of cylinder head in advance. Make sure that the bushing (19) pushed in is free from a raised shoulder.
2
Too
司
公
销 营
B. Use the press to push in the dust ring (18). C. Install the guard ring and the U-ring (17) sequentially in the U-groove.
● Install the U-ring (17) in correct direction. Make sure that the U-ring is intact before installation.
19
Under pressure
ZX335-1006174
Fig. 8-185
● Inverse installation will cause leak of oil.
● Make sure that the U-ring is free from any corrugation or permanent deformation after installation. D. Installation of buffer ring (16) ● Make sure that the seal is installed in correct direction. Inverse installation can cause high pressure between the buffer ring (16) and the U-ring (17), which may lead to deformation or breakage of oil cylinder.
Tool
U-groove
Press in
ZX335-1006175
Fig. 8-186
E. Install the elastic ring (20) to prevent the fall of the bushing (19). 8-92
18
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
3. Assembling the piston assembly
Press in
A. Installation of seal (14). ● Install first the O-ring seal and the one-side guard ring (13) on the piston. Place the piston on the press. As shown in the illustration on the right, the seal (14) is installed with the tools indicated.
Press in
Block
Tool
13 Tool
Tool for correction
Piston
B. Correction of seal (14) 12 14
● Install the seal (14) and the guard ring (13) on the other side. In order to prevent the expansion of the seal (14), a corrector must be used to correct the seal (14) which has been stretched during installation. The piston rod may not be able to go in the cylinder barrel if the seal (14) is not corrected timely.
O-ring
In Ma t rk er n et a in ti o g n De al pt .
13
ZX335-1006176
Fig. 8-187
C. Installation of slide ring (12)
● Slightly open the slide ring (12) and install it axially. Excessive opening of the slide ring (12) can fail installation.
司
公
销 营
4. Assembling the piston rod assembly
Assembling tool
A. Fix the piston rod (1).
2
B. Install the cylinder (2) on the piston rod. ● Make sure that the U-ring lip is shoulder of any inder head and the tools.
the dust ring lip or not stopped by the part. Install the cylthe piston rod with
1
ZX335-1006177
Fig. 8-188
Shop Manual - April 2014
8-93
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
C. If the bottom side of cylinder contains a buffer (not for bucket cylinder), install the buffer bearing and the buffer seal in the following order.
The opening faces the threads. Threads
a. Let the notched side of the buffer seal (10) face the piston while installing the buffer seal (10) in the groove.
Piston rod
b. Install the buffer sleeve (8) according to the indication in the illustration on the right.
9
c. Install the stopper ring (11) in the groove. Install the elastic ring after the buffer sleeve (8) is pushed to the bottom. A rubber hammer should be used for the tapping job in order to avoid damaging the piston rod and the buffer bearing.
11
8
10
(Two piece type)
In Ma t rk er n et a in ti o g n De al pt .
With one opening
D. If the head side of cylinder contains a buffer, install the buffer sleeve (6) and the buffer seal (23) according to the following order.
Head end buffering
ZX335-1006178
Fig. 8-189
23
6
司
公
销 营
5
a. The piston nut must be installed after installation of the buffer bearing. b. T h e b u ff e r s e a l ( 2 3 ) m u s t b e installed in the groove, with its notches facing the piston. c. The buffer sleeve (6) must be installed according to the illustration on the right.
The opening faces the piston side. Rod end buffer
ZX335-1006179
Fig. 8-190
E. Tighten the piston nut (5). Piston nut (arm):
9600 Nm {979.6 kgm} Piston nut (boom and bucket): 6200 Nm {632.6 kgm} ● Insufficient tightening can cause oil leakage, loose nut and thread breakage. In addition, excessive tightening can cause expansion of the buffer shaft on the extending side or deformation of 8-94
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
piston on the contact side. ● Thoroughly clean and grease (with banana oil) the threaded portions of the piston, nuts and piston rod before tightening the nuts.
Rivet
Punch
F. Treatment of the piston against loosening ● After the piston nut (5) is tightened, put in the steel ball (4), tighten the setscrew (3) and punch to rivet the two peripheral points.
3 4
In Ma t rk er n et a in ti o g n De al pt .
Setscrew (3):
66.9 Nm {6.8 kgm}
5. Install the piston into the cylinder barrel.
A. Fix the barrel in a vertical or level manner.
ZX335-1006180
Fig. 8-191
B. Install the piston rod into the cylinder barrel.
● If fixed in a vertical manner, the piston rod falls into the barrel under its gravity.
司
公
销 营
● Make sure that the slide ring does not fall while the piston is inserted into the barrel.
Tool Nylon sleeve (two pieces)
(Move the notch 180 degrees away.)
ZX335-1006181
Fig. 8-192
Shop Manual - April 2014
8-95
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Tightening of cylinder head Tighten the bolts following the sequence shown in the illustration on the right.
1
8 4
Bolt: 267 Nm {27.2 kgm} 7. Install the tubing.
9
12
5
6
11
10
In Ma t rk er n et a in ti o g n De al pt .
3 2
7
Bolt tightening sequence
ZX335-1006182
Fig. 8-193
司
公
销 营
8-96
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.28 Work Equipment AS
8.28.1 Removal Fully extend the arm and the bucket. Lower the work equipment to the ground. Move the hydraulic lockout control to the LOCK position. Release remaining pressure in the hydraulic circuit. See “Remaining Pressure in Hydraulic Lines - Relieve” on page 6-36. 1. Disconnect the grease hose (1).
In Ma t rk er n et a in ti o g n De al pt .
5
2. Lift the boom cylinder assembly (2). Remove the lockbolt (3).
1
3
3. Remove the plate (4) and then the pin roll (5 ). ● There are shims installed. Count the shims and check the thickness. Place the shims in a safe place. 4. Start the engine and retract the piston rod.
4
司
公
销 营
● Secure the piston rod with a wire rope in order to prevent the piston from slipping out. Place the cylinder on a bench or support. The grease fitting on the bottom side must be removed in the later case.
2
ZXT335-1006183
Fig. 8-194
● Remove the other boom cylinder in the same way.
5. Remove the two hoses (6) of bucket cylinder and the two hoses (7) of the arm cylinder.
● Cork the hoses to prevent outflow of oil. Tie the hoses to the valve side 6. Remove the mid-connector (8) used for work lamp.
8 7
7
7
6
6 ZXT335-1006184
Fig. 8-195
Shop Manual - April 2014
8-97
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
7. Lift the work equipment and remove the plate (9). Remove the bottom pin roll (10). 10
There are shims installed. Count the shims and mark their locations.
9 ZXT335-1006185
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-196
8. Lift the work equipment assembly (11) in order to disassemble it.
11
Work equipment assembly:
Model
Weight
SY365H-9
5,652 kg
SY365BH-9
7,102 kg
司
公
销 营
ZXT335-1006186
Fig. 8-197
8-98
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.28.2 Installation ● Installation is performed in the reverse procedure of removal. A clearance (a: 0.5 - 1.5 mm) should be left between the plate and the nut when tightening the locknut. Greasing after assembling the pin: Grease (MoS2 G2-L1)
In Ma t rk er n et a in ti o g n De al pt .
WARNING
a
● Never use your finger to align the pin holes.
ZX335-1006187
Fig. 8-198
● Adjust the shim thickness in order to have a desired clearance (a: 0.5 ＜ a ＜ 1 mm) between the piston end (12) and the plate (4).
12
a
4
司
公
销 营
● Standard shim thickness: 1.0 mm and 2.0 mm. Greasing after assembling the pin:
Grease (MoS2 G2-LI)
ZX335-1006188
Fig. 8-199
WARNING
● Never use your finger to align the pin holes. ● Refilling the hydraulic oil
Refill hydraulic oil to the specified level. Start the engine to circulate the oil in the hydraulic system, and check the oil level again. Add more hydraulic oil if necessary. ● Purging the air Purge the air from travel motor. See “Air in Each Component - Purge” on page 6-41.
Shop Manual - April 2014
8-99
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.29 Air Conditioner AS Special tools ID
Part Name
Model
S
Refrigerant refiller
-
Necessity Qty ●
1
8.29.1 Removal NOTICE
In Ma t rk er n et a in ti o g n De al pt .
S
● Always disconnect the cable from negative post of the battery before you proceed.
ZXT335-1006189
Fig. 8-200
1. Drain the coolant.
Coolant: Approx 22.5 L
2. Recover refrigerant from the air-conditioning system with the tool (S).
司
公
销 营
3. Remove the pad on the bottom cover (1).
1
ZXT335-1006190
Fig. 8-201
4. Use the start key to open the left rear cover of the cab. Remove the external air filter element (2).
Cover
2 ZXT335-1006191
Fig. 8-202 8-100
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. Remove the monitor lower covers (3) and (4). Disconnect the wire (M19) of the cigar lighter before removing the cover (3). 6. Remove the air duct (5) on the right side.
4
3
5 ZXT335-1006192
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-203
7. Remove the back cover (6).
6
司
公
销 营
ZXT335-1006193
Fig. 8-204
8. Remove the back air duct (7).
8
7
9. Remove the left air duct (8). 10. Remove the baffle (9).
11. Remove the right air duct (10).
10
9
ZXT365-1308197
Fig. 8-205
Shop Manual - April 2014
8-101
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
12. Remove the cover (11). 13. Remove the cab's center connector (12). 14. Remove the radio antenna(13).
13
12 11
ZXT335-1006195
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-206
15. Remove the air duct (14) and the controller wiring connector (15). Disconnect the wiring connector (16). Remove the air conditioner relay (17). Remove the three (3) mounting bolts (18) and then the board (19).
17
16
司
公
销 营
18
14
15
19
ZXT335-1006196
Fig. 8-207
16. Remove the air conditioner water pipes (20) and (21) as well as the dripping tube (22) under the bottom cover.
22
20
21
ZXT335-1006197
Fig. 8-208
8-102
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
17. Remove the air conditioner unit (23). Also disconnect the two hoses connecting to the bottom of the air conditioner when removing the air conditioner unit.
23
ZXT335-1006198
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-209
8.29.2 Installation
● Installation is performed in the reverse procedure of removal.
Keep the hoses free from contamination by dirt, dust or water while installing the return hose of the air conditioner.
司
公
销 营
Make sure that the O-ring seal is present in the connection before connecting a hose of the air conditioner. Make sure that the O-ring seals are free from any damage or deformation.
● Apply compressor oil (ND8#) to the threads of the parts connected with the refrigerant lines. Tighten the line connections with a double-end spanner. Screw (hose clamp):
8.83~14.7 Nm {0.9~1.5 kgm} Bolt (pressure plate): 13.5±1.2 Nm {1.38±0.12 kgm} ● Refilling refrigerant Refill refrigerant (HFC-134a) into the air conditioner circuit with the tool (S).
Shop Manual - April 2014
8-103
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.30 Counterweight AS 8.30.1 Removal 1. Install lift pin (1) in lift eye of counterweight. Slowly tighten the wire rope (2) with lifting equipment to hold the counterweight.
2
In Ma t rk er n et a in ti o g n De al pt .
1
ZX365-1308163
Fig. 8-210
2. Remove the four mounting bolts (2 ) and washers. 3. Lift the counterweight with lifting equipment.
司
公
销 营
Take care not to damage the engine, radiator and cooler. Counterweight AS: 6800 kg
3
ZX365-1308164
8-104
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.30.2 Installation ● Installation is performed in the reverse procedure of removal. Threads (mounting bolt - counterweight): Thread adhesive (Tianshan 1277) Mounting bolt (counterweight):
In Ma t rk er n et a in ti o g n De al pt .
2,295±200 N·m {214~255 kgf·m} ● Counterweight Installation and adjustment
A. Lift the counterweight with a crane to a suitable position over the frame.
门
c=0±5
B. Push the counterweight and install the bolts. Adjustment is to be made according to the following specification.
Unit: mm
Counterweight
a=10±4
● Clearance with swivel:
司
公
销 营
10±5 mm(L&R)
b=0±5
● Clearance with bodywork door:
Swing frame
10±5 mm(L&R)
● Step difference from swing frame in left to right direction
ZX335-1006202
Fig. 8-211
b: max. 5 mm
● Step difference from bodywork door in left to right direction
a: 10±4
● Step difference from bodywork top cover in upper to lower direction
c: max. 5 mm
Shop Manual - April 2014
8-105
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.31 Cab AS 8.31.1 Removal NOTICE ● Always disconnect the cable from negative post of the battery before you proceed.
1
In Ma t rk er n et a in ti o g n De al pt .
1. Remove the floor mat (1). ZXT335-1006203
Fig. 8-212
2. Remove the back covers (2) and (3).
2
司
公
销 营
3
ZXT335-1006204
Fig. 8-213
3. Disconnect the left harness (4), the monitor harness connector (5) and the window washer harness (6).
4
5
4. Remove the right air duct (7).
6 7 ZXT335-1006205
Fig. 8-214 8-106
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. Remove the fresh air filter element (8).
8 ZXT335-1006206
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-215
6. Remove the fresh air duct (9).
9
司
公
销 营
ZXT335-1006207
Fig. 8-216
7. Remove the storage box (10) of console.
10
ZXT335-1006208
Fig. 8-217
Shop Manual - April 2014
8-107
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8. Disconnect the radio connector (11). 9. Disconnect the radio harness (12). 11
12
ZXT335-1006209
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-218
10. Remove the window washer fluid reservoir (13).
13
司
公
销 营
ZXT335-1006210
Fig. 8-219
11. Remove the window washer hose (14).
14
ZXT335-1006211
Fig. 8-220
8-108
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
12. Remove the decorative cap (15).
15
ZXT335-1006212
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-221
13. Remove the five (5) bolts (16) and the four(4) nuts (17). ● Check the length of bolt before removal.
16
17
司
公
销 营
ZXT365-1308210
Fig. 8-222
14. Lift the cab assembly (18) in order to remove it.
18
Cab AS: 105 kg
8.31.2 Installation
● Installation is performed in the reverse procedure of removal.
ZXT365-1308211
Bolt: 200 Nm {20.4 kgm}
Fig. 8-223
Nut: 210 Nm {21.4 kgm}
Shop Manual - April 2014
8-109
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.32 Cab Window Glass
10
10 9
8
1
2
In Ma t rk er n et a in ti o g n De al pt .
10
7
6
10 11
司
公
销 营
4
5
12
10
3
ZX215-1006218
Fig. 8-224
(1) Right window glass (2) Front window glass (3) Lower front glass (4) Cab door window glass (upper) (5) Cab door window glass (lower) (6) Cab door window glass (upper) (7) Left side rear window glass (8) Rear window glass (9) Roof window glass (10) Rubber sealing strip (11) Center adjusting seal (12) Front window assembly
● Cab window glasses (1), (2), (5), (7) and (9) are adhered to the window frame. ● When replacing front window glass (2), disassemble front window assembly (12). (If the cab is install with a front window assembly, do not only replace the front window glass.) ● For detailed information, See “Front Window AS” on page 8-126.
(Glass and frame) 8-110
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.32.1 Removal CAUTION
3
In Ma t rk er n et a in ti o g n De al pt .
● Be careful with sharp edges that may cut your fingers when handling broken or cracked window glasses. Put a piece of adhesive film (or adhesive tapes ) onto the broken or cracked window glass to prevent possible personal injury before you proceed. Remove all glass fragments. 1. Removal of glass (3)
ZX215-1006219
Fig. 8-225
Glass (3) is hold in place by sealing strips. Pull it upward carefully to remove it. 2. Removal of glass (4) and (6)
A. Remove the sealing strip from the frame of the cab door. B. Push the glass outward carefully from inside of the cab and remove glass (4) and (6) together with the frame.
司
公
销 营
6
4
ZX215-1006220
Fig. 8-226
C. Remove glass (4) and (6) from the frame with a screw driver.
Frame Seal
6 4
ZX215-1006221
Fig. 8-227
Shop Manual - April 2014
8-111
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
3. Removal of glass (8) A. Remove the retainer from the groove on the rubber with an ordinary screw driver.
8
B. Put a thin bamboo chip inside part A of the retaining rubber and detach the retainer along the edge. C. Pat the glass from inside of the cab and remove it. This job requires two people. ZX215-1006222
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-228
4. Removal of glass (1), (2), (5), (7) and (9)
9
1
7
2
司
公
销 营
5
ZX215-1006223
Fig. 8-229
A. Remove the resin board, decor strip and retainer along the edge of the glass.
Cab
Glass
B. Punch a hole through the adhesive with a drill (or a cutter) as illustrated.
Drill
Adhesive ZX215-1006224
Fig. 8-230
8-112
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
C. Pull a piece of piano string (or steel wire) through the hole as illustrated.
Piano string (or metal wire)
ZX215-1006225
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-231
D. Fix both ends of the piano string onto two screw drivers. Pull the wire back and forth in order to cut the adhesive and detach the glass from the cab. This job requires 2-3 people.
Run the string along the center of the adhesive. The string may break when it becomes very hot. Use different sections of the string while cutting the adhesive.
(Outside of cab)
Cab
Glass
司
公
销 营
Adhesive
(Inside of cab)
ZX215-1006226
Fig. 8-232
Shop Manual - April 2014
8-113
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.32.2 Installation 1. Clean the remaining adhesive and rubber on cab frame (contact surface) with a knife or scraper (5). ● Remove the remaining adhesive and rubber so that they will not affect the application of new adhesive. Do not scrape the original paint on the surface. (Scraping of paint reduces the performance of the adhesive.)
In Ma t rk er n et a in ti o g n De al pt .
5 ZXT215-1006227
Fig. 8-233
2. Clean the grease, dust and dirt on the cab (8) and the glass (9) with unleaded gasoline. ● Contaminant on the contact surface reduces the performance of adhesive.
司
公
销 营
● Clean the black part on the back of the glass.
8
● After cleaning, dry the glass for at least 5 minutes.
ZXT215-1006228
Fig. 8-234
9
ZXT215-1006229
Fig. 8-235 8-114
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
3. Priming coat (10) ● Priming paint expires four (4) months after production. Do not use expired paint.
Cab
11
● Use the paint within two (2) hours after it is unsealed.
10
● Use the paint within 24 hours even if it is sealed again immediately unsealing. (Dispose the paint 24 hours after it is unsealed)
Old adhesive edge on cab side
ZX215-1006230
A. Make sure the adhesive paint and glass priming paint are well agitated before application.
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-236
● If the priming paint is stored in a refrigerator, keep it under ambient temperature for at least half a day before agitation.
(If the paint is unsealed immediately after it is taken out of a refrigerator, water will condense on it.)
司
公
销 营
B. Always wash a used brush (11) with unleaded gasoline before using it.
● Check the brush for contaminants after it has been washed.
8
● Prepare two brushes for priming paint, one for painted surface and the other for glass surface.
C. Apply priming paint (for painted surface) evenly onto the surface where sealing rubber is to be adhered and where adhesive agent is to be applied (on the cab (8)).
ZXT215-1006231
Fig. 8-237
Priming paint (for painted surface): Sunrise MSI Primer 24
8
● Do not apply primer more than twice; otherwise, the performance of the primer will be reduced.
6
● Applying location: Cover the whole area of (a)
a
● Dimension of (a): 25mm
ZX215-1006232
Fig. 8-238 Shop Manual - April 2014
8-115
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Besides the above locations, apply primer also onto the right window glass and the cab door lower window glass.
b
● Additional priming area on the right window glass: (b) ● Additional priming area on the cab door lower window glass: (c) ● Dry the primer for at least 5 minutes (within 8 hours). ZX215-1006233
In Ma t rk er n et a in ti o g n De al pt .
● Do not use wrong priming paint. If, for example, glass primer is mistakenly used, wash it with unleaded gasoline.
c
司
公
销 营
ZX215-1006234
Fig. 8-239
D. Apply priming paint (for glass surface) onto the contact surface of window glass (9).
9
Glass primer:
Sunrise MSI Primer 35
● Do not apply the primer more than twice; otherwise, the performance of the primer will be reduced.
ZX215-1006235
Fig. 8-240
8-116
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Priming area: Apply the priming paint on the contact surface of glass (9) (rubber seal (6)adhering location) and along cab frame (8).
8
6
● Leave a 5 mm margin uncoated along the black strip adjacent to the clear area of the glass.
d
● When priming paint has been coated, dry it for at least 5 minutes (within 8 hours).
9 ZX215-1006236
Fig. 8-241
● Do not use wrong primer.
In Ma t rk er n et a in ti o g n De al pt .
If wrong glass primer is used, wash it with unleaded gasoline.
4. Adhere rubber seal (6) (with adhesive tape on both sides) along the inner edge of the contact surface of the glass.
● Do not detach the waxed paper on the rubber seal before the window glass is installed.
司
公
销 营
● Do not touch the cleaned area on the glass before rubber seal is adhered. ● Be careful not to allow the rubber seal on the corners to peel off.
● When sticking rubber seal (6) along the window frame, do not overlap the two ends of the seal. A 5 mm gap (e) between the two ends of the seal is recommended.
6
ZXT225-1006245
Fig. 8-242
A. Stick rubber seal (6) onto the right cab window frame as illustrated.
e
6
ZXT225-1006246
Fig. 8-243
Shop Manual - April 2014
8-117
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Adhere additional rubber seal (6a) onto the right cab window
f 6a
Position of the additional rubber seal: (f): 50 mm h
(f): 90 mm (h): 250 mm g
ZXT225-1006247
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-244
B. Adhere rubber seal (6) on the left cab window as illustrated.
6
司
公
销 营
ZXT225-1006248
Fig. 8-245
C. Adhere rubber seal (6) onto the lower cab door window as illustrated.
6
ZXT225-1006249
Fig. 8-246
8-118
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Adhere additional rubber seal (6b) onto the lower cab door window frame as illustrated.
j
Position of additional rubber seal:
6b
(j): 110 mm (k): 90 mm
m
(m): 200 mm
k
ZXT225-1006250
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-247 D. Adhere rubber seal (6) onto the front window glass as illustrated.
6
司
公
销 营
ZX215-1006243
Fig. 8-248
● Different from the rubber seal (6) on other window, rubber seal (6c) on the bottom of the front window shall be adhered onto the external edge of the lower part of the front window frame. (If it is adhered along the inner edge, the rubber seal will be seen through the clear part of the glass.)
6
6c
ZXT225-1006252
Fig. 8-249
Shop Manual - April 2014
8-119
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. Positioning of new window glass 9
A. Check the clearance between the edge of glass and the cab in 4 directions, and position the glass. Make sure the clearance is even.
n
B. Put a tape [6] across the glass (9) and cab (8) and draw a line (n) on it for alignment.
[6]
Adhere tape [6] at 3 points as illustrated for precise alignment of right window glass, left rear window glass and cab door lower window glass.
8 ZXT215-1006245
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-250
C. Cut the tapes across the glass (9) and the cab (8) and remove the glass.
● Do not remove the tape on the left side of the glass until the glass is installed.
[6]
8
[6]
[6]
司
公
销 营
9
ZX215-1006246
Fig. 8-251
● When positioning front window glass (4), cover it across the width of the window frame in the horizontal direction.
P
Set the clearance (p) between the top edge of the glass and the upper frame at 3 mm when positioning it in the vertical direction.
4
ZX225-1006255
Fig. 8-252
8-120
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Adhesive 13
● Store adhesion agent in dark places where temperature is blow 25℃ . ● Do not heat the adhesive to above 30℃ . ● Before using adhesive that has been unsealed, remove the hardened part at the nozzle.
12
A. Open the aluminum seal (13) on the head of the cylinder (12) and install the nozzle.
ZX215-1006247
Fig. 8-253
In Ma t rk er n et a in ti o g n De al pt .
Adhesive:
Sunrise MSI SR sealant U90 4463876
B. Cut the tip of nozzle as illustrated. Dimension of the cut: (q): 10 mm
r
14
(r): 5 mm
司
公
销 营
q
ZX215-1006248
Fig. 8-254
C. Set the cylinder (12) in the gun [7].
An electrical caulking gun is more efficient.
12
[7]
ZX215-1006249
Fig. 8-255
Shop Manual - April 2014
8-121
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4) Remove the waxed paper of the rubber seal on the surface where adhesive is to be applied.
15 6
5) Apply adhesive (15) along the external edge of the rubber seal (6).
ZX215-1006250
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-256
● Adhesive (15) for rubber seal (6) on cab (8) shall be applied as illustrated:
8
s
Dimension of (s): 10 mm Dimension of (t): 15 mm
● Adhesive (15) shall be thicker that the rubber seal (6).
6
t
司
公
15
销 营
● Apply adhesive of the same thickness evenly.
ZX215-1006251
Fig. 8-257
8-122
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Apply adhesive (15) onto the additional rubber seal of the right window (6a) and additional rubber seal of the cab door lower window (6b).
6a 15
ZX215-1006252
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-258
6b
15
司
公
销 营
ZX215-1006253
Fig. 8-259
7. Install window glass
A. Install window glass (9) and align it with the mark on the cab. (See step 5)
● Since the glass can not be remove once installed, be very careful when performing this task. ● Install the glass properly within 5 minutes after adhesive has been applied. B. Press the perimeter of the glass (9) after is has been put in place until it is securely stuck to the rubber seal. ● Press the corners of the glass hard.
9
ZXT215-1006254
Fig. 8-260
Shop Manual - April 2014
8-123
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● After the front window glass has been installed, fill the clearance between the glass on area (s) and the center adjusting seal (16) to the dimension of (t) and (u). Coat primer onto glass (4) on section A-A and apply the adhesive as fillers.
A
A
● Dimension of (t): 2 mm
S
● Dimension of (u): 5 mm ● Use a rubber spatula to cover the edge of the glass and trim the adhesive.
t 4
In Ma t rk er n et a in ti o g n De al pt .
● Remove surplus adhesive. Glass primer：
Sunrise MSI Primer 35
Adhesive：
Sunrise MSI SR Sealant U90 4463876
u
16
A-A
ZX215-1006255
司
公
销 营
Fig. 8-261
8. Fix the glass
A. After the right window glass (1) has been adhered to the cab, put positioning chips (a) (1 or 2 pcs) beneath the glass in order to fix it.
1
a
ZXT215-1006256
8-124
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
B. Use foam polystyrene blocks [9] and rubber band [10] to fix the glass and the rubber seal as illustrated.
[10]
9. After the glass has been fixed, remove all the remaining primer and adhesive on the cab and on the glass. ● Clean the adhesive with unleaded gasoline before it is hardened. ● Do not apply impacting force onto the glass when cleaning it.
[9]
10. Protection of fixed window glass
ZX215-1006257
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-262
A. Remove the positioning chips, foam polystyrene blocks and the rubber band after 10 hours.
(Condition: Temperature: 20; humidity: 60%)
B. Wait for another 14 hours after the removal of positioning chips, foam polystyrene blocks and rubber band before operating the machine.
司
公
销 营
Shop Manual - April 2014
8-125
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.33 Front Window AS Lower the work equipment onto the ground and shut down the engine. ● The front window assembly must be removed from the cab in order to replace the front window glass. Disassembling and assembling method of front window assembly (frame and glass) is illustrated in the following part.
In Ma t rk er n et a in ti o g n De al pt .
8.33.1 Disassembly 1. Raise the front window assembly to the roof and secure it with the rear locks (at both sides).
2. Remove left corner plate (1) and right corner plate (2).
2
● Mounting bolt (4) and washer (3) of the left corner plate will be used in Step 6 to hang the pull rod.
4
3
1
司
公
销 营
ZX215-1006258
Fig. 8-263
3. Release the rear lock of the cab.
4. Lower the front window assembly carefully a bit. Take out and hold the rollers (5) and (6) at the bottom of the front window from the removed parts in Step 2. 5. Remove roller (5) and (6) from both sides of the bottom of the front window.
6
5 ZX215-1006259
Fig. 8-264
8-126
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Remove pin (7) at the lower left side.
9
● Plate (8) at the end of the pull rod (9) will come out by removing of pin (7).
8
● Hang plate (8) onto the mounting bolt of left corner plate (using the washer) and fix it.
6
NOTICE 7
ZX215-1006260
In Ma t rk er n et a in ti o g n De al pt .
● A return load of 58.8 N {6 kg}is applied onto the rear of the cab. Be very careful when removing pin (7) to disconnect pull rod (9).
9
8
司
公
销 营
ZX215-1006261
Fig. 8-265
7. Pull out the front window assembly (10) from the opened part of the guide rail and lower the assembly gradually.
10
ZX215-1006262
Fig. 8-266
Shop Manual - April 2014
8-127
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8. Lower the front window assembly (10) completely. 10
● Be careful not to allow the front window assembly to damage the machine monitor.
ZX215-1006263
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-267 9. Move the front window assembly (10) to the right and the left and remove the two upper rollers (11) and (12) from the guide rail. Then, remove the front window assembly (10).
10
司
公
销 营
ZX215-1006264
Fig. 8-268
12
10
Fig. 8-269 8-128
Shop Manual - April 2014
11
ZX215-1006265
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.33.2 Assembly ● Reverse the disassembling sequence.
● Adjust the opening and closing of the front window assembly as per the following instruction. 1. Open and close the front window assembly and check if it interferes with the guide rail. Check if the roller is jammed.
In Ma t rk er n et a in ti o g n De al pt .
2. If the front window can not be opened or closed properly, loosen the mounting bolt of the roller adjusting bracket (13) and adjust the condition of the front window. Tighten the mounting bolt after adjusting.
13
ZX215-1006266
Fig. 8-270
● Make sure bracket (13) is installed without an angle.
Mounting bolt ： 34.3 N·m {3.5 kgf·m}
司
公
销 营
3. Raise the front window assemble and fix it with rear locks (at both sides). ● Check if the locks at the rear of the cab are securely fixed.
a
4. Install the right corner plate (2).
2
● After the "locked" position is adjusted in Step 6, tighten the corner plate. ● Install the right corner plate. Clearance (a) between the guide rail and the right corner plate (2) is 0 – 2.0 mm.
a
ZX215-1006267
Fig. 8-271
● Install the right corner plate. Keep the surface (R) of the roller without a level error.
R
ZX215-1006268
Fig. 8-272
Shop Manual - April 2014
8-129
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. Install left corner plate (1) ● After the "locked" position is adjusted in Step 6, tighten the corner plate.
b
● Install left corner plate. Clearance (b) between the guide rail and the left corner plate (1) is 0 – 2.0 mm. ● Install left corner plate and keep the surface (R) of the roller without a level error. (See the previous illustration).
b
1 ZX215-1006269
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-273
6. Adjust the "locked" position of the lock of front window assembly as per the following instruction.
A. Tighten the left corner plate (1) and the right corner plate (2) in a nearly correct position so that front window glass (14) is pressed closely against the adjusting seal (19) on the cab.
15
司
公
销 营
14
ZX215-1006270
Fig. 8-274
8-130
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
B. Open and close the front window assembly and check the working condition of left lock (16) and right lock (17). ● If left lock (16) and right lock (17) do not work properly,
17
16
a. Loosen the mounting bolt (18) of the lock and move the lock (16) forward. Tighten the bolt after that. Adjust the right lock with the same method.
ZX215 1006271
In Ma t rk er n et a in ti o g n De al pt .
b. C h e c k a g a i n t h e a d a p t a b i l i t y between the front window assembly (14) and the adjusting seal (15) on the cab. (Checked in Step 1)
Repeat Step a) and Step b) until the condition of front window glass and lock (16) and (17) is satisfactory. Tighten the mounting bolts of the left and right corner plates.
7. After adjustment is finished, flush the front window glass with abundant water and check if any water penetrates into the cab.
司
公
销 营
16
18
ZX215-1006272
8. Adjust the "locked" position of the lock of front window assembly
A. After the "locked" position of the lock of front window assembly is adjusted in Step 6 and Step 7, raise the assembly to the roof.
B. Set the locks of the front window assembly at the rear of the cab at the "locked" position, and check the following items:
19
18
● Check the conditions of left lock (16) and right lock (17). ● The front window assembly must contact the left and right rubber stopper (18), and the rubber stoppers must be pushed backward by 1.5 – 3.0 mm.
ZX215-1006273
● The front window assembly shall push the limit switch 4 – 7mm backward.
Shop Manual - April 2014
8-131
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
C. Close the front window assembly (10). D. Loosen the retaining nut (20) at the left and right side of rubber stopper (18), and pull the two rubber stoppers (18) inward so that they can not contact the "unlocked" front window assembly.
20
18
ZX215-1006274
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-275 E. Adjust the position of latch bolt (21).
Latch bolt(21): M10, Inner diameter of plate (23): ø14.5 mm
21
司
23
公
销 营
ZXT225-1006284
Fig. 8-276
F. Adjustment of left and right rubber stopper (18) a. Allow front window assembly (10) to contact the left and right rubber stopper (18). (when the lock is "unlocked")
10
17
19
21 ZX215-1006276
Fig. 8-277
8-132
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
b. Lock front window assembly (10). c. Turn the left/right rubber stopper (18) to the left by one and a half round. ● Turning the rubber stopper (18) leftward for one round is equivalent to pressing it by 1.5 mm. 18
● When front window assembly is “unlocked”, it must move the left/ right rubber stopper (18) by 1.5 – 3.0 mm.
ZX215-1006278
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-278
d. Tighten the retaining nuts (20) at both sides of the rubber stopper (18).
18
20
司
公
销 营
ZX225-1006287
Fig. 8-279
Shop Manual - April 2014
8-133
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
9. Adjust the front window assembly retainer (24). A. Adjust and lock both sides of the retainer (24) so that surface (d) of stopper (D) of front window assembly contacts surface (c) of retainer (24) when front window assembly is raised.
24 10
D
ZX215-1006279
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-280
24
D d
司
公
销 营
c
ZX215-1006280
Fig. 8-281
10. Check the locking ability of front window assembly.
A. After the adjustment from Step 6 to Step 9 is finished, check the locking force of left lock (16) and right lock (17).
16
17
● Check the locking force at the "locked" side (front of cab) and the "unlocked" side (rear of cab).
ZX215-1006271
Left lower pin:
Fig. 8-282
27 – 34 N·m {2.75 – 3.47 kgf·m} Mounting bolt：adhesive(LT-2)
8-134
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.34 Monitor - Remove and Install 8.34.1 Removal NOTICE
3
● Always disconnect the cable from negative post of the battery before you proceed.
4 5
2 1
In Ma t rk er n et a in ti o g n De al pt .
1. Unscrew the three (3) bolts (4). Remove the mounting plate and the monitor assembly from the bracket (3).
2. Remove the nut (1) and the gasket (2) to separate the monitor (5) from the mounting plate.
ZX335-1006215
Fig. 8-283
8.34.2 Installation
● Installation is to be performed in the reverse order of removal.
司
公
销 营
Shop Manual - April 2014
8-135
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.35 Controller AS 8.35.1 Removal NOTICE
1
● Always disconnect the cable from negative post of the battery before you proceed. 2
1. Remove the back plates (1) and (2).
In Ma t rk er n et a in ti o g n De al pt .
2. Remove the controller wiring connectors (3) and (4).
ZXT335-1006216
3. Remove the two(2) bolts. Remove the controller assembly (5).
Fig. 8-284
2
司
公
销 营
4
3
ZXT335-1006217
Fig. 8-285
8.35.2 Installation
● Installation is to be performed in the reverse order of removal.
8-136
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.36 Radio 8.36.1 Structure
In Ma t rk er n et a in ti o g n De al pt .
1. Main structure
司
公
销 营
ZX335-1006218
Fig. 8-286
Shop Manual - April 2014
8-137
8-138 销 营
司
公
Fig. 8-287
Shop Manual - April 2014 RADIO ANTENNA
BLACK — L. SOUND TRACK OUTPUT –
WHITE — L. SOUND TRACK OUTPUT +
LIGHT — R. SOUND TRACK OUTPUT – BLACK
GRAY — R. SOUND TRACK OUTPUT +
BLACK — GROUND
YELLOW — BATT POWER SUPPLY
RED — ACC IGNITION
WHITE — R. SOUND TRACK INPUT
RED — L. SOUND TRACK INPUT
In Ma t rk er n et a in ti o g n De al pt . AUDIO INPUT
Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator
2. Wiring
BACK PANEL
POWER, GROUND AND AUDIO OUTPUT
ZX335-1006219
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.36.2 Removal and installation Console cover
Removal 1. Remove the console cover (1).
NOTICE ● The power must be turned off before removal.
Radio ZX335-1006220
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-288 2. Remove the radio connector CN-003F.
司
公
销 营
Connector CN-003F
Cab harness
ZX335-1006221
Fig. 8-289
3. Remove the four(4) screws and the washers in order to remove the radio and the radio mounting brackets from the console cover.
Console
4. Remove the four(4) screws and the washers in order to remove the radio from the radio mounting brackets.
Radio bracket
Washer
Radio
Screw ZX335-1006222
Installation
Fig. 8-290
● Installation is to be performed in the reverse order of removal.
Shop Manual - April 2014
8-139
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.36.3 Connector model and wiring
1
5
3
6
7
2
3
20b
R+
L+
0
20b
R-
L-
4
5
6
7
In Ma t rk er n et a in ti o g n De al pt .
4
2
1
Harness socket terminals Model: Deutsch DJ7072-3-21
Radio wiring terminals
Fig. 8-291
司
公
销 营
8-140
Shop Manual - April 2014
ZX335
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.37 Battery 8.37.1 Structure
C
E
In Ma t rk er n et a in ti o g n De al pt .
6
J
10
11
A
B
2
D
I
G
H
F
8
司
公
销 营
7
5
9
4
3
1 ZX335-1006224
Fig. 8-292 (1) (2) (3) (4) (5) (6)
Spinning post Charge densimeter Heat-sealing cover PP casing Central polar ear Forged grid
(7) Paste (active material) (8) "Bag-type" screen (9) Polar group (10) Liquid-gas separator (11) Central busbar
Shop Manual - April 2014
8-141
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.37.2 Removal and installation NOTICE ● Turn the start switch to the OFF position before removal.
Removal
In Ma t rk er n et a in ti o g n De al pt .
● Do not remove the charge densimeter. Tighten the densimeter clockwise, if it is loosened, with a suitable tool.
Bolt
3. Removal of battery grounding wire
● Open the tarpaulin, unscrew the bolt, and remove the terminal from the battery wiring post.
Terminal
Grounding cable
A VART
CAUTION
Battery
● Battery gas can cause explosion. No sparks or flames are allowed near the battery.
MAINTE
NANGE-
TTER FREE BA
Y
司
公
销 营
ZX335-1006225
Fig. 8-293
2. Disconnect the battery wiring cable and the battery breaker cable.
Cable
VARTA
VARTA
Battery
Breaker cable ZX335-1006226
Fig. 8-294
8-142
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
3. Remove the four(4) bolts and washers. Remove the battery assembly from the bottom plate. Remove the battery.
In Ma t rk er n et a in ti o g n De al pt .
VAR TA
VAR TA
Battery
Bolt
Washer
Battery box ZX335-1006227
Fig. 8-295
Installation
● Installation is to be performed in the reverse order of removal.
司
公
销 营
8.37.3 Replacement
There are two 12V batteries with grounding negative (-) posts in the machine. If one battery fails in the 24V system, it must be replaced with one of the same type. Batteries of different types are probably charged at different speeds, which may cause one of them to fail due to overloading.
NOTICE
● Apply Vaseline, when required during installation, to battery terminals to prevent corrosion.
Shop Manual - April 2014
8-143
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.38 Start Switch 8.38.1 Structure 22
20
18
17
15
13
12,11
28
6
10,9,8,7
In Ma t rk er n et a in ti o g n De al pt .
23
25,24
21
1
14
19
16
26
司
公
销 营
5
4,3,2
1 2 3
4 5 6
27
ZX335-1006228
Fig. 8-296 (1) (2) (3) (4) (5) (6) (7)
Housing Key Ring Dial Nut Cylinder Cap
8-144
(8) Shield (9) Pin (10) Spring (11) Disc (12) Spring (13) Plug (14) Rotor
(15) (16) (17) (18) (19) (20) (21)
Cover Spring Ball Spring Contact SPR-B Contact A Seat
Shop Manual - April 2014
(22) (23) (24) (25) (26) (27) (28)
Contact SPR-A Contact B Terminal Bolt O-ring seal Harness AS Washer
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.38.2 Removal 1. Unscrew the setscrew to remove the console cover.
;
0$
7
67$5
/2
&.
2))
21
0,1
Start switch
Console cover
Setscrew ZX335-1006229
Fig. 8-297 2. Remove both setscrews in order to remove the mounting plate and the start switch from the console cover.
Console cover
In Ma t rk er n et a in ti o g n De al pt .
Setscrew
NOTICE
● Disconnect the power supply of the start switch before removal.
司
公
销 营
Mounting plate
Start switch
ZX335-1006230
Fig. 8-298
3. Remove the nut so as to remove the start switch from its mounting plate.
Start switch
Mounting plate
Nut ZX335-1006231
Fig. 8-299 Shop Manual - April 2014
8-145
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.38.3 Working principle
On/off status Gear position
Battery (B)
Battery relay (BR)
Preheat plug
Accessory (ACC)
(R1)
(R2)
Start relay (C)
3B OFF 1B 2B ZX335-1006232
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-300
8.38.4 Wiring
1
B
BR
ACC
3
1
22
13
3
4
16
11
6
司
公
销 营
4
R1
R2
C
6
Start switch wiring terminal Jacket model: Yazaki 7222-7464-30
Fig. 8-301
8-146
Shop Manual - April 2014
Harness plug terminal Jacket model: Yazaki: 7123-7464-30
ZX335-1006233
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.39 Fuse Box Removal Cover
1. Remove the cover.
In Ma t rk er n et a in ti o g n De al pt .
ZX335-1006234
Fig. 8-302
2. Remove the bolts and take off the back cover along with the fuse box.
Back cover
Fuse box cover
司
公
销 营
Bolt
ZX335-1006235
Fig. 8-303
3. Remove the bolts so as to separate the fuse box and harness from the back cover.
Harness
Bolts
Back cover
ZX335-1006236
Fig. 8-304
Shop Manual - April 2014
8-147
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.40 Wiper 8.40.1 Structure
Wiper blade
In Ma t rk er n et a in ti o g n De al pt .
Driving mechanism
Wiper arm
Wiper motor
Connector
司
公
销 营
Mounting bracket
ZX335-1006237
Fig. 8-305
8-148
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.40.2 Working principle
Green (low speed) Yellow (reset)
M Blue (high speed)
In Ma t rk er n et a in ti o g n De al pt .
Red (power +)
Black (power -)
司
公
销 营
ZX335-1006238
Fig. 8-306
Shop Manual - April 2014
8-149
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.40.3 Removal 1. Remove the decorative button in order to remove the interior decoration.
Decorative button
Interior decoration
ZX335-1006239
Fig. 8-307
In Ma t rk er n et a in ti o g n De al pt .
2. Remove the moving mechanism and the motor.
● Unscrew the bolts to remove the wiper motor and moving mechanism from the cab.
Bolt
Moving mechanism
Wiper motor
司
公
销 营
Bolt
ZX335-1006240
Fig. 8-308
3. Remove the arm and the blade.
● Unscrew the nut to remove the wiper arm and blade from the cab.
Arm bracket
8.40.4 Installation ● Installation is to be performed in the reverse order of removal.
Guard Locknut
Cab
Fig. 8-309 8-150
Shop Manual - April 2014
ZX335-1006241
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.40.5 Angle adjustment of wiper arm ● The arm should stops moving when the blade reaches the stopper.
Mechanical stopper
● If the arm is still working when the blade reaches the stopper or the arm already stops working before the blade reaches the stopper, the moving angle of wiper should be adjusted to prevent breakdown of the wiper.
Wiper blade
Arm
In Ma t rk er n et a in ti o g n De al pt .
● Adjust the wiper in such a way. Loosen the locknut; adjust the arm working angle according to actual condition. Make sure that the wiper motor stops working at the moment that the blade reaches the mechanical stopper.
Locknut
司
公
销 营
ZX335-1006242
Fig. 8-310
Shop Manual - April 2014
8-151
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.41 Relays
S
8.41.1 Engine relays 1. Starter relay - check
B
● Check the conduction and action. Replace the relay in case of any failure.
AA2A
S B
SW
1 SW(-) L(-) 2
L
ZX335-1006243
Fig. 8-311
In Ma t rk er n et a in ti o g n De al pt .
2. Mains relay - check
1(+)
● Check the conduction and action. Replace the relay in case of any failure.
2(-)
3
4
Battery terminal (+)
司
公
销 营
3
4
1(+) 2(-)
ZX335-1006244
Fig. 8-312
3. Heater relay
5(-)
● Check the conduction and action. Replace the relay in case of any failure.
1
4. Safety relay
5 (-)
● Measure the resistance between terminal 2 and terminal 3. Standard Value
Approx. 200W
● Check the conduction and action. Replace the relay in case of any failure.
8-152
Fuse
2
1
2 3 4 (+)
4(+) 3 ZX335-1006245
Fig. 8-313
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.41.2 Other relays Function and location
Relay harness Horn relay
Start control relay Pilot cotnrol relay
In Ma t rk er n et a in ti o g n De al pt .
Headlight relay
司
公
销 营
Parking relay
Work lamp relay
Mounting plate
ZX335-1006246
Fig. 8-314
Shop Manual - April 2014
8-153
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.41.3 Removal and installation
Relay harness
Mounting plate
Removal 1. Remove relay from its seat. 2. Remove the screw in order to remove the relay seat and harness from the mounting plate. Installation ● Installation is to be performed in the reverse order of removal. Setscrew
In Ma t rk er n et a in ti o g n De al pt . Relay seat
Relay
ZX335-1006247
Fig. 8-315
8.41.4 Relay connector and wiring
5
4
1
2
司
公
销 营
3
Relay wiring terminal
Relay model：HELLA 4RD 007 903-027
Headlight K2
Sart switch K3
77 ③ ① 74
④
⑤ 73
27 ③
11 ③
②
0
②
①
620
④ 105
27
⑤
④ 105 606
②
①
31
⑤
11a
④
Shutdown delay K8
21 ③
34 ③
32 ③
②
①
Work lamp K6
Horn K5
Pilot valve K4
0
②
①
33
④
0
①
621 ④
⑤
⑤
⑤
23
24
15a
② 0
Relay socket Jacket 8JA003526-00
Wiring socket terminal Relay socket model: Jacket 8JA003526-00
Fig. 8-316 8-154
Shop Manual - April 2014
ZX335-1006248
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.42 Sensors 1. Water temperature sensor - check 1
● Put the sensor into a vessel containing engine oil. ● Heat the oil to the specified temperature. Stir the oil at the same time.
Sensor body
● Measure the resistance value between the terminal 1 and the sensor body at different temperatures. 80±10Ω
60℃
56.3Ω(ref.)
80℃
29.5Ω(ref.)
100℃
16.5Ω(ref.)
ZX335-1006249
In Ma t rk er n et a in ti o g n De al pt .
50±0.2℃
Standard Value
Fig. 8-317
106±0.3℃ 14.3±1.0Ω 120℃
10Ω(ref.)
● Replace the sensor if the measured value exceeds the standard one.
司
公
销 营
2. Engine speed sensor - check
● Measure the resistance between terminal 1 and terminal 2. Std. Value(25℃ )
2.3±0.2kΩ
● Replace the sensor if the measured value exceeds the standard one.
2
NOTICE
1
ZX335-1006250
Fig. 8-318
● Insufficient tightening of the engine speed sensor may cause signal output failure. Tighten the sensor to specified torque.
Shop Manual - April 2014
8-155
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
3. Pressure sensor - check Pressure joint
● Input volt: 4.75~5.25 VDC
Body
Connector
● Output volt: 0.5~4.5 V ● Pressure range: 0~50 BAR Terminal B Terminal A
Terminal C
W365813081
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-319 4. Fuel level sensor - check
● Swing the float up and down in order to measure the effective angle of radial swing, i.e. the line through the float and the turning point will swing 105° . ● Swing the float up and down. The vertical distance between the upper limit and the lower limit of the float should be 500 mm.
Float
司
Lever
公
销 营
● Move the float to its upper limit. Measure the resistance between the sensor terminal R and ground with a multimeter. The measured resistance should be Ru ≦ 9.6Ω.
Terminal R
Shell
● Move the float to its lower limit. Measure the resistance between the sensor terminal R and ground with a multimeter. The measured resistance should be Rd ≧ 86Ω.
Connector
ZX335-1006252
Fig. 8-320
8-156
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.43 Connector Terminals 8.43.1 Insertion
In Ma t rk er n et a in ti o g n De al pt .
1. Hold tightly a wire terminal at a distance of about 25 mm from its end.
ZX215-1006320
Fig. 8-321
2. Hold the connector. Let the rear seal face you.
司
公
销 营
ZX215-1006321
Fig. 8-322
3. Align the terminal with a hole on the seal and push it perpendicularly to the bottom. Slightly pull back the wire in order to ensure that the terminal is locked in place.
ZX215-1006322
Fig. 8-323
Shop Manual - April 2014
8-157
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.43.2 Removal 1. Hold the connector, with its back end facing you. Select a suitable tool and clip on the wire.
In Ma t rk er n et a in ti o g n De al pt .
ZX215-1006323
Fig. 8-324
2. Push the tool along the wire into the connector so that the tool can expand the terminal lock shoulder and reach its flanged part.
司
公
销 营
ZX215-1006324
Fig. 8-325
3. Pull out the tool to remove the wire with terminal.
ZX215-1006325
Fig. 8-326
8-158
Shop Manual - April 2014
Disassembly and Assembly
BLMaInt e r AkNe rn a tKi t i ng o PAD nal eGp tE.
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
Shop Manual - April 2014
8-159
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
System Schematics 9 System Schematics 9.1 9.2 9.3 9.4 9.5 9.6
Diagram of Hydraulic Lines...................................................................................... 9-3 Electrical diagram of chassis ................................................................................... 9-4 Electrical diagram of control switches...................................................................... 9-5 Electrical diagram of operator station ...................................................................... 9-6 Electrical diagram of air conditioner......................................................................... 9-7 Electrical diagram of monitor ................................................................................... 9-8 司
公
销 营
Shop Manual - April 2014
9-1
System Schematics
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
9-2
Shop Manual - April 2014
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
Swing
9.1 Diagram of Hydraulic Lines
Arm
Bucket
Boom
Left travel
Right travel
SH D
D
PG MB
MA
VA
(4) Right swing To XBs
IN
(10)Arm in
g
(3)Arm out To XAa1 lower
To XBa1 XBa2 PaL Arm hold valve
To XBc
XBb2 PbL Boom hold valve
Arm 1
Backward (2)Right travel
XAa1
Backup
LCAP2
ARC
Pna1
LCa
XBo
司
公
销
Boom 2
4 T P
Swing
na Right travel
To XAtL upper
io
XAc XBc Drb PbL Ab (HEAD) Bb (ROD)
XBb2
XBb1 LCb
Lcb2
Bs As XAs Xbs Dr4 Pns Px Btr Atr XAtr
XAtL XBtL
LCs CT2
CP2
Φ0.7
PH
CMR1
CMR2
Φ0.7 R3
PG
Pz
MR
P1 rear pump
T PH1
A1
a2
a1
A2
PH2 Psv2
(COOLER)
P1
A1 2nd bost
Travel speed change
A2
A3
Front pump adjuster
A4
PPC lock valve
A6
A5
2.5bar
cc
A7
电液控转换
bb 变功率调节
C
Pf
Rear pump adjuster
电液比例阀
A8
4.5bar
Pf
dd Pi1
负压调节
P1
Engine
FRONT
P2
B
Pi2 A4
A
REAR As
DR
10μm
In
te
rn
at
P2 front pump
Left travel
(PTa)
(PTb) CT1
Φ0.7
Boom 1
CpG
XBtr
Py
Bucket
XAb1 AtL BtL
cp1
Psv1
10μm
Forward 2
Left travel
PAcs
BbR
Dr2
l
1
To XBtL lower
Bc(HEAD)
HVb
Ccb
XAb2
Backward (1)Left travel
Ac(ROD)
LCk
LCo
Arm 2
AcR
XAo
营
To XAtr upper
XAa2
BcR
BoR
AoR
AbR
Forward
XBa2
LCAT2
(Bo) (Ao)
To XBtr lower
Ba2(HEAD)
BaR
Dr3
PAcs
Dr1
CCk
P2
4 3
XAb1 lower DOWN (7)Boom up ToXAb2
CC0
AaR
B1
B3
A3
10μm
2
3
T P
UP
(6)Boom down To XBb1 upper
XBp2
HVa
Aa (ROD) Ba1 (HEAD) XBa1
(9)Bucket dump To XAc lower
rk e
XBp2
DIG
Central swivel joint
N2 N1 XBp1
Dra PaL
Ma
(5)Bucket dig DUMP
Right travel
(R4) (P4)
R1 R2
Bucket
Boom
P4
RS2
RS1
ti n
XAa2
1
Arm
OUT
2
P
4
3
T
VB
1
De
A
B
To XAs
(8) Left swing
Swing
VA
pt
PA
PB
Transitional block
MA
MB
REG
VB
.
P
P
DB
M
GER
80~150目
WX365-1309001
9-3
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
9.2 Electrical diagram of chassis
CN-501M
To cab harness CN-506M
CN-502F
CN-506F
5
103
509
0
508
F-300
106
510
1
0 15 20 21
2
42
66
T-501 To power supply T-500 grounding wire
CN-113M
T-101
511
pt
12
T-100
200 201 202
204 205 206
T-107
21 16
208
g
17
602
606 607 608 609
502 702 703 511 108A
22 64 63 0 65
108B
To preheat resistance To rpm sensor CN-125F
50A 1 507 2 MT- 3 4 00 5 MT+ 6
rk e
501
T-107
108A 108B
ti n
603
To compressor clutch
T-134 To preheat fuse T-109
207
1 2 3 4 5 6
To throttle motor CN-124F
To parking motor CN-801F
609 1
司
公
营
106 510
销
0 606
2
CN-137F
1
To pilot SV
508 0 S 66 103 509 704
608
0
0 702 0 602 0
34
32
0#
1
1
B
1
2
CN-102M
F-104 F-103
To work lamp
To horn C
2
CN-507M
1
2
CN-503F
D
0
0 00
502
50
A B C
00 501
A B C
50
00
200
A B C
50
00
201
A B C
50
00
202
50
00
208
50
00
205
50
00
207
50
00
206
A B C
A B C
A B C
A B C
A B C
CN-122M
CN-123M
CN-124M
CN-125M
CN-126M
50
00
204
A B C
50
00
21 1
2
CN-504F
12 1
20
CN-116F
2
R. pump main pressure sensor
CN-115F
F. pump main pressure sensor
CN-133F
2 1 2
CN-120M
Left travel pressure sensor
CN-121M
Right travel pressure sensor
Arm OUT pressure sensor
Bucket DIG pressure sensor
Swing pressure sensor
Boom DOWN pressure sensor
Boom UP pressure sensor
CN-128M
Bucket DUMP pressure sensor
To R. pump SV CN-134F
To F. pump SV CN-132F
1 2
2
CN-138F
Hi/Lo travel SV CN-131F
1 2
CN-135F
203 704
A B C
1
Power limit SV 0
16 17
2
607 1
603
50
CN-136F
1
1
rn 0
In
te
2
2
703
at
3
A
T-102 T-101 To battery T-104 relay KB T-120
57
De
203
io
4
21
F-301
CN-101F
Ma
17 18 19 20 21 22 23 24 25 26 27 28 29 30 32
6
60
T-102 T-135 CN-103M
Oil press High-temp Low-temp Hydraulic oil switch Temp sensor switch switch temp sensor
l
7
14
Air plugging Fuel level Start motor switch sensor
na
8
21
0
42 34 60 14 15 32
22 65 50A 64 63 MT- MT+ 507 50 00 57
1 2 3 4 5 6 7 8 9 10 11 13 14 15 16
T-103 T-116 CN-800F
345678
2 3 4 5 6 7 8 9 10 11 12
To cab harness CN-501F
Alternator terminals
.
To cab harness CN-502M
9
CN-129M
2
CN-114F
Arm IN pressure sensor
CN-505M
E
F
G
H
I
J
K
L
M
N
9-4
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
9.3 Electrical diagram of control switches
9
22
13
62
61
33
3
5
CN-507F
CN-505F
7
1
24
35H
3
5
25 35L
7
1
36
3
37
5
7
25
108B 506 50 61
De
8
1
.
TERMINAL B BR ACC R1 R2 C HEAT OFF ON START
Washer switch
Wiper switch
CN-503F
pt
Wrok lamp switch
Start switch
11
62
g 14
1
5
506
00
2
74
3
73 74
1
司
5
F-507
F-505
F-508
F-509
25 33
7
5
35L 60
6
1
A
10A
Charging indicator
F3
5A
Horn loop
F4
15A
work lamp
F5
5A
wiper & washer
F6
10A
Radio
F7
10A
Cab lamp
F8
20A
Air conditioner
5A
Access lamp
5A
Monitor
F11
20A
Controller
F12
15A
Head lamp
F13
10A
F14
10A
F15
15A
F1
22
7 8 9 10 11 12 CN-203M
20
13
F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 14 23 24 25 20b 26 38 28 29 42 73 43 27 100
13
1
14
2
29 42 20 20 21
3
21
4 5 6 7 8 CN-222F
To cab harness CN-122M
te
F9 F10
B
l
na
F2
io
Start loop
4
To cab harness CN-203F
rn
20A
2
24
27 28
In
3
20
System
Rated value
F1
at
Fuse No.
22
21
Fuse box harness
2
37
13 14
Head lamp switch
1 3
11
CN-508F
4
11 12
35H 36
销
CN-501F
To fuel control dial
9 10
CN-202F
73
3
5
To cab harness CN-202M
公
营
4
8
ti n 69
Ma
50 14
60
3
7
rk e
6
2
6
69 7
1
38 73 22 100 43 20b 23 24
1 2 3 4 5 6 7 8
Aux. controller
9
25
26
10 11 12 CN-221M
Solenoid valve GP Cigarette lighter
C
D
To cab harness CN-121F E
F
G
H
I
J
K
L
M
N
9-5
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
9.4 Electrical diagram of operator station To chassis harness CN-502F
To control switch harness CN-202F
4
36
5
37
6 7
35L
8 10
14
11 12
7
6
4
To chassis harness CN-506F
4
108 B 506 50A
5
6
61 62
0
2
10 11 12 69 73 74
3
4
5
6
7
8 9
1
50 00 57
65 50A 63 64 MT- MT+ 507
22
10 11 12 2
1
3 45
2
0
74
1
3 45
77
1
73
0 11a
14
1
68
60
2
2
14
15 32
66 61 68
1
To alternator
To safety relay
2
3
0
4
69
0
1
A
2
0
1
3 45
1
606 31
27
64
2
3
4
65
2
3 4 5
2
3 4 5
0 32
23
1
2
3 45
1
33
2
3 45
0 34
24
1
2
1
621
2
0
2
3 45
13
3 45
21 15a
CN-201F To horn button
1
15
2
15a 15
1 2
37
2
0#
203
105
0# 20b
R+ L+ 20b
5
2
3
0# R-
4
5
25
7
35H
CN-112M C 0-S
B
C
B
To wiper harness
CAN-
A
CN-115 CAN+
销
57
1
207
60a
l
61a
208
42
42
1
607
2
0
0
3
0-S CAN-CAN+
703 208 502
38
702
702 501 201
23
00
00 206 207
28 29 30 31
7
8
205 00 50 00
9
511 202
00
0
200
510 204
10 11 12 19 21 22 23 30 32 33
203
38
108 A 108 B 106 510
27
28
1
2
38 73 22 100 43 20 b 23
3
103
4
5
6
7
8 9
24
25
26
26
8 CN-140M
0#
7 77
Access lamp
B
C
D
42 20
2
4
20
5
6
21
7
21
42
8
43
1
CN-122M CN-505M
To fuse box harness CN-222M F
G
100 11 13 607 MT- MT+
2
3
4
5
6
7
0
8 9
0#
620 621
10 11 12
103
1
106 506 507 508 509 50A 704 60a 61a
2
3
4
5
6
7
8 9
10
To cab radio harness
2 1
108 A 108 B
1
2
CN-114F
20 12 1 2
E
3
R+
14
CN-150M
4
L+
1
To fuse box harness CN-221M
5
L-
CN-121F
704
6
0#
R-
13
10 11 12
To A/C panel
8
34 35
rn
703 511
CN-207F
7
at
502
5
0#
CN-141M
501
4
6
00
8 10 11 12 17 18 19 20 22
io
606
28 29 30 32
4
CAN- CAN+
206
66
CN-110M
司
204
508
3
35 L 5
120Ω
A
To pilot switch
2
36 CN-003F To radio control panel
CN-106F
2
1
L-
6
1
公
营
205
26
1
0
1
Ma
202
te
2
1
3 45
To parking relay CN-180M
201
In
17 18 19 20 21 22 23 24 25
To chassis harness CN-501F
2
27
62 63
1
5 6
200
CN-501F 3
11a
14
1
3
4
13 14
1
3 45
11
60
na
5
3 45
2
105
620
CN-181M To preheat relay
1 2 3 4 5 6 7 8 9
2
1
23
To washer motor
34
6 7 8
3
24
42
5
2
22
3 CN-506M
1
11 13
Shutdown delay relay
31
60
9
Work lamp relay
Horn relay
.
35H
Pilot valve relay
pt
3
Start control relay
De
To control switch harness CN-203M
33
Head lamp relay
CN-502M
g
CN-203F 8
2
CN-202M
ti n
9
25
rk e
1
CN-113F
CN-111M
To monitor harness CN-7-113M To start motor H
I
To monitor harness CN-7-111M
J
K
L
To monitor harness CN-7-114M
M
N
9-6
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
9.5 Electrical diagram of air conditioner Control panel
CN-M29
pt
.
0.5GO
0.5BrY 0.5LO 0.5VR 0.5PB 0.5YB 0.5VW 0.5WY 0.5WR 0.5Sb 0.5BR 0.5B
0.5GW 0.5PG 0.5BY 0.5RW 0.5RY
0.5R
0.5BL 0.5BrW 0.5OW
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
0.5WO 0.5BG 0.5BW 0.5LgR
CN-M30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
ACM 9
De
0.5B 0.5GO
0.5Sb 0.5BR
1 2 3 4 5 6 7 8
CN-M27
g
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
ti n
0.5B 0.5GO
0.5Sb 0.5BR
0.5WY 0.5WR
0.5YB 0.5VW
0.5LO
0.5VR 0.5PB
0.5BrY
0.5RW 0.5RY
0.5PG 0.5BY
0.5OW 0.5GW
0.5R
0.5BL 0.5BrW
0.5WO 0.5BG 0.5BW 0.5LgR
7
Diffuser conversion servo motor FOOT FACE(DEF) Pt GND
THI
2 1
2 1
0.5BW
0.5WY 0.5WR 0.5BrW
Ma
S S
0.5BR
050 CN-P15
0.5GO 0.5Sb 0.5OW
0.5BR 0.5GW
1 2
7 6 5 4 3 2 1
1 2
CN-M34
7 6 5 4 3 2 1
rk e
6
2
MV
Internal temp sensor
Vz
1 2 3 4 5 6 7 8 9 10 11 12
SWP CN-M33
SWP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12
SWP CN-M28
0.5WY 0.5WR
0.5YB 0.5VW
0.5LO
0.5VR 0.5PB
0.5BrY
0.5RW 0.5RY
0.5PG 0.5BY
0.5OW 0.5GW
0.5BL 0.5BrW
0.5R
0.5WO 0.5BG 0.5BW 0.5LgR
8
5
司
公
营
M
S CN-M26
rn In
1
A
B
C
D
0.5BW
3
0.5BR
2 1
1 2
1 2
GND
FRE REC Pt Vz
Diffuser conversion servo motor MV
I
Fresh air/recirculation conversion sero motor
GND
Mcool Mhot Pt
A/M servo motor
Vz GND MA
M
Low-temp sensor
0.5BY 0.5BR
0.5B
0.5lgR
C
R LB
Compressor cltch relay
2 1
TRANSACTION OF INPUT SIGNEL
VOLTAGE CORRECTION
MB
M
Blower relay
F
2 1
2 1 RL
2 1
PROTECTION FOR TEMP. DRIVING CIRCUIT
E
7 6 5 4
Vz
1.25RL 3 3
0.5BL 2
2 1 2 1
2
3 4 2 1 3 4 2 1
2G 2RL
2Br 2RL 0.5LO 0.5R
3 4 2 1 3 4 2 1
2B
1.25RL
1.25RL 72C 40C 1.25G
RL R L C
2 1
FACE FOOT Pt
THF
0.85W 2Br 0.5BrY 0.5R
te
2
3
7 6 5 4 3 2 1
7 6 5 4 3 2 1
0.5BR 0.5PG
2G
24V
5A
4
0.5RY 0.5BR
1
2 1
4
3 3
2 1
1
TO CN-P15-2 TO CN-A30-1
7 6 5 4
7 6 5 4 3 2 1
1.25G
20A TO CN-M26-2 TO CN-M26-1
2 1
0.5PB 0.5VR 0.5BG
2G
TO CN-P15-1 TO CN-A30-2
TO CN-M26-7 TO CN-M26-7
0.85W 2B 0.5BW 0.5RW 2Br 1.25R
0.5BR
0.5BR
at
TO CN-E06-1
TO CN-M26-A 3
12 12 11 11 10 10 9 9 8 8 7 7 6 6 5 5 4 4
3
0.5BW
io
CN-E06
1
1
ECC EC
0.5BW
0.5YB 0.5VW 0.5WO
na
TH A
4
2 1
2RL
2 1
l
CN-A30
销
7 6 5 4
G
Blower motor
THW
SPH L
BLC
Coolant temp sensor
Hi/Lo pressure switch
H
I
J
K
L
M
N
9-7
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
9.6 Electrical diagram of monitor
.
9
CN-7-707M
pt
Sunlight sensor
Cigar lighter
CN-7-706M
8
1
2
100
0#
60a
2
De
1
61a
7
g
CN-7-113M CN-142M
GND
6
CAN bus low RPM sensor signal Coolant temp high switch Eng oil press sw input RPM sensor GND Oil level sensor signal Fuel control dial signal Start control signal Hi/Lo travel speed ctrl sgnl
5 24 V power supply 5V power output
GND Motor driving signal + Motor driving signal -
4
Shutdown delay control
507
704 0 CAN108A
42
106 508 108B 509 506 620 607
1
43
2
100
3
11
4
13
5
607
6
MT-
7
MT+ 0
8 9
0#
10
620
11
621
12
司
公
营
43 50 A
销
0 MT+ MT621 CAN+
CN-7-111F
To cab harness CN-111M 103 106
io
CAN bus high
ti n
Pwr lmt vlv ctrl sgnl
42
rk e
thrttl mtr position fdbck sgnl
13 103
Ma
Air block sw sgnl input
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
To cab harness CN-113F
l
24V power supply
11
na
Start signal Power-on signal
507 508
rn
at
3
506
108A 108B A
S
C
te
2
B
CAN+ CANA
B
1 2 3 4 5
509
6
50 A
7
704
8
60 a
9
61 a
10
0-S C
CN-7-114M
CN-7-112F
To cab harness CN-114F
In
To cab harness CN-112M
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
9-8
Quality Changes the World
Crawler Hydraulic Excavator Shop Manual SY365(B)H-9
Crawler Hydraulic Excavator
SY365H-9 SY365BH-9
SANY HEAVY MACHINERY LIMITED 318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P.R. of China 201413
Tel: (86) 21 5700 8518 Service hotline: (86) 4006 098 318 E-mail: [email protected] Documentation No.: B06T03ENAN1-SY365(B)H-9
Shop Manual
SY365(B)H-9 Crawler Hydraulic Excavator
SY365(B)H-9 Crawler Hydraulic Excavator Shop Manual
WARNING ● Read and follow the safety precautions and instructions in this manual and on the machine decals. Failure to do can cause serious injury, death or property damage. Keep this manual with the machine for reading and future reference. Shop Manual - April 2014
SY365(B)H-9 Crawler Hydraulic Excavator
Sany Group Sany Heavy Machinery Limited 318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P. R. of China 201413 http://www.sanygroup.com Tel: 0086-21-57008518 Fax: 0086-21-58596210 Service hotline: 0086-21-58592902 Complaint hotline: 0086-21-58590631 E-mail: [email protected]
© 2012 by Sany Group. All right reserved. No part of this publication may be reproduced, used, distributed or disclosed except during normal operation of the machine as described herein. All information included within this publication was accurate at the time of publication. Product improvements ,revisions, etc., may result in differences between your machine and what is presented here. Sany Group assumes no liability. For more information, Contact Sany Group. Shop Manual - April 2014
Table of Contents
SY365(B)H-9 Crawler Hydraulic Excavator
Table of Contents 1 Introduction 1.1 How to Read the Manual ......................................................................................... 1-3 1.1.1 Shop manual organization ............................................................................. 1-3 1.1.2 Revision and distribution ................................................................................ 1-4 1.1.3 Symbols ......................................................................................................... 1-5 1.1.4 Units ............................................................................................................... 1-5 1.2 Technical Terms ....................................................................................................... 1-6 1.2.1 Standard size and tolerance .......................................................................... 1-6 1.2.2 Standard clearance and value ....................................................................... 1-7 1.2.3 Standard interference .................................................................................... 1-7 1.2.4 Repair limit and allowable value .................................................................... 1-8 1.2.5 Clearance limit ............................................................................................... 1-8 1.2.6 Interference limit ............................................................................................ 1-8 1.3 Handling Electrical and Hydraulic Components....................................................... 1-9 1.3.1 Points to remember when handling electric components .............................. 1-9 1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9 1.3.1.2 Main failures occurring in wiring harness ............................................ 1-10 1.3.1.3 Removing, installing, and drying connectors and wiring harnesses ... 1-12 1.3.1.4 Handling the integrated control monitor .............................................. 1-16 1.3.1.5 Electric circuits troubleshooting precautions ....................................... 1-17 1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18 1.3.2.1 Be careful of the operating environment ............................................. 1-18 1.3.2.2 Disassembly and maintenance work in the field ................................. 1-18 1.3.2.3 Sealing openings ................................................................................ 1-18 1.3.2.4 Do not let any dirt or dust get in during refilling operations ................. 1-19 1.3.2.5 Change hydraulic oil when the temperature is high ............................ 1-19 1.3.2.6 Flushing operations............................................................................. 1-19 1.3.2.7 Cleaning operations ............................................................................ 1-20 1.4 Hose Connector ..................................................................................................... 1-20 1.4.1 Type of hose connector................................................................................ 1-21 1.4.2 Hose connector tightening torque table ....................................................... 1-21 1.4.3 Connection of O-rings .................................................................................. 1-22 1.5 Table of Standard Tightening Torques .................................................................. 1-23 Shop Manual - April 2014
I
Table of Contents
SY365(B)H-9 Crawler Hydraulic Excavator
1.6 Type of Bolts .......................................................................................................... 1-24 1.7 Tightening Sequence ............................................................................................. 1-24 1.8 Maintenance of Half Flanges ................................................................................. 1-25 1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25 1.8.2 Temperature ................................................................................................. 1-31
2 Shop Safety 2.1 Hazard Alert Information .......................................................................................... 2-3 2.2 General Shop Safety ............................................................................................... 2-5 2.2.1 Rules and shop behavior ............................................................................... 2-6 2.2.2 Housekeeping ................................................................................................ 2-6 2.2.3 Shop Liquids Storage..................................................................................... 2-7 2.2.4 Cleaning the Parts ......................................................................................... 2-7 2.2.5 Cleaning the Machine .................................................................................... 2-8 2.2.6 Appropriate Working Apparel ......................................................................... 2-8 2.2.7 Personal Protective Equipment...................................................................... 2-8 2.2.8 Using the Correct Tools.................................................................................. 2-9 2.2.9 Fire Extinguisher and Emergency Exits ......................................................... 2-9 2.2.10 Electrical Dangers ...................................................................................... 2-10 2.2.11 Hoisting a Load .......................................................................................... 2-10 2.3 Before Repair..........................................................................................................2-11 2.3.1 Safe Work Preparations ................................................................................2-11 2.3.2 Preparing yourself ........................................................................................ 2-12 2.3.3 Lockout/Tagout............................................................................................. 2-13 2.3.4 Two people when engine running ................................................................ 2-15 2.3.5 Safety Partners ............................................................................................ 2-15 2.4 Repair Precautions ................................................................................................ 2-16 2.4.1 Running the Machine ................................................................................... 2-16 2.4.2 Mounting and Dismounting .......................................................................... 2-17 2.4.3 Removing Attachments ................................................................................ 2-18 2.4.4 Jacking Up the Machine............................................................................... 2-18 2.4.5 Adding Fluids to a System ........................................................................... 2-18 2.4.6 Aligning Parts or Components ..................................................................... 2-19 2.4.7 Driving Pins .................................................................................................. 2-19 2.4.8 When compressed air is used...................................................................... 2-19 2.4.9 Welding operation ........................................................................................ 2-20 II
Shop Manual - April 2014
Table of Contents
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.10 Track Recoil Springs .................................................................................. 2-20 2.4.11 High-Pressure Fluid Lines .......................................................................... 2-21 2.4.12 Air-conditioning system maintenance ........................................................ 2-22 2.4.13 High voltage precautions ........................................................................... 2-22 2.4.14 Disconnecting the System Power .............................................................. 2-23 2.4.15 Accumulator ............................................................................................... 2-23 2.4.17 Battery Hazards ......................................................................................... 2-24 2.4.18 Jump-Start Safety ...................................................................................... 2-25 2.4.19 Avoiding fire and explosion ........................................................................ 2-26 2.4.20 Chemical hazard ........................................................................................ 2-27 2.4.21 Material Safety Data Sheets (MSDS) ........................................................ 2-27 2.4.22 Proper disposal of wastes .......................................................................... 2-28 2.5 Other Precautions .................................................................................................. 2-29 2.5.1 Sling work and giving signals ....................................................................... 2-29 2.5.2 Using mobile crane ...................................................................................... 2-31 2.5.3 Using overhead hoist crane ......................................................................... 2-31 2.5.4 Selecting wire ropes..................................................................................... 2-33
3 Specifications 3.1 Specific Dimension .................................................................................................. 1-3 3.1.1 Dimension ...................................................................................................... 1-3 3.1.2 Working ranges .............................................................................................. 1-4 3.2 Technical Specifications........................................................................................... 1-5 3.3 Weight Table ............................................................................................................ 1-7 3.4 Engine oil, Fuel and Coolant.................................................................................... 1-8 3.5 Engine Performance Curves.................................................................................... 1-9
4 Structure and Functions 4.1 Engine and Cooling System ................................................................................... 4-5 4.1.1 Engine-related parts....................................................................................... 4-5 4.1.2 Radiator and intercooler................................................................................. 4-6 4.2 Power Train.............................................................................................................. 4-7 4.2.1 Overview ........................................................................................................ 4-7 4.2.2 Travel reducer AS ......................................................................................... 4-8 4.2.3 Swing reducer mechanism........................................................................... 4-10 4.2.4 Swing bearing .............................................................................................. 4-12 Shop Manual - April 2014
III
Table of Contents
SY365(B)H-9 Crawler Hydraulic Excavator
4.3 Undercarriage Travel System ............................................................................... 4-14 4.3.1 Track frame and tensioning mechanism ...................................................... 4-14 4.3.2 Idler .............................................................................................................. 4-16 4.3.3 Carrier roller ................................................................................................. 4-18 4.3.4 Track roller ................................................................................................... 4-19 4.3.5 Track ........................................................................................................... 4-20 4.3.6 Tri-grouser track shoe .................................................................................. 4-23 4.4 Hydraulic System, Part 1 ....................................................................................... 4-24 4.4.1 Deployment of hydraulic parts ..................................................................... 4-24 4.4.2 Hydraulic tank and filter ............................................................................... 4-26 4.4.3 Hydraulic pump ............................................................................................ 4-28 4.4.3.1 Outline................................................................................................. 4-29 4.4.3.2 Function .............................................................................................. 4-31 4.4.3.3 Structure ............................................................................................. 4-31 4.4.3.4 Operating principle .............................................................................. 4-32 4.4.3.5 Oil delivery control .............................................................................. 4-33 4.4.4 Pilot pump .................................................................................................... 4-34 4.4.5 Regulator .................................................................................................... 4-35 4.5 Hydraulic system, Part 2 ........................................................................................ 4-48 4.5.1 Main control valve ........................................................................................ 4-48 4.5.1.1 Overview ............................................................................................ 4-48 4.5.1.2 Main valve structure ............................................................................ 4-50 4.5.2 Hydraulic circuit (With bucket confluence function) .............................................. 4-56 4.6 Hydraulic System, Part 3 ....................................................................................... 4-79 4.6.1 Swing motor ................................................................................................. 4-79 4.6.2 Swing holding brake..................................................................................... 4-81 4.6.3 Relief valve section ...................................................................................... 4-82 4.6.4 Anti-jerk valve............................................................................................... 4-84 4.6.4.1 Operation diagram .............................................................................. 4-84 4.6.4.2 Effect illustration.................................................................................. 4-84 4.6.5 Central Swivel Joint ..................................................................................... 4-86 4.6.6 Travel motor ................................................................................................. 4-87 4.6.7 Reducer ....................................................................................................... 4-89 4.6.8 Travel motor (Nabtesco) .............................................................................. 4-91 4.6.9 Operating principle of the basic components ............................................... 4-93 4.6.9.1 Double-balanced valve ....................................................................... 4-93 IV
Shop Manual - April 2014
Table of Contents
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.9.2 Operation of parking brake ................................................................. 4-98 4.6.9.3 Operation of braking valve .................................................................. 4-99 4.6.10 Control system ......................................................................................... 4-108 4.6.11 Manual pilot valve .....................................................................................4-110 4.6.12 Travel pilot valve .......................................................................................4-114 4.6.12.1 Operating principle ...........................................................................4-116 4.6.13 Solenoid valve...........................................................................................4-118 4.6.14 PPC accumulator ......................................................................................4-119 4.6.15 Pilot oil filter.............................................................................................. 4-121 4.6.16 Hydraulic cylinders ................................................................................... 4-122 4.6.16.2 Lubrication at every 100 service hours ........................................... 4-123 4.6.16.1 Lubrication at every 500 service hours ........................................... 4-123 4.7 Work Equipment .................................................................................................. 4-124 4.7.1 Component dimensions ............................................................................. 4-124 4.7.2 Arm dimensions ......................................................................................... 4-126 4.7.2.1 Bucket dimensions ............................................................................ 4-128 4.8 Operator Station and Its Attachments .................................................................. 4-130 4.8.1 Air conditioner lines .................................................................................... 4-130 4.8.1.1 Layout of A/C components ................................................................ 4-132 4.8.1.2 A/C control panel............................................................................... 4-133 4.8.1.3 Diagram of electrical circuit ............................................................... 4-134 4.8.1.4 Operating principle ............................................................................ 4-136 4.8.1.5 Compressor ...................................................................................... 4-137 4.8.1.6 Clutch ................................................................................................ 4-139 4.8.1.7 Condenser ........................................................................................ 4-140 4.8.1.8 Expansion valve ................................................................................ 4-141 4.8.1.9 Evaporator ........................................................................................ 4-141 4.8.1.10 Dehydrator ..................................................................................... 4-142 4.8.1.11 Pressure switch .............................................................................. 4-143 4.8.1.12 Fresh air sensor .............................................................................. 4-144 4.8.2 Refrigerant ................................................................................................. 4-145 4.8.2.1 Compressor oil .................................................................................. 4-163 4.9 Engine Control ..................................................................................................... 4-164 4.9.1 System operation ....................................................................................... 4-165 4.9.1.1 Engine starting .................................................................................. 4-165 4.9.1.2 Engine speed control ........................................................................ 4-165 Shop Manual - April 2014
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4.9.1.3 Engine shutdown .............................................................................. 4-165 4.9.2 System components .................................................................................. 4-166 4.9.2.1 Fuel control dial................................................................................. 4-166 4.9.2.2 Controller .......................................................................................... 4-168 4.10 Electrical Control System................................................................................... 4-170 4.10.1 Control function ........................................................................................ 4-170 4.10.2 Diagram of machine control system......................................................... 4-171 4.10.3 Engine-pump combination control ........................................................... 4-173 4.10.4 Pump control function .............................................................................. 4-177 4.10.4.1 Constant power control ................................................................... 4-180 4.10.4.2 ESS control ..................................................................................... 4-180 4.10.5 Valve control function ............................................................................... 4-181 4.10.6 Dual travel speed control ......................................................................... 4-183 4.10.7 Engine preheat/overheat alarm ............................................................... 4-185 4.10.8 Auto deceleration/acceleration control ..................................................... 4-187 4.10.9 Engine speed calibration function ............................................................ 4-188 4.10.10 System parts and components .............................................................. 4-190 4.11 Monitoring System ............................................................................................. 4-195 4.11.1 Monitor ..................................................................................................... 4-196 4.11.2 Monitor panel ........................................................................................... 4-197 4.11.2.1 Alert and signal indicators .............................................................. 4-197 4.11.2.2 Operation keys ................................................................................ 4-199 4.11.3 Monitor display and operation .................................................................. 4-201 4.11.3.1 Default page .................................................................................... 4-201 4.11.3.2 Password entry to system information ............................................ 4-202 4.11.3.3 Main menu ...................................................................................... 4-202 4.11.3.4 Engine & throttle signals ................................................................. 4-203 4.11.3.5 Pilot pressure signals ...................................................................... 4-203 4.11.3.6 Main pump & main valve signals..................................................... 4-204 4.11.3.7 Failure codes................................................................................... 4-204 4.11.3.8 Throttle help information ................................................................. 4-205 4.11.3.9 Language selection ......................................................................... 4-205 4.11.3.10 System clock setup ....................................................................... 4-206 4.11.3.11 GPS information ............................................................................ 4-207 4.11.3.12 System setup ................................................................................ 4-208 4.11.3.13 Machine configuration ................................................................... 4-208 VI
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4.11.3.14 4.11.3.15 4.11.3.16 4.11.3.17 4.11.3.18 4.11.3.19
Service hour setup ....................................................................... 4-209 Machine configuration setup ......................................................... 4-210 Hydraulic oil temperature ...............................................................4-211 Screen brightness setup ................................................................4-211 System lockout (level 1) ................................................................ 4-212 System lockout (level 2) ................................................................ 4-212
5 Table of Standard Values 5.1 Standard Values for Engine-Related Parts .............................................................. 5-3 5.2 Standard Values for Chassis-Related Parts ............................................................ 5-4
6 Testing and adjusting 6.1 Engine Speed - Test and Adjust............................................................................... 6-3 6.2 Exhaust Gas Color - Test ......................................................................................... 6-5 6.3 Valve Clearance - Adjust.......................................................................................... 6-7 6.3.1 Testing............................................................................................................ 6-8 6.3.2 Adjusting ........................................................................................................ 6-9 6.4 Compression force - Test ....................................................................................... 6-10 6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13 6.5.1 Testing.......................................................................................................... 6-14 6.5.2 Adjusting ...................................................................................................... 6-18 6.6 A/C Compressor Belt Tension - Test and Adjust .................................................... 6-19 6.6.1 Testing ......................................................................................................... 6-19 6.6.2 Adjusting ...................................................................................................... 6-19 6.7 Swing Bearing Clearance - Test ............................................................................ 6-20 6.8 Track Tensioner - Test and Adjust .......................................................................... 6-21 6.8.1 Testing.......................................................................................................... 6-21 6.8.2 Adjusting ...................................................................................................... 6-22 6.9 Oil in Hydraulic Circuits - Test and Adjust .............................................................. 6-23 6.9.1 Testing.......................................................................................................... 6-23 6.9.2 Adjusting ...................................................................................................... 6-25 6.10 Control Oil Circuit Pressure - Test and Adjust...................................................... 6-28 6.10.1 Testing........................................................................................................ 6-28 6.10.2 Adjusting .................................................................................................... 6-28 6.11 Solenoid Valve Output Pressure - Test ................................................................ 6-29 6.12 Pilot Valve Output Pressure - Test ....................................................................... 6-31 Shop Manual - April 2014
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6.13 6.14 6.15 6.16 6.17
SY365(B)H-9 Crawler Hydraulic Excavator
Work Equipment and Swing Pilot Valves - Adjust ................................................ 6-33 Hydraulic Drift of Work Equipment - Test ............................................................. 6-34 Remaining Pressure in Hydraulic Lines - Relieve................................................ 6-36 Oil Leakage Amount - Test................................................................................... 6-37 Air in Each Component - Purge ........................................................................... 6-41
7 Troubleshooting 7.1 Checks before Troubleshooting ............................................................................... 7-5 7.2 Failure Symptoms and Troubleshooting Codes ....................................................... 7-6 7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-9 7.3.1 Connector location layout ............................................................................ 7-13 7.3.2 Diagram of system electrical elements ........................................................ 7-18 7.3.3 Diagram of electrical control system ........................................................... 7-20 7.3.4 SWP connectors .......................................................................................... 7-22 7.3.5 A/AMP connectors ....................................................................................... 7-23 7.3.6 DT connectors.............................................................................................. 7-24 7.4 Troubleshooting with an Event Code ..................................................................... 7-25 7.5 Troubleshooting Electrical System (E-Mode)......................................................... 7-49 7.6 Troubleshooting Hydraulic and Mechanical Systems (H-mode) ............................ 7-81
8 Disassembly and Assembly 8.1 How to Read This Manual ....................................................................................... 8-5 8.1.1 Removing and installing an assembly............................................................ 8-5 8.2 Operating Precautions ............................................................................................. 8-6 8.3 Start Motor AS ........................................................................................................ 8-9 8.3.1 Removal ......................................................................................................... 8-9 8.3.2 Installation ...................................................................................................... 8-9 8.4 Fuel Injection Pump AS ........................................................................................ 8-10 8.4.1 Removal ....................................................................................................... 8-10 8.4.2 Installation .................................................................................................... 8-12 8.5 Engine Front Oil Seal ............................................................................................ 8-13 8.5.1 Removal ....................................................................................................... 8-13 8.5.2 Installation .................................................................................................... 8-13 8.6 Engine Rear Oil Seal ............................................................................................ 8-14 8.6.1 Removal ....................................................................................................... 8-14 8.6.2 Installation .................................................................................................... 8-14 VIII
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8.7 Cylinder Head AS .................................................................................................. 8-15 8.7.1 Removal ....................................................................................................... 8-15 8.7.2 Installation .................................................................................................... 8-19 8.8 Radiator AS ........................................................................................................... 8-20 8.8.1 Removal ....................................................................................................... 8-20 8.8.2 Installation .................................................................................................... 8-23 8.9 Engine and Hydraulic Pump AS ............................................................................ 8-24 8.9.1 Removal ....................................................................................................... 8-24 8.9.2 Installation .................................................................................................... 8-30 8.10 Final Drive AS ..................................................................................................... 8-31 8.10.1 Removal ..................................................................................................... 8-31 8.10.2 Installation .................................................................................................. 8-32 8.11 Final Drive AS ...................................................................................................... 8-33 8.11.1 Disassembly ............................................................................................... 8-33 8.11.2 Assembly .................................................................................................... 8-36 8.12 Swing Motor and Swing Drive AS ....................................................................... 8-42 8.12.1 Removal ..................................................................................................... 8-42 8.12.2 Installation .................................................................................................. 8-43 8.13 Swing Motor and Swing Drive AS ....................................................................... 8-44 8.13.1 Disassembly............................................................................................... 8-44 8.13.2 Assembly.................................................................................................... 8-49 8.14 Idler AS ............................................................................................................... 8-54 8.14.1 Disassembly............................................................................................... 8-54 8.14.2 Assembly.................................................................................................... 8-55 8.15 Sprocket .............................................................................................................. 8-58 8.15.1 Removal ..................................................................................................... 8-58 8.15.2 Installation .................................................................................................. 8-58 8.16 Track AS ............................................................................................................. 8-59 8.16.1 Removal ..................................................................................................... 8-59 8.16.2 Installation .................................................................................................. 8-60 8.17 Swing Bearing AS ............................................................................................... 8-62 8.17.1 Removal ..................................................................................................... 8-62 8.17.2 Installation .................................................................................................. 8-63 8.18 Swing frame AS .................................................................................................. 8-64 8.18.1 Removal ..................................................................................................... 8-64 8.18.2 Installation .................................................................................................. 8-66 Shop Manual - April 2014
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8.19 Swivel Joint AS .................................................................................................... 8-67 8.19.1 Removal ..................................................................................................... 8-67 8.19.2 Installation .................................................................................................. 8-69 8.20 Central Swivel Joint AS ....................................................................................... 8-70 8.20.1 Disassembly............................................................................................... 8-70 8.20.2 Assembly.................................................................................................... 8-70 8.21 Hydraulic Tank AS ............................................................................................... 8-71 8.21.1 Removal ..................................................................................................... 8-71 8.21.2 Installation .................................................................................................. 8-73 8.22 Control Valve AS .................................................................................................. 8-74 8.22.1 Removal ..................................................................................................... 8-74 8.22.2 Installation .................................................................................................. 8-79 8.23 Hydraulic Pump AS ............................................................................................. 8-80 8.23.1 Removal ..................................................................................................... 8-80 8.23.2 Installation .................................................................................................. 8-83 8.24 Middle Oil Seal (Hydraulic Pump Input Shaft) ..................................................... 8-84 8.24.1 Removal ..................................................................................................... 8-84 8.24.2 Installation .................................................................................................. 8-84 8.25 Pilot Valve AS (Work Equipment) ....................................................................... 8-85 8.26 Travel Pilot Valve AS ........................................................................................... 8-86 8.27 Hydraulic Cylinder AS ......................................................................................... 8-87 8.27.1 Disassembly............................................................................................... 8-88 8.27.2 Assembly.................................................................................................... 8-92 8.28 Work Equipment AS ............................................................................................ 8-97 8.28.1 Removal ..................................................................................................... 8-97 8.28.2 Installation .................................................................................................. 8-99 8.29 Air Conditioner AS ............................................................................................. 8-100 8.29.1 Removal ................................................................................................... 8-100 8.29.2 Installation ................................................................................................ 8-103 8.30 Counterweight AS ............................................................................................. 8-104 8.30.1 Removal ................................................................................................... 8-104 8.30.2 Installation ................................................................................................ 8-105 8.31 Cab AS .............................................................................................................. 8-106 8.31.1 Removal ................................................................................................... 8-106 8.31.2 Installation ................................................................................................ 8-109 8.32 Cab Window Glass ............................................................................................8-110 X
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8.32.1 Removal ....................................................................................................8-111 8.32.2 Installation .................................................................................................8-114 8.33 Front Window AS ............................................................................................... 8-126 8.33.1 Disassembly............................................................................................. 8-126 8.33.2 Assembly.................................................................................................. 8-129 8.34 Monitor - Remove and Install ............................................................................. 8-135 8.34.1 Removal ................................................................................................... 8-135 8.34.2 Installation ................................................................................................ 8-135 8.35 Controller AS ..................................................................................................... 8-136 8.35.1 Removal ................................................................................................... 8-136 8.35.2 Installation ................................................................................................ 8-136 8.36 Radio ................................................................................................................. 8-137 8.36.1 Structure .................................................................................................. 8-137 8.36.2 Removal and installation .......................................................................... 8-139 8.36.3 Connector model and wiring .................................................................... 8-140 8.37 Battery ............................................................................................................... 8-141 8.37.1 Structure .................................................................................................. 8-141 8.37.2 Removal and installation .......................................................................... 8-142 8.37.3 Replacement ............................................................................................ 8-143 8.38 Start Switch........................................................................................................ 8-144 8.38.1 Structure ................................................................................................. 8-144 8.38.2 Removal ................................................................................................... 8-145 8.38.3 Working principle ..................................................................................... 8-146 8.38.4 Wiring ....................................................................................................... 8-146 8.39 Fuse Box............................................................................................................ 8-147 8.40 Wiper ................................................................................................................. 8-148 8.40.1 Structure .................................................................................................. 8-148 8.40.2 Working principle ..................................................................................... 8-149 8.40.3 Removal ................................................................................................... 8-150 8.40.4 Installation ................................................................................................ 8-150 8.40.5 Angle adjustment of wiper arm................................................................. 8-151 8.41 Relays ................................................................................................................ 8-152 8.41.1 Engine relays ........................................................................................... 8-152 8.41.2 Other relays ............................................................................................. 8-153 8.41.3 Removal and installation .......................................................................... 8-154 8.41.4 Relay connector and wiring...................................................................... 8-154 Shop Manual - April 2014
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8.42 Sensors.............................................................................................................. 8-155 8.43 Connector Terminals ......................................................................................... 8-157 8.43.1 Insertion ................................................................................................... 8-157 8.43.2 Removal ................................................................................................... 8-158
9 System Schematics 9.1 9.2 9.3 9.4 9.5 9.6
XII
Diagram of Hydraulic Lines...................................................................................... 9-3 Electrical diagram of chassis ................................................................................... 9-4 Electrical diagram of control switches...................................................................... 9-5 Electrical diagram of operator station ...................................................................... 9-6 Electrical diagram of air conditioner......................................................................... 9-7 Electrical diagram of monitor ................................................................................... 9-8
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Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Introduction 1 Introduction
1.1 How to Read the Manual ......................................................................................... 1-3 1.1.1 Shop manual organization ............................................................................. 1-3 1.1.2 Revision and distribution ................................................................................ 1-4 1.1.3 Symbols ......................................................................................................... 1-5 1.1.4 Units ............................................................................................................... 1-5 1.2 Technical Terms ....................................................................................................... 1-6 1.2.1 Standard size and tolerance .......................................................................... 1-6 1.2.2 Standard clearance and value ....................................................................... 1-7 1.2.3 Standard interference .................................................................................... 1-7 1.2.4 Repair limit and allowable value .................................................................... 1-8 1.2.5 Clearance limit ............................................................................................... 1-8 1.2.6 Interference limit ............................................................................................ 1-8 1.3 Handling Electrical and Hydraulic Components....................................................... 1-9 1.3.1 Points to remember when handling electric components .............................. 1-9 1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9 1.3.1.2 Main failures occurring in wiring harness ............................................ 1-10 1.3.1.3 Removing, installing, and drying connectors and wiring harnesses ... 1-12 1.3.1.4 Handling the integrated control monitor .............................................. 1-16 1.3.1.5 Electric circuits troubleshooting precautions ....................................... 1-17 1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18 1.3.2.1 Be careful of the operating environment ............................................. 1-18 1.3.2.2 Disassembly and maintenance work in the field ................................. 1-18 1.3.2.3 Sealing openings ................................................................................ 1-18 1.3.2.4 Do not let any dirt or dust get in during refilling operations ................. 1-19 1.3.2.5 Change hydraulic oil when the temperature is high ............................ 1-19 司
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Introduction
1.4
1.3.2.6 Flushing operations............................................................................. 1-19 1.3.2.7 Cleaning operations ............................................................................ 1-20 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 Table of Standard Tightening Torques .................................................................. 1-23 Type of Bolts .......................................................................................................... 1-24 Tightening Sequence ............................................................................................. 1-24 Maintenance of Half Flanges ................................................................................. 1-25 1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25 1.8.2 Temperature ................................................................................................. 1-31
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1.5 1.6 1.7 1.8
SY365(B)H-9 Crawler Hydraulic Excavator
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1 INTRODUCTION 1.1 How to Read the Manual ● Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult Sany distributors. ● Materials and specifications are subject to change without notice.
1.1.1 Shop manual organization
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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. Introduction
This section provides an overview of what is covered in the rest of this manual and how to use this manual,.
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Shop Safety
This section covers basic shop safety information relating to this equipment. It also describes what the hazard alerts mean that are used throughout the manual. Specifications
Technical specification of work equipment and optional parts are given in this section. Structure and functions
This section explains the structure and function of each component. It helps the reader to get a better understanding of the machine structure, and also serves as a reference for troubleshooting.
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SY365(B)H-9 Crawler Hydraulic Excavator
Standard Values This section explains the standard values for a new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. Testing and adjusting
In Ma t rk er n et a in ti o g n De al pt .
This section details the inspection before and after repair work as well as the adjustment during inspection and repair work. Troubleshooting table that involves “Fault”and “Cause”are also included in this section. Troubleshooting
This section explains the way to detect faulty parts and the method to repair them. This section is divided into the following parts: Electrical system, Engine, Hydraulic and mechanical system and Monitoring system.
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Disassembly and assembly
This section explains the procedures as well as precautions for removing, installing, disassembling and assembling of each component. Engine
This section provides information the cooling system, lubricating system, electrical system and alternator in addition to disassembly and reassembly of the engine. System Schematics
This section provides hydraulic circuit diagrams and electrical circuit diagrams.
1.1.2 Revision and distribution Any complements, revisions, or other change of notices will be sent to Sany distributors. Get the most up-to-date information before you start any work.
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1.1.3 Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Remarks
Safety
Special safety precautions are necessary when performing work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for tightening torque during assembly.
Coat
Places to be coated with adhesives, etc. during assembly.
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★
Item
Oil, Coolant
Places where oil, etc. must be added, and capacity. 司
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Drain
Places where oil, etc. must be drained, and quantity to be drained.
1.1.4 Units
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 { }.
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1.2 Technical Terms The maintenance standard values necessary for judgment of products and parts are described by the following terms.
1.2.1 Standard size and tolerance ● To be accurate, the finishing size of parts is a little different from one to another.
In Ma t rk er n et a in ti o g n De al pt .
● To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. ● The above size set temporarily is called the "standard size" and the range of difference from the standard size is called the "tolerance".
● The tolerance with the symbols of + or – is indicated on the right side of the standard size.
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Example
Standard size 120
Tolerance –0.022 –0.126
Std.size F 60
★ The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)
Tolerance of hole (upper):+0.046
Std.clearance (max.):0.122 Std.clearance (min.):0.030 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. ● Indication of size of rotating shaft and hole and relationship drawing of them.
ZX215-1000003
Fig. 1-1
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Introduction
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Example Standard size φ60
Tolerance Shaft -0.030
Hole +0.046
-0.076
0
1.2.2 Standard clearance and value
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● The clearance made when new parts are assembled is called the "standard clearance", which is indicated by the range from the minimum clearance to the maximum clearance.
● When some parts are repaired, the clearance is generally adjusted to the standard clearance.
● A value of performance and function of new products or equivalent is called the "standard value", which is indicated by a range or a target value.
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● When some parts are repaired, the value of performance/function is set to the standard value.
1.2.3 Standard interference
● 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 difference (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.
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Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.2.4 Repair limit and allowable value ● The size of a part changes due to wear and deformation while it is used. The limit of changed size is called the "repair limit". ● If a part is worn to the repair limit must be replaced or repaired.
In Ma t rk er n et a in ti o g n De al pt .
● The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the "allowable value". ● If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
1.2.5 Clearance limit
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● Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the "clearance limit". ● If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired.
1.2.6 Interference limit
● The allowable maximum interference between 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 exceeds the interference limit, they must be replaced or repaired.
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1.3 Handling Electrical and Hydraulic Components
In Ma t rk er n et a in ti o g n De al pt .
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be carried out. This section deals particularly with correct repair 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 equipment" (particularly gear oil and hydraulic oil).
1.3.1 Points to remember when handling electric components 1.3.1.1 Handling wiring harnesses and connectors
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Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection 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.
ZX215-1000004
Fig. 1-2
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Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.3.1.2 Main failures occurring in wiring harness 1. Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely 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.
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Improper insertion
ZX215-1000005
Fig. 1-3
2. Defective crimping or soldering of connectors
The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
Crimped portion
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ZX215-1000006
Fig. 1-4
3. Disconnections in wiring
If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
ZX215-1000007
Fig. 1-5
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Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
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 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-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
In Ma t rk er n et a in ti o g n De al pt .
ZX215-1000008
Fig. 1-6
5. Oil or dirt stuck to connector
If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so 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 compressed air and spray it with a contact restorer.
司
公
销 营
★ When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins.
ZX215-1000009
Fig. 1-7
★ 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 - April 2014
1-11
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.3.1.3 Removing, installing, and drying connectors and wiring harnesses 1. Disconnecting connectors A. Hold the connectors when disconnecting. Press lightly when removing
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 stopper, press down the stopper with your thumb and pull the connectors apart.
In Ma t rk er n et a in ti o g n De al pt .
Lock stopper
ZX215-1000010
Fig. 1-8
★ Never pull with one hand. B. When removing from clips
● Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
Both stoppers
司
公
销 营
ZX215-1000011
Fig. 1-9
● When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. ★ If the connector is twisted up and down or to the left or right, the housing may break.
ZX215-1000012
Fig. 1-10
1-12
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
C. Action to take after removing connectors 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 cover the connector.
ZX215-1000013
In Ma t rk er n et a in ti o g n De al pt .
Fig. 1-11
2. Connecting connectors
A. Check the connector visually
Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins.
Clicks into position
司
公
销 营
Check that there is no damage or breakage to the outside of the connector.
ZX215-1000022
Fig. 1-12
★ 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 wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. ★ If there is any damage or breakage, replace the connector.
B. Fix the connector securely. Align the position of the connector cor-
Shop Manual - April 2014
1-13
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
rectly, and then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. C. Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
ZX215-1000014
Fig. 1-13
In Ma t rk er n et a in ti o g n De al pt .
★ If the connector cannot be corrected easily, remove the clamp and adjust the position. ● If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps. 3. Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty wire connectors have 2 latches respectively, push them in until they click 2 times. ● Male connector: 1
司
公
销 营
ZX215-1000015
Fig. 1-14
● Female connector: 2
● Normal locking state (Horizontal): a, b, d
2
a
1
c
● Incomplete locking state (Diagonal): c
b
d ZX215-1000016
Fig. 1-15
1-14
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
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. A. Disconnect the connector and wipe off the water with a dry cloth.
ZX215-1000009
★ If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
In Ma t rk er n et a in ti o g n De al pt .
Fig. 1-16
B. Dry the connector with a dryer.
If water gets inside the connector, use a dryer to dry the connector.
★ Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
司
公
销 营
ZX215-1000017
Fig. 1-17
C. Carry out a continuity test on the connector.
After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. ★ After completely drying the connector, blow it with contact restorer and reassemble.
T adapter
ZX215-1000018
Fig. 1-18
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1-15
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.3.1.4 Handling the integrated control monitor 1. The integrated control monitor contains a microcomputer, an electronic control circuits, an LCD monitor and GPS positioning circuit. They control all of the electronic circuits on the machine, so be extremely careful when handling the integrated control monitor. 2. Do not place objects on the integrated control monitor.
ZX135-1000001
3. Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand.
In Ma t rk er n et a in ti o g n De al pt .
Fig. 1-19
4. Do not leave it where it may be exposed to rain.
Tool Box
5. Do not place the integrated control monitor on oil, water, or soil, or in any hot place, even for a short time. 6. Precautions for arc welding
司
公
销 营
When welding on the controller, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
ZX215-1000020
Fig. 1-20
ZX215-1000021
Fig. 1-21
1-16
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.3.1.5 Electric circuits troubleshooting precautions 1. Always turn the power OFF before disconnecting 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.
In Ma t rk er n et a in ti o g n De al pt .
3. Always connect any disconnected connectors before going on to the next step. ★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester.
司
公
销 营
★ If there is any change, there is probably defective contact in that circuit.
Shop Manual - April 2014
1-17
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.3.2 Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
In Ma t rk er n et a in ti o g n De al pt .
1.3.2.1 Be careful of the operating environment Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.
1.3.2.2 Disassembly and maintenance work in the field
If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dust-proof workshop, and the performance should be checked with special test equipment.
ZX215-1000023
司
公
销 营
Fig. 1-22
1.3.2.3 Sealing openings
After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
ZX215-1000024
Fig. 1-23 1-18
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.3.2.4 Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
ZX215-1000025
In Ma t rk er n et a in ti o g n De al pt .
Fig. 1-24
1.3.2.5 Change hydraulic oil when the temperature is high
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
司
公
销 营
1.3.2.6 Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing 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.
Flushing oil
ZX215-1000026
Fig. 1-25
Shop Manual - April 2014
1-19
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.3.2.7 Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running 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 it is an extremely effective device.
ZX215-1000027
In Ma t rk er n et a in ti o g n De al pt .
Fig. 1-26
1.4 Hose Connector
Hose connector is used to connect hoses with a small diameter. The metal sealing surface (4) of the joint (1) must be in close contact with the metal sealing surface (5) of the hose (2) to seal pressurized oil.
NOTICE
1
3
5
2
司
公
销 营
● Do not over-tighten the nut (3). Excessive force applied on the metal sealing surface (4) and (5) may cause the joint (1) to break. Be sure to tighten nut (3) according to technical specifications.
Connector
ZX215-1000028
Fig. 1-27
● Scratches or other damages on sealing 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
4
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.4.1 Type of hose connector 24° 24°
Male
Female
ZX215-1000029
In Ma t rk er n et a in ti o g n De al pt .
Fig. 1-28
1.4.2 Hose connector tightening torque table
Type
Wrench size mm
Wrench size mm
Tightening torque
Connecting nut
Hose joint
N·m(kgf·m,Ibf·ft)
19
19
59(6,44)
22
22
98(10,72)
27
118(12,87)
36
36
235(24,173)
41
41
295(30,218)
50
50
490(50,361)
60
60
670(68,494)
70
70
980(100,723)
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)
27
司
公
销 营
24° Male
24° Female
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.
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Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.4.3 Connection of O-rings Place O-ring (6) in contact with the contact surface of the joint (7) to seal the pressurized oil.
7
6
9
NOTICE ● Replace o-rings (6) with new ones when re-connecting hoses.
8
● Before tightening nut (9), make sure the o-ring (6) has been placed into the oring seat (8).Displacement of the o-ring may have it damaged and cause leaks.
10
Hose connector
In Ma t rk er n et a in ti o g n De al pt .
ZX215-1000030
Fig. 1-29
● Be careful not to damage the o-ring seat (8) or the sealing surface (10). Damaged o-ring (6) may cause oil leakage.
● If oil leakage due to loosened nut (9) is detected, do not try to stop the leakage by tightening nut (9). Instead, replace o-ring (6) with a new one and make sure it is well positioned, and tighten nut (9).
1-22
司
公
销 营
Wrench size mm
Wrench size mm
Tightening torque
Connecting nut
Hose joint
N·m (kgf·m,Ibf·ft)
19
17
44(4.5,32)
22
19
59(6,44)
27
22
118(12,87)
36
30, 32
235(24,173)
41
36
295(30,218)
50
46
490(50,361)
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
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 diameter
Bolt grade
Wrench Hex wrench size size
M6
10.9
10
M8
10.9
M10
Hexagonal bolt
Hexagonal socket head bolt
kgf·m
lbf·ft
N·m
kgf·m
lbf·ft
4
13.2
1.37
9.74
13.2
1.37
9.74
13
6
31
3.16
22.87
31
3.16
22.87
10.9
17
8
66
6.73
48.7
66
6.73
48.7
M12
10.9
19
10
113
11.53
83.39
113
11.53
83.39
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
10.9
27
14
382
38.98
281.9
382
38.98
281.9
M20
10.9
30
17
549
56.02
405.16
549
56.02
405.16
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
In Ma t rk er n et a in ti o g n De al pt .
N·m
司
公
销 营
M12
12.9
19
8
137
13.98
101.1
137
13.98
101.1
M16
12.9
24
14
339
34.6
250.18
339
34.6
250.18
M20
12.9
30
17
664
67.75
490
664
67.75
490
NOTICE
The following items apply to fine thread and coarse thread.
● 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.
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Introduction
SY365(B)H-9 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
8.8
Use correct bolts and tighten them properly when assembling machines or components.
Socket head hex bolt
12.9
10.9
ZX215-1000031
In Ma t rk er n et a in ti o g n De al pt .
Fig. 1-30
1.7 Tightening Sequence
When two or more bolts are being tightened, follow the tightening sequence shown on the right to ensure even tightening.
Cross tightening
Diagonal tightening 1
1
3
6
3
4
5
4
CAUTION
2
● Always use suitable tools for specific work. Use of improper tools and methods may cause a hazardous situation.
● Use tools of correct sizes when loosening or tightening the nuts or bolts. Otherwise, the tools may slide and cause personal injury.
2
Central and diagonal tightening
司
公
销 营
12
9
4
1
6
7
14
13
8
5
2
3
10
11
ZX215-1000032
Fig. 1-31
ZX215-1000033
Fig. 1-32
1-24
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.8 Maintenance of Half Flanges 1. Clean the sealing surface of the flange and check it carefully. Scratches and coarseness 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 the O-rings are not damaged. Do not file the surface of the O-ring. Apply grease onto the O-ring to locate it.
ZX215-1000034
In Ma t rk er n et a in ti o g n De al pt .
Fig. 1-33
3. Tighten the half flanges carefully. Locate the opening at the center so that it is perpendicular to the oil opening. Tighten the bolt manually to maintain the location of the components.
Improper
司
公
销 营
ZX215-1000035
Fig. 1-34
1.8.1 Table of tightening torques for half flange bolts
★ Unless specified otherwise, tighten the half flange bolts to the torques below. Thread diameter of bolt
Width across flats
Tightening torque
mm 10
mm 14
Nm 59~74
kgm 6.0~7.5
12
17
98~123
10.0~12.5
16
22
235~285
23.5~29.5
Shop Manual - April 2014
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Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
Conversion Table Method of using conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches Convert 55 mm into inches Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A).
In Ma t rk er n et a in ti o g n De al pt .
Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). Take the point where the two lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. Convert 550 mm into inches
The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. Carry out the same procedure as above to convert 55 mm to 2.165 inches. 司
公
销 营
The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
1-26
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
Millimeters to Inches 1mm=0.03937in
(B) 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
50
1.969
2.008
2.047
2.087
2.126
(C) 2.165
2.205
2.244
2.283
2.323
In Ma t rk er n et a in ti o g n De al pt .
(A)
0
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
Millimeters to Inches
司
公
销 营
1mm=0.03937in
0
1
2
3
4
5
6
7
8
9
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.535
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
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
0 10 20 30 40
50 60
Shop Manual - April 2014
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Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
Kilogram to Pound 1kg=2.2046 lb 1
2
3
4
5
6
7
8
9
0
0
2.20
4.41
6.61
90.39
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
112.43
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
134.48
55.12
57.32
59.52
61.73
63.93
30
66.14
68.34
70.55
72.75
156.53
77.16
79.37
81.57
83.77
85.98
40
88.18
90.39
92.59
94.80
178.57
99.21
101.41
103.62
105.82
108.03
50
110.23
112.43
114.64
116.84
200.62
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
222.66
143.30
145.50
147.71
149.91
152.12
154.32
156.53
158.73
160.94
244.71
165.35
167.55
169.75
171.96
174.16
176.37
178.57
180.78
182.98
266.76
187.39
189.60
191.80
194.00
196.21
198.41
200.62
202.82
205.03
288.80
209.44
211.64
213.85
216.05
218.26
60
In Ma t rk er n et a in ti o g n De al pt .
0
15.852
16.116
16.380
16.645
16.909
17.173
17.437
17.701
17.966
18.230
70
18.494
18.758
19.022
19.287
19.551
19.815
20.079
20.343
20.608
20.872
80
21.136
21.400
21.664
21.929
22.193
22.457
22.721
22.985
23.250
23.514
90
23.778
24.042
24.306
24.571
24.835
25.099
25.363
25.627
25.892
26.156
70 80 90
Liters to U.S. Gallons
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1 L=0.2642 U.S.Gal
0 10 20 30 40
50
1-28
0
1
2
3
4
5
6
7
8
9
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.114
2.378
2.642
2.906
3.170
3.435
3.699
3.963
4.227
4.491
4.756
5.020
5.284
5.548
5.812
6.077
6.341
6.605
6.869
7.133
7.398
7.662
7.926
8.190
8.454
8.719
8.983
9.247
9.511
9.775
10.040
10.304
10.568
10.832
11.096
11.361
11.625
11.889
12.153
12.417
12.682
12.946
13.210
13.474
13.738
14.003
14.267
14.531
14.795
15.059
15.324
15.588
Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
Liters to U.K. Gallons 1 L=0.21997 U.K.Gal 1
2
3
4
5
6
7
8
9
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.739
3.959
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.699
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.779
50
10.999
11.218
11.438
11.658
11.878
12.098
12.318
12.538
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
17.598
17.818
18.038
18.258
18.477
18.697
18.917
19.137
19.357
19.577
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
70 80 90
In Ma t rk er n et a in ti o g n De al pt .
0 0
kgm to ft.lb
1 kgm=7.233 ft.lb
0
1
2
3
4
5
6
7
8
9
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0 72.3 144.7 217.0 289.3
7.2 79.6 151.9 224.2 296.6
14.5 86.8 159.1 231.5 303.8
21.7 94.0 166.4 238.7 311.0
28.9 101.3 173.6 245.9 318.3
36.2 108.5 180.8 253.2 325.5
43.4 115.7 188.1 260.4 332.7
50.6 123.0 195.3 267.6 340.0
57.9 130.2 202.5 274.9 347.2
65.1 137.4 209.8 282.1 354.4
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.4 520.8 593.1 665.4
383.3 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.1 542.5 614.8 687.1
405.0 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
419.5 491.8 564.2 636.5 708.8
426.7 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 795.6 868.0 940.3 1012.6
730.5 802.9 875.2 947.5 1019.9
737.8 810.1 882.4 954.8 1027.1
745.0 817.3 889.7 962.0 1034.3
752.2 824.6 896.9 969.2 1041.6
759.5 831.8 904.1 976.5 1048.8
766.7 839.0 911.4 983.7 1056.0
773.9 846.3 918.6 990.9 1063.3
781.2 853.5 925.8 998.2 1070.5
788.4 860.7 933.1 1005.4 1077.7
150 160 170 180 190
1085.0 1157.3 1229.6 1301.9 1374.3
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.2 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
0 10 20 30 40 50 60 70 80 90
Shop Manual - April 2014
1-29
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
kg/cm2 to lb/in2
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.3
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.0
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
In Ma t rk er n et a in ti o g n De al pt .
1 kg/cm2=14.2233 lb/in2
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
996
1010
1024
1038
1053
1067
1081
1095
1109
1124
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
2133
2148
2162
2176
2190
2205
2219
2233
2247
2262
2276
2290
2304
2318
2333
2347
2361
2375
2390
2404
2418
2432
2446
2461
2475
2489
2503
2518
2532
2546
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
2702
2717
2731
2745
2759
2774
2788
2802
2816
2830
2845
2859
2873
2887
2902
2916
2930
2944
2958
2973
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3342
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
70 80 90 100 110 120 130 140 150 160 170 180 190 200 210
1-30
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Shop Manual - April 2014
Introduction
SY365(B)H-9 Crawler Hydraulic Excavator
1.8.2 Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
℃
In Ma t rk er n et a in ti o g n De al pt .
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
-40.0 -37.2 -34.4 -31.7 -28.9 -28.3 -27.8 -27.2 -26.7 -26.1 -25.6 -25.0 -24.4 -23.9 -23.3 -22.8 -22.2 -21.7 -21.1 -20.6 -20.0 -19.4 -18.9 -18.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2
-40 -35 -30 -25 -20 -2 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10
℉
℃
-40.0 -31.0 -22.0 -13.0 -4.0 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0
-11.7 -11.1 -10.6 -10.0 -9.4 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0.0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
℉
℃
51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0
7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7
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46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
Shop Manual - April 2014
℉
℃
114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0
27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.8 65.6 68.3 71.1 73.9 76.7 79.4
℉ 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175
177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
1-31
Introduction
BL In Ma t ArkNer n etK a in ti Pg Aona DG l ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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1-32
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Shop Safety 2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3 2.2 General Shop Safety ............................................................................................... 2-5 2.2.1 Rules and shop behavior ............................................................................... 2-6 2.2.2 Housekeeping ................................................................................................ 2-6 2.2.3 Shop Liquids Storage..................................................................................... 2-7 2.2.4 Cleaning the Parts ......................................................................................... 2-7 2.2.5 Cleaning the Machine .................................................................................... 2-8 2.2.6 Appropriate Working Apparel ......................................................................... 2-8 2.2.7 Personal Protective Equipment...................................................................... 2-8 2.2.8 Using the Correct Tools.................................................................................. 2-9 2.2.9 Fire Extinguisher and Emergency Exits ......................................................... 2-9 2.2.10 Electrical Dangers ...................................................................................... 2-10 2.2.11 Hoisting a Load .......................................................................................... 2-10 2.3 Before Repair..........................................................................................................2-11 2.3.1 Safe Work Preparations ................................................................................2-11 2.3.2 Preparing yourself ........................................................................................ 2-12 2.3.3 Lockout/Tagout............................................................................................. 2-13 2.3.4 Two people when engine running ................................................................ 2-15 2.3.5 Safety Partners ............................................................................................ 2-15 2.4 Repair Precautions ................................................................................................ 2-16 2.4.1 Running the Machine ................................................................................... 2-16 2.4.2 Mounting and Dismounting .......................................................................... 2-17 2.4.3 Removing Attachments ................................................................................ 2-18 2.4.4 Jacking Up the Machine............................................................................... 2-18 2.4.5 Adding Fluids to a System ........................................................................... 2-18 司
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Shop Manual - April 2014
2-1
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
2.4.6 Aligning Parts or Components ..................................................................... 2-19 2.4.7 Driving Pins .................................................................................................. 2-19 2.4.8 When compressed air is used...................................................................... 2-19 2.4.9 Welding operation ........................................................................................ 2-20 2.4.10 Track Recoil Springs .................................................................................. 2-20 2.4.11 High-Pressure Fluid Lines .......................................................................... 2-21 2.4.12 Air-conditioning system maintenance ........................................................ 2-22 2.4.13 High voltage precautions ........................................................................... 2-22 2.4.14 Disconnecting the System Power .............................................................. 2-23 2.4.15 Accumulator ............................................................................................... 2-23 2.4.17 Battery Hazards ......................................................................................... 2-24 2.4.18 Jump-Start Safety ...................................................................................... 2-25 2.4.19 Avoiding fire and explosion ........................................................................ 2-26 2.4.20 Chemical hazard ........................................................................................ 2-27 2.4.21 Material Safety Data Sheets (MSDS) ........................................................ 2-27 2.4.22 Proper disposal of wastes .......................................................................... 2-28 2.5 Other Precautions .................................................................................................. 2-29 2.5.1 Sling work and giving signals ....................................................................... 2-29 2.5.2 Using mobile crane ...................................................................................... 2-31 2.5.3 Using overhead hoist crane ......................................................................... 2-31 2.5.4 Selecting wire ropes..................................................................................... 2-33 司
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2-2
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2 SHOP SAFETY 2.1 Hazard Alert Information Most accidents are usually caused by the failure to follow fundamental repair procedures and safety rules for the system under repair. To avoid accidents it is important to read and understand all information outlined in this manual before performing repairs on the machine system.
In Ma t rk er n et a in ti o g n De al pt .
The following (ANSI/ISO) signal words are used to inform you that there is a potentially hazardous situation that may lead to damage, personal injury or even death. In this manual, on the machine, part or component decals and different signal words are used to express the potential level of a hazard.
DANGER
WARNING
● Indicates an imminent hazard which WILL result in serious injury or death if message is ignored.
CAUTION
● Indicates a potentially hazardous situation which COULD result in serious injury or death if message is ignored.
NOTICE
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● Indicates a potentially hazardous situation which COULD RESULT IN MINOR OR MAJOR INJURY if message is ignored.
● Indicates THE MACHINE MAY BE DAMAGED if improperly operated or maintained.
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.
Besides the above signals words, the following words are also used to remind you of rules to be followed or to provide you with very useful information. Note: It is followed by measures that must be taken to prevent reduction of machine service life. Remark: It is followed by very useful information.
Shop Manual - April 2014
2-3
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
WARNING ● Improper repair procedures on this machine can be hazardous and could result in serious injury or even death. ● All personnel involved with the repair of this machine must read this manual thoroughly before performing any procedures on this equipment. ● Some actions involved in the operation or repair of this machine could cause a serious accident if they are not performed in the manner described in this manual.
In Ma t rk er n et a in ti o g n De al pt .
● All precautions outlined in this manual apply only to intended repair procedures of the machine or system. If you perform any repairs not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual. ● SANY delivers machines that comply with all applicable regulations and standards of the country to which the machines have been shipped. If this machine has been purchased in another 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 applicable standards and regulations of your country, contact your SANY representative before performing repairs on this machine. 司
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2-4
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 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.
In Ma t rk er n et a in ti o g n De al pt .
Always keep in mind, shop safety is NOT something to be studied at the start of a project and then forgotten; most accidents are caused by carelessness, being in a hurry or by simply disregarding safety rules. Remember this, if you are DILIGENT and follow instructions outlined in this shop manual with care, repair operations can be safe and enjoyable. Safe work practices, should become a force of habit.
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WARNING
● Mistakes in operation are extremely hazardous. Read the Safety, Operation & Maintenance Manual that came with the machine carefully before operating the machine. Failure to follow this alert could result in serious injury or death.
Shop Manual - April 2014
2-5
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.2.1 Rules and shop behavior ● Study all shop rules relating to the procedure carefully and constantly apply them. When in doubt about any task, get help! DO NOT take chances.
In Ma t rk er n et a in ti o g n De al pt .
● Know your job. It is foolish, and often disastrous, to make repairs to a machine without first receiving proper instructions. Always use the shop manual when performing any repair tasks. Get additional help if you are NOT sure what must be done or how a task should be performed. ● The shop is a place to work, not play. It is NOT a place for “horseplay”. A “joker” in a repair shop is a “walking hazard” to everyone. Daydreaming or socializing on the job also increases your chances of injury. ● If you must smoke, smoke only in the area provided for smoking. Never smoke while on the shop floor or work area.
Fig. 2-2
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2.2.2 Housekeeping
● Oils, grease, fuel, antifreeze or any fluid spills should be mopped up immediately. These items pose a serious slip hazard. Regardless of who was responsible for the spill, it is your job as a shop employee to secure and clean up the spill area. ● Keep the shop clean. Scrap or old parts should be disposed of properly. Never allow 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.
WX235R-1200001
Fig. 2-1
● Always keep in mind, proper house cleaning is vital for a safe and pleasant work environment.
2-6
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.2.3 Shop Liquids Storage ● Liquids, cleaning solvents or machine fluids 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.
In Ma t rk er n et a in ti o g n De al pt .
● Never leave open containers of liquids sitting around. These could spill or catch fire. Always read the container label for information on storage and handling of the liquids.
WX235R-1200002
Fig. 2-3
● Never store liquids in containers that are not properly labeled for that liquid. Confusion could result in equipment damage, fire or an unexpected explosion. ● Never smoke or bring open flames around liquids, doing so could result in an unexpected fire or explosion.
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● Never handle liquids without using personal protective equipment. Treat all liquids with caution.
2.2.4 Cleaning the Parts
Never use gasoline, diesel fuel or similar flammable liquids to clean parts. Always use approved non-flammable solvents to clean parts. Failure to do so could result in explosion or fire.
WX235R-1200003
Fig. 2-4
Shop Manual - April 2014
2-7
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.2.5 Cleaning the Machine ● Always use high-pressure hot water and mild, nonflammable grease-cutting soaps or cleaning agents to clean the machine parts. Never use flammable or caustic cleaning agents. ● Never use high-pressure steam cleaners to clean the machine. Steam cleaners will damage the paint, hoses or electrical system. ● Never pressure-wash or flood the inside of an operator cab. This will damage sensitive electrical components.
In Ma t rk er n et a in ti o g n De al pt .
WX235R-1200007
Fig. 2-5
2.2.6 Appropriate Working Apparel
Improper or loose clothing, casual dress clothing, 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.
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WX235R-1200005
Fig. 2-6
2.2.7 Personal Protective Equipment
If your shop specifies the use of safety equipment, 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 without the proper personnel protective equipment even for a moment. Always keep personnel protective equipment in good condition and replace them as required.
CZ335-1102002
Fig. 2-7 2-8
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.2.8 Using the Correct Tools ● Always use the proper authorized tools for the job. Using tools that are not authorized, incorrect for the job, defective or damaged could cause serious injury. ● Keep all tools in good condition, learn the correct way to use them. ● Before starting the work, thoroughly check the tools, machine, forklift, crane, service car, etc. ● Keep your tools clean, and when the job is complete, take inventory of the tools you were using to be sure no tools were left in the machine.
In Ma t rk er n et a in ti o g n De al pt .
ZX215-1000033
Fig. 2-8
● 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 carry out the work.
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2.2.9 Fire Extinguisher and Emergency Exits
● It is important to know where all emergency exits and fire extinguishing equipment are located if a fire should occur in the shop.
● Before preparing for work, take time and walk around the shop to make a mental note of where all exits and fire equipment are located. If you are performing repairs in the field, always have a fire extinguisher handy and within reach.
● If you do not know how to use a fire extinguisher contact someone who can instruct you in the proper use of this equipment.
WX235R-1200006
Fig. 2-9
Shop Manual - April 2014
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.2.10 Electrical Dangers ● When testing electrical circuits, always be aware of what you will be checking in these systems. High voltage or high amp circuits could damage your equipment or cause a spark, explosion or possible fire. ● Before performing any repairs or testing on an electrical system be sure of the system voltage dangers. Always check the circuit to be sure it is off before performing any repairs.
In Ma t rk er n et a in ti o g n De al pt .
● When working around flammable liquids or explosive systems, use only approved antiexplosion proof work lamps. Non-approved work lamps can cause an explosion or fire.
Fig. 2-10
2.2.11 Hoisting a Load
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If you will be lifting parts or components that weigh more than 35 lbs (16 kg), it is important to follow some basic rules.
● Always use the appropriate lifting equipment such as hoist, crane, forklift etc. to handle a loads if possible. ● Be sure the lifting equipment is in good condition and rated for the load you are 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.
2-10
Fig. 2-11
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.3 Before Repair 2.3.1 Safe Work Preparations Before starting any repairs, be sure the machine is sitting on a level stable surface.
In Ma t rk er n et a in ti o g n De al pt .
Lower all the work equipment to a safe and stable position on the ground. Turn the engine OFF and neutralize the work equipment controls by rotating them to the left and right (joystick control) or moving them back and forth (lever control). This function will relieve system pressure. Block the tracks (if equipped) or wheels (if equipped) with chocks to prevent the machine from moving. If equipped, set the hydraulic lock lever in the LOCKED position. If equipped, set the parking brake in the PARK position. Be sure all personnel and equipment is clear of your work area and you can be seen by all working personnel especially if performing repairs in the field.
Fig. 2-12
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Shop Manual - April 2014
2-11
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.3.2 Preparing yourself Only approved personnel can maintain or repair the machine. An observer may be assigned if necessary. ● Wear protective clothing and shoes necessary for the job. ● Wear rubber apron and rubber gloves when handling corrosive materials. Wear heavy gloves when handling wooden materials, wire ropes or sharp-edged metals.
CZ335-1102069
Fig. 2-13
In Ma t rk er n et a in ti o g n De al pt .
● Wear a face shield when removing spring or elastic parts, or adding acid to battery. Wear safety hat and goggles when you weld or cut with a torch. ● Never carry out grinding, flame cutting or welding without an aspirator and ventilation equipment. If you have to weld on the machine, refer to related instructions and understand the correct operating procedure.
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CZ335-1102070
Fig. 2-14
2-12
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.3.3 Lockout/Tagout
In Ma t rk er n et a in ti o g n De al pt .
Due to the size and complexity of this machine, 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 energy, and to ensure that the machine is“locked out and tagged out” before anyone performs repairs on the machine. Sequence of procedures
Only authorized employees performing repairs on the machine shall perform Lockout/Tagout in accordance with this procedure listed below.
If the employee performing repairs to the machine is issued a lock and key, the employee shall not share the lock or key with other employees until all repair procedures are complete and the machine is ready to put back into service.
DA
NG
ER
DO OP NO ER T AT E
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销 营
The following steps shall be performed in the sequence listed when the equipment is to be either locked-out or tagged-out for repair.
Locking out of service
1. Notify all employees who may be potentially affected by the repair process on the machine.
2. Secure the machine in a safe position. If equipped, set the parking brake or hydraulic lock lever in the PARK or LOCKED position.
Fig. 2-15
3. Identify, remove or disconnect all power
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
or energy sources and be sure to install a Lockout/Tagout device on them. If the machine is equipped with a Maintenance Alert Tag, attach this tag to the machine controls.
DANGER
4. Be sure all employees involved in the repairs have installed there lock on the power source before performing any repairs. Once an employee has completed there repair procedure, they must remove there lock and not access the machine in any manor.
DO NOT OPERATE When this is not being used, keep it in the storage compartment.
In Ma t rk er n et a in ti o g n De al pt .
Fig. 2-16
Returning to service
1. The authorized person who performed the Lock out/Tagout procedure shall check the area around the machine to ensure that no one is exposed to any hazard before startup.
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.
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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 machine will be back in service. 4. Remove the Lockout/Tagout equipment and any additional alert equipment and reenergize the machine for return to service.
2-14
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.3.4 Two people when engine running In order to prevent injury, do not perform the service while the engine is running. If the service 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 operation seat and be ready to turn off the engine at any time. All the operators must keep in touch with each other.
In Ma t rk er n et a in ti o g n De al pt .
● Set the safety lock control lever to the lock position.
● Do not touch any control lever. If some control lever must be operated, send signal to other people and warn them to transfer to safe place quickly. ● Do not drop or insert the tools and other objects into the fan or fan belt, or the parts will be broken or thrown out.
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2.3.5 Safety Partners
No one should be allowed to perform work operations in any shop alone. It should be a general shop safety rule for a minimum of two people in the shop area at all times when work procedures are performed. A person alone in the shop might not be able to get emergency help in the event of a shop accident.
When working together always maintain clear contact with each other at all times to avoid the occurrence of unexpected incidents. When carrying out any operation with two or more workers, always agree on the operating procedures and signals before starting.
Fig. 2-17
Shop Manual - April 2014
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4 Repair Precautions 2.4.1 Running the Machine Run the machine during repair procedures ONLY if directed to do so in this shop manual. If the machine must be run when making repairs, it is important to follow some basic safety rules. ● Always be aware of rotating components.
In Ma t rk er n et a in ti o g n De al pt .
● 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 repairs on the machine at all times.
CZ335-1102077
Fig. 2-18
● If equipped, all lock levers must be in the LOCK position or the parking brake must be in the PARK position. ● The person in the cab must never touch any controls. If a control lever must be operated, always maintain a clear view to the person doing the repair and signal them when you are about to move the control lever.
● Be aware of hot surfaces. During running operations, most surfaces will be hot, and some surfaces will be extremely hot. If necessary, use personnel protective equipment when working around high temperature surfaces.
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CC13031805
Fig. 2-19
● Keep in mind that during running operations, hydraulic systems, cooling systems and fuel systems will be under extremely high pressure and at high temperatures. ● Always use caution when working on or near these systems.
CZ335-1102012
Fig. 2-20 2-16
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.2 Mounting and Dismounting It is important to follow these procedures when mounting or dismounting the equipment: ● Use all hand-holds and step plates on your equipment. ● Never jump off or onto the equipment. ● Wipe off any oil, grease, or mud from your shoes, rails, steps or platforms before getting on the equipment; always keep these areas clean and in good condition.
In Ma t rk er n et a in ti o g n De al pt .
● Never get on or off moving equipment. These actions may lead to serious injury. Always bring the equipment to a full stop and turn the engine OFF.
● When getting on or off the equipment, always face the equipment and maintain a three-point contact (both feet and one hand or one foot and both hands) with the handrails, steps and platforms to ensure that you support yourself correctly.
Fig. 2-21
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● Never climb on areas of the machine that are not designated walk areas.
● Never climb on or off the machine with tools, parts or similar objects in your hands. ● Never use machine controls or non-specified points on the equipment to get on or off the machine. ● Use all hand-holds when on the machine.
Fig. 2-22
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.3 Removing Attachments ● If you will be removing large heavy attachments 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 storing is sitting stable on a stable surface and clear of all walkways or fire exits.
In Ma t rk er n et a in ti o g n De al pt .
WX235R-1200009
Fig. 2-23
2.4.4 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 machine or a hydraulic jack to support the machine during repairs.
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● Always lower the work equipment to the ground and check the stability of the machine before going under the machine.
CZ335-1102078
Fig. 2-24
2.4.5 Adding Fluids to a System
If it should be necessary to add fluids to a system during running operations, always be aware that these systems may be hot and under high pressure. Before adding fluids, shut the machine down and allow the systems to cool down to outdoor ambient temperatures before removing any caps. Failure to do so may result in serious burns or a sudden loss of fluid.
Fig. 2-25
2-18
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.6 Aligning Parts or Components ● Be careful when installing or aligning parts or components. ● Avoid using your fingers or hands to position holes or part mating surfaces, serious injury could result if your hand or fingers should get ought between the surfaces.
In Ma t rk er n et a in ti o g n De al pt .
● Always use tools to align a part or component to avoid any finger or hand injuries.
WX235R-1200012
Fig. 2-26
2.4.7 Driving Pins
When using a hammer to drive pins, metal particles may fly off. This may lead to serious eye injuries. Always do the following: ● Always wear a face shield or goggles when striking a metal object with a metal hammer.
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● Before performing any of these procedures, 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. Damage to the component may result. Always use a soft or non-ferrous hammer to drive a component or a pin.
CZ335-1102069
Fig. 2-27
2.4.8 When compressed air is used When compressed air is used for cleaning, flying particles may cause personal injury. In this case, wear goggles, dust-preventive mask, gloves and other protective gear.
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.9 Welding operation There is possibility of fire or electrocution during welding. Therefore, welding must be performed by qualified personnel with suitable equipment. Never allow other people to do the welding.
In Ma t rk er n et a in ti o g n De al pt .
CZ335-1102070
Fig. 2-28
2.4.10 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.
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Be careful when removing or installing tracks on track-type machines. When removing the master track link the track system may separate suddenly and cause possible injury.
Always stand clear of the track travel path when separating the master link section of the track.
2-20
Fig. 2-29
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.11 High-Pressure Fluid Lines Always keep in mind that these systems are under high pressure. When inspecting or replacing piping or hoses, always check to be sure the pressure in the system has been relieved before proceeding. Working on a system still under pressure could lead to serious injury, always do as follows:
In Ma t rk er n et a in ti o g n De al pt .
● If you will be removing a line or component with fluid in the system, always cap and seal the opening to avoid leakage or system 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 cardboard when checking for leaks from small holes.
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● If high pressure fluids should penetrate your skin or get into your eyes, seek medical attention immediately.
CZ335-1102082
Fig. 2-30
Shop Manual - April 2014
2-21
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.12 Air-conditioning system maintenance WARNING ● Refrigerant R134 a is a harmless gas under room temperature. It will change into highly toxic gas when burning. ● Refrigerant getting into eyes may cause blindness. It may cause frostbite if splashed on your skin.
In Ma t rk er n et a in ti o g n De al pt .
● Keep fire source away when servicing airconditioning system. ● In maintenance of air-conditioning system, observe the instruction on the refrigerant cylinder and use it correctly. The type of refrigerant is R134a. Use of other refrigerants may damage the air-conditioning system. ● Obey local material disposal regulations. Never discharge refrigerant directly into the air.
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CZ335-1102083
Fig. 2-31
2.4.13 High voltage precautions
You must understand the elements before testing electric circuit. High voltage or current could lead to machine damage, spark, explosion or fire.
You must know the voltage before repairing or testing electrical system. Always check the circuit and make sure it is disconnected before doing repair job. Only explosion-proof light can be used when you work near flammable fluids or explosive system. Unapproved illumination equipment could lead to explosion or fire.
2-22
CZ335-1102084
Fig. 2-32
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.14 Disconnecting the System Power Before starting any repair operations, remove the battery leads from the battery or set the main disconnect on the machine in the OFF position. For the location of the machine main electrical disconnect switch, refer to the machines Safety, Operation & Maintenance Manual for location and procedures.
In Ma t rk er n et a in ti o g n De al pt .
If the battery must be disconnected, remove the negative (-) terminal clamp first then remove the positive (+) clamp last.
Fig. 2-33
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.
2.4.15 Accumulator
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If the machine is equipped with an accumulator 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. ● Never strike the accumulator.
● Use only nitrogen gas to charge the accumulator. Unapproved gases could be explosive.
CZ335-1102085
Fig. 2-34
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2-23
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.17 Battery Hazards Working around batteries always poses a hazard, especially if the battery has been in service 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 equipment when working around batteries. ● Battery gasses are extremely explosive. When opening a battery compartment, always allow ample time for the gasses to escape before servicing the battery.
In Ma t rk er n et a in ti o g n De al pt .
CZ335-1102061
Fig. 2-35
● When working with batteries, always work in a well ventilated area.
● If the battery is corroded, flush the area with a baking soda and warm water mix.
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销 营
CZ335-1102062
Fig. 2-36
● If battery acid should get on your skin or in your eyes, flush the area immediately with fresh water and seek medical attention.
CZ335-1102083
Fig. 2-37
2-24
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.18 Jump-Start Safety CAUTION ● Never use a welder or a machine with a higher voltage system to jump-start the machine. Doing so may damage the machine’s electrical system or cause an unexpected explosion or fire resulting in minor or major injury.
In Ma t rk er n et a in ti o g n De al pt .
When using jumper cables to start the machine, connect the positive (+) jumper first, then the negative (-) jumper to a remote location on the chassis away from the battery.
Fig. 2-38
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2-25
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.19 Avoiding fire and explosion WARNING
In Ma t rk er n et a in ti o g n De al pt .
● Never smoke when handling the fuel or maintaining the fuel system. The gases in empty fuel tank can cause explosion easily. Never carry out flame-cutting or welding operation on fuel pipe, fuel tank or fuel vessels, which can lead to fire, explosion, injury or death.
● Then engine must be shut down and electrical equipment must be switched off when refueling the tank. Be extremely careful when adding fuel to a hot engine. No sparks shall occur around the grounding nozzle. ● Handle all solvents and dry chemicals in a place with good ventilation according to the steps indicated on vessel.
● Clean the machine of all dust and residuals. Never place greasy rag or other flammable materials on machine.
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CZ335-1102014
Fig. 2-39
● When cleaning the parts and components, use nonflammable solvents instead of gasoline, diesel oil or other flammable fluids. ● Store flammable liquids and materials in suitable vessels as required by safety laws and regulations.
● Check fire extinguishers, fire-fighting system and fire detectors (if equipment) and make sure they are ready for use.
2-26
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.20 Chemical hazard
In Ma t rk er n et a in ti o g n De al pt .
Exposure to hazardous chemicals pose a serious danger if released or mishandled. Handling hazardous materials often releases substances that could pose a hazard. Temporary implication or possible residual injury may result unless proper precautions are observed while working with these materials. All workers involved in handling hazardous materials should use approved personal protective equipment and follow all environmental safety regulations.
2.4.21 Material Safety Data Sheets (MSDS)
Material Safety Data Sheet (MSDS) information relating to the materials the workers could be exposed to.
● MSDS data sheets provide both workers and emergency personnel with the proper procedures for handling or working with a particular substance. Information includes physical data, health effects, first aid, reactivity, storage, disposal and protective equipment required.
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● Be sure all personnel involved are familiar with all MSDS-related information as it relates to the hazardous materials they could be exposed to. Keep MSDS data sheets handy in site of all employees and emergency personnel where they can be easily accessed.
Fig. 2-40
● Never handle hazardous materials without the proper MSDS information. Always verify the data on the MSDS sheet before handling any hazardous materials.
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.4.22 Proper disposal of wastes Improper disposal of wastes harms the environment and ecology. Consult local environmental protection department or Sany distributors for methods of recycling and waste disposal. ● Potential harmful substances used in Sany products include hydraulic oil, fuel, cooling liquid, refrigerant, filter and batteries etc.. ● Use leak-proof vessels to hold discharged fluids. Never use food or beverage containers.
CZ335-1102086
In Ma t rk er n et a in ti o g n De al pt .
Fig. 2-41
● Never dump waste fluids directly to the ground, sewage or water source.
● Leaking of refrigerant from air conditioner can spoil the atmosphere of the globe. Related laws and regulations must be followed to recover or regenerate the refrigerant.
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CZ335-1102087
Fig. 2-42
2-28
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.5 Other Precautions 2.5.1 Sling work and giving signals
Load capacity kN(kg)
1. Only one appointed worker is allowed to give signals and co-workers must communicate with each other frequently. The appointed signal person must give specified signals clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The signal person must always stand in front of the load and guide the operator safely.
19.6 2000 19.6 2000
kN kg 18.6 1900
16.7 1700
13.7 1400
9.8 1000
9.8 1000
In Ma t rk er n et a in ti o g n De al pt .
● Do not stand under the load.
30
60
90
120
4.9 500
150
Hanging angle (Deg.)
● Do not step on the load.
2. Check the slings before starting sling work.
ZX215-1000001
Fig. 2-43
3. Always wear gloves during sling work. (Wear leather gloves, if available.) 4. Measure the weight of the load by the eye and check its center of gravity.
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5. Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 销 营
6. Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.
7. Limit the hanging angle to 60º, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120 ° . If the 2 ropes sling a 19.6 kN {2,000 kg} load
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
at a lifting angle of 150 ° , each of them is subjected to a force as large as 39.2 kN {4,000 kg}. 8. When installing wire ropes to an angular load, apply softeners to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9. Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 100%
88%
79%
71%
In Ma t rk er n et a in ti o g n De al pt .
10. Apply wire ropes to the middle portion of the hook.
● Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
ZX215-1000002
Fig. 2-44
11. Do not use twisted or kinked wire ropes.
12. When lifting up a load, observe the following.
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● Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. ● After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and softener. ● If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. ● Do not lift up the load slantingly. 13. When lifting down a load, observe the following.
● When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. ● Check that the load is stable, and then remove the sling. 2-30
41%
Shop Manual - April 2014
Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
● Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
2.5.2 Using mobile crane CAUTION
In Ma t rk er n et a in ti o g n De al pt .
● Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
2.5.3 Using overhead hoist crane
1. Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety.
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销 营
2. Observe the signals for sling work. 3. Operate the hoist at a safe place.
4. Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail 5. Do not sling a load slantingly. Do not move the crane while the slung load is swinging.
6. Do not raise or lower a load while the crane is moving longitudinally or laterally. 7. Do not drag a sling.
8. When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9. Consider the travel route in advance and lift up a load to a safe height. 10. Place the control switch on a position where it will not be an obstacle to work and passage.
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
11. After operating the hoist, do not swing the control switch. 12. Remember the position of the main switch so that you can turn off the power immediately in an emergency. 13. If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state.
In Ma t rk er n et a in ti o g n De al pt .
14. If you find an obstacle around the hoist, stop the operation.
15. After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
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Shop Safety
SY365(B)H-9 Crawler Hydraulic Excavator
2.5.4 Selecting wire ropes Select adequate ropes according to the weight of parts to be hoisted. See the table below. Wire Rope (Standard Z or S type of strand, ungalvanized) Nominal Diameter
Allowable Load
kN
t
10
9.8
1.0
11.5
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
18
35.5
3.6
20
43.1
4.4
22.4
54.9
5.6
30
98.1
10.0
176.5
18.0
50
274.6
28.0
60
392.2
40.0
In Ma t rk er n et a in ti o g n De al pt .
mm
40
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CAUTION
● The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
Shop Manual - April 2014
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Shop Safety
BLM In t aAr e kNe rn a tKi t i nP o gA n al DG ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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2-34
Shop Manual - April 2014
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Specifications 3 Specifications
3.1 Specific Dimension .................................................................................................. 1-3 3.1.1 Dimension ...................................................................................................... 1-3 3.1.2 Working ranges .............................................................................................. 1-4 3.2 Technical Specifications........................................................................................... 1-5 3.3 Weight Table ............................................................................................................ 1-7 3.4 Engine oil, Fuel and Coolant.................................................................................... 1-8 3.5 Engine Performance Curves.................................................................................... 1-9 司
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Shop Manual - April 2014
3-1
Specifications
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
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3-2
Shop Manual - April 2014
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
3 SPECIFICATIONS 3.1 Specific Dimension 3.1.1 Dimension
A D
I
C
In Ma t rk er n et a in ti o g n De al pt .
E
G B
H
L
F
J K
Fig. 3-1
CZ425-1103002
司
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Item
Unit
SY365H-9
SY365BH-9
Shipping length
mm
11,360
11,380
Overall width
mm
3,190
3,190
Shipping height
mm
3,550
3,640
Top width
mm
3,150
3,150
Overall height (to cab top)
mm
3,320
3,320
Standard width of track shoe
mm
600
600
Gauge
mm
2,590
2,590
Min. ground clearance
mm
550
550
Tail swing radius
mm
3,380
3,380
J
Track grounding length
mm
4,140
4,140
K
Track length
mm
5,065
5,065
L
Upper-structure ground clearance
mm
1,250
1,250
A B C D E F G H I
Shop Manual - April 2014
1-3
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
3.1.2 Working ranges
a
In Ma t rk er n et a in ti o g n De al pt .
f
g
b
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d
c
e
CZ425-1103004
Fig. 3-2
1-4
Shop Manual - April 2014
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
Unit
SY365H-9
SY365BH-9
a
Max. cutting height
mm
9,900
9,850
b
Max. dumping height
mm
6,930
6,815
c
Max. digging depth
mm
7,040
6,750
d
Max. vertical wall depth
mm
5,180
4,870
e
Max. digging reach
mm
10,610
10,405
f
Min. swing radius
mm
4,330
4,300
g
Max. height at min. swing radius
mm
8,600
8,720
In Ma t rk er n et a in ti o g n De al pt .
Item
3.2 Technical Specifications Item
Unit
SY365H-9
SY365BH-9
Bucket capacity
m3
1.6（Rockwork）
1.8（Earthwork）
Operating weight
kg
35,000
35,000
Max bucket digging force
KN
235
235
Max arm-in force
KN
180
206
Swing speed
rpm
9.5
9.5
Travel speed (high/low)
km/h
5.5/3.5
5.5/3.5
Degree
35
35
KPa
63
63
Gradeability
Specific ground pressures
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Shop Manual - April 2014
1-5
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
Machine Model
SY365H-9
SY365BH-9
In Ma t rk er n et a in ti o g n De al pt .
Performance
ISUZU AA-6HK1XQP-01 6 cylinders, 4 cycles, water cooling, in-line, and direct injection Type No. Of cylinder-bore × 6-Φ115mm×125mm mm 7.8 stroke L Total displacement Rated power kW/rpm 190.5/ 2000 Max. torque N·m/rpm 873 / 1700 Max. speed at zero load rpm 2200±25 1000±25 Min. speed at zero load rpm 237 Min. fuel consumption g/kWh Start motor 24V/5kW 24V/50A Alternator Carrier roller (each side) 2
Track shoe (each side)
49
Type KAWASAKI (two variable swash plate plunger pumps, constant Max main pump delivery power control and proportional solenoid valve) L/min 2×158 Main safety valve presMpa 34.3 sure
Type X No. Control method
Hydraulic motor
Hydraulic pump
9
Control valve
Track roller (each side)
Hydraulic cylinder
Hydraulic system
Undercarriage
Engine
Model
司
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KMX32NA/P45001×1 Hydraulic type
Angle type variable plunger motor A6VE107HZ3/63WVZL22XB-S Planetary gear reducer F80/121/OM/MB (Including brake valve and parking brake)×2 Angle type plunger motor - planetary gear reducer (upright) M5×180CHB-10A-3NA/265 - RG20D25G2-140 (Swing stop controller)×1 Boom Arm Bucket Boom Arm Bucket
Travel motor
Swing motor
Type Cylinder inner diameter Piston rod diameter Stroke
Reciprocal plunger mm mm mm
140 100 1420
170 120 1748
Hydraulic tank Hydraulic oil filter element Hydraulic oil cooler 1-6
140 100 1135
Reciprocal plunger 140 100 1480
Closed type Tank return side Air-cooling type Shop Manual - April 2014
160 110 1685
140 100 1748
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
3.3 Weight Table Unit: kg SY365H-9
SY365BH-9
Engine
720
720
Radiator assembly Hydraulic tank assembly (excluding hydraulic oil) Fuel tank assembly (excluding fuel)
118
118
234
234
235
235
Swing platform
3040
3040
Operator station
150
150
In Ma t rk er n et a in ti o g n De al pt .
Machine Model
Operator seat & console
76
76
Counterweight
6800
6800
Hydraulic pump
186
186
Main control valve
380
380
Swing reducer assembly
422
422
Travel reducer assembly
389×2
389×2
45
45
4612 544 175×2 190×2 35×4 44×18
4612 544 175×2 190×2 35×4 44×18
2574
2574
Arm assembly
1165
1200
Bucket assembly
1620
1582
264×2
264×2
Arm cylinder assembly
484
484
Bucket cylinder assembly
150
150
Connecting rod
114
105
35×2
40×2
Swivel joint Track frame Swing bearing Idler Tensioning device Carrier roller Track roller Boom assembly
Boom cylinder assembly
Rocker arm
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Note: The weight table is only used as a reference for handling the components or transporting the machine.
Shop Manual - April 2014
1-7
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
3.4 Engine oil, Fuel and Coolant Reservoir
Liquid type
-22 -30
-4 -20
14 -10
Ambient temperature 32 50 68 0 10 20
86 30
104 40
SAE 30 SAE 10W Engine oil pan SAE 10W-30
Engine oil
In Ma t rk er n et a in ti o g n De al pt .
SAE 15W-40 Carrier roller Idler Track roller Swing drive Final drive
SAE 30
Gear oil
SAE 10W
SAE 10W-30
Engine oil
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SAE 15W-40
Hydraulic system
HDZ32 low temp, wear-resistant
Hydraulic oil
HDZ46 wear-resistant
HDZ68 wear-resistant
GB252 super 0#
Fuel tank
GB252 super -20#
Diesel oil
GB252 super -35#
Grease fitting
Grease
Cooling system
Coolant
NLGI No.2 TEEC-L35 antifreeze
Note: 1) Sany recommends using API CF-4 or above, not lower than API CD. 2) Sany recommends using gear oil GL-5. 3) To ensure oil quality, always buy genuine oil from Sany or your Sany distributor. 1-8
Shop Manual - April 2014
122 ℉ 50℃
Specifications
SY365(B)H-9 Crawler Hydraulic Excavator
3.5 Engine Performance Curves AA-6HK1XQP-01 Test condition: 1. Temperature 298K, one standard atmospheric pressure. 2. Maximum output power: 183.9KW (with fan); 190.5KW (without fan) Max torque
1050
872.8 or more Ｎｍ/approx.1700 min-1 (872.8～/approx.1700 min -1)
In Ma t rk er n et a in ti o g n De al pt .
950 850 750 650
Max output power
183.9±2.9 kW/2000 min-1 (181.0～186.8kW/2000min-1 )
200
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150
100
50
Max speed without load
2275±25 min-1 -1 (2250～2300min )
0
Rate of fuel consumption (Max output power)
280
236.6 g/kWh or less （～236.6 g/kWh)
260 240 220 200 180
800
1000
1200
1400
1600
1800
2000
2200
2400 W36531305
Fig. 3-3 Shop Manual - April 2014
1-9
Specifications
BLM In t aAr e kNe rn a tKi t i nP o gA n al DG ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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1-10
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Structure and Functions
In Ma t rk er n et a in ti o g n De al pt .
2
4 Structure and Functions
4.1 Engine and Cooling System ................................................................................... 4-5 4.1.1 Engine-related parts....................................................................................... 4-5 4.1.2 Radiator and intercooler................................................................................. 4-6 4.2 Power Train.............................................................................................................. 4-7 4.2.1 Overview ........................................................................................................ 4-7 4.2.2 Travel reducer AS ......................................................................................... 4-8 4.2.3 Swing reducer mechanism........................................................................... 4-10 4.2.4 Swing bearing .............................................................................................. 4-12 4.3 Undercarriage Travel System ............................................................................... 4-14 4.3.1 Track frame and tensioning mechanism ...................................................... 4-14 4.3.2 Idler .............................................................................................................. 4-16 4.3.3 Carrier roller ................................................................................................. 4-18 4.3.4 Track roller ................................................................................................... 4-19 4.3.5 Track ........................................................................................................... 4-20 4.3.6 Tri-grouser track shoe .................................................................................. 4-23 4.4 Hydraulic System, Part 1 ....................................................................................... 4-24 4.4.1 Deployment of hydraulic parts ..................................................................... 4-24 4.4.2 Hydraulic tank and filter ............................................................................... 4-26 4.4.3 Hydraulic pump ............................................................................................ 4-28 4.4.3.1 Outline................................................................................................. 4-29 4.4.3.2 Function .............................................................................................. 4-31 4.4.3.3 Structure ............................................................................................. 4-31 4.4.3.4 Operating principle .............................................................................. 4-32 司
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Shop Manual - April 2014
4-1
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
4.4.3.5 Oil delivery control .............................................................................. 4-33 4.4.4 Pilot pump .................................................................................................... 4-34 4.4.5 Regulator .................................................................................................... 4-35 4.5 Hydraulic system, Part 2 ........................................................................................ 4-48 4.5.1 Main control valve ........................................................................................ 4-48 4.5.1.1 Overview ............................................................................................ 4-48 4.5.1.2 Main valve structure ............................................................................ 4-50 4.5.2 Hydraulic circuit (With bucket confluence function) .............................................. 4-56 4.6 Hydraulic System, Part 3 ....................................................................................... 4-79 4.6.1 Swing motor ................................................................................................. 4-79 4.6.2 Swing holding brake..................................................................................... 4-81 4.6.3 Relief valve section ...................................................................................... 4-82 4.6.4 Anti-jerk valve............................................................................................... 4-84 4.6.4.1 Operation diagram .............................................................................. 4-84 4.6.4.2 Effect illustration.................................................................................. 4-84 4.6.5 Central Swivel Joint ..................................................................................... 4-86 4.6.6 Travel motor ................................................................................................. 4-87 4.6.7 Reducer ....................................................................................................... 4-89 4.6.8 Travel motor (Nabtesco) .............................................................................. 4-91 4.6.9 Operating principle of the basic components ............................................... 4-93 4.6.9.1 Double-balanced valve ....................................................................... 4-93 4.6.9.2 Operation of parking brake ................................................................. 4-98 4.6.9.3 Operation of braking valve .................................................................. 4-99 4.6.10 Control system ......................................................................................... 4-108 4.6.11 Manual pilot valve .....................................................................................4-110 4.6.12 Travel pilot valve .......................................................................................4-114 4.6.12.1 Operating principle ...........................................................................4-116 4.6.13 Solenoid valve...........................................................................................4-118 4.6.14 PPC accumulator ......................................................................................4-119 4.6.15 Pilot oil filter.............................................................................................. 4-121 4.6.16 Hydraulic cylinders ................................................................................... 4-122 4.6.16.2 Lubrication at every 100 service hours ........................................... 4-123 4.6.16.1 Lubrication at every 500 service hours ........................................... 4-123 4.7 Work Equipment .................................................................................................. 4-124 4.7.1 Component dimensions ............................................................................. 4-124 4.7.2 Arm dimensions ......................................................................................... 4-126 司
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4-2
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
4.7.2.1 Bucket dimensions ............................................................................ 4-128 4.8 Operator Station and Its Attachments .................................................................. 4-130 4.8.1 Air conditioner lines .................................................................................... 4-130 4.8.1.1 Layout of A/C components ................................................................ 4-132 4.8.1.2 A/C control panel............................................................................... 4-133 4.8.1.3 Diagram of electrical circuit ............................................................... 4-134 4.8.1.4 Operating principle ............................................................................ 4-136 4.8.1.5 Compressor ...................................................................................... 4-137 4.8.1.6 Clutch ................................................................................................ 4-139 4.8.1.7 Condenser ........................................................................................ 4-140 4.8.1.8 Expansion valve ................................................................................ 4-141 4.8.1.9 Evaporator ........................................................................................ 4-141 4.8.1.10 Dehydrator ..................................................................................... 4-142 4.8.1.11 Pressure switch .............................................................................. 4-143 4.8.1.12 Fresh air sensor .............................................................................. 4-144 4.8.2 Refrigerant ................................................................................................. 4-145 4.8.2.1 Compressor oil .................................................................................. 4-163 4.9 Engine Control ..................................................................................................... 4-164 4.9.1 System operation ....................................................................................... 4-165 4.9.1.1 Engine starting .................................................................................. 4-165 4.9.1.2 Engine speed control ........................................................................ 4-165 4.9.1.3 Engine shutdown .............................................................................. 4-165 4.9.2 System components .................................................................................. 4-166 4.9.2.1 Fuel control dial................................................................................. 4-166 4.9.2.2 Controller .......................................................................................... 4-168 4.10 Electrical Control System................................................................................... 4-170 4.10.1 Control function ........................................................................................ 4-170 4.10.2 Diagram of machine control system......................................................... 4-171 4.10.3 Engine-pump combination control ........................................................... 4-173 4.10.4 Pump control function .............................................................................. 4-177 4.10.4.1 Constant power control ................................................................... 4-180 4.10.4.2 ESS control ..................................................................................... 4-180 4.10.5 Valve control function ............................................................................... 4-181 4.10.6 Dual travel speed control ......................................................................... 4-183 4.10.7 Engine preheat/overheat alarm ............................................................... 4-185 4.10.8 Auto deceleration/acceleration control ..................................................... 4-187 司
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Shop Manual - April 2014
4-3
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
4.10.9 Engine speed calibration function ............................................................ 4-188 4.10.10 System parts and components .............................................................. 4-190 4.11 Monitoring System ............................................................................................. 4-195 4.11.1 Monitor ..................................................................................................... 4-196 4.11.2 Monitor panel ........................................................................................... 4-197 4.11.2.1 Alert and signal indicators .............................................................. 4-197 4.11.2.2 Operation keys ................................................................................ 4-199 4.11.3 Monitor display and operation .................................................................. 4-201 4.11.3.1 Default page .................................................................................... 4-201 4.11.3.2 Password entry to system information ............................................ 4-202 4.11.3.3 Main menu ...................................................................................... 4-202 4.11.3.4 Engine & throttle signals ................................................................. 4-203 4.11.3.5 Pilot pressure signals ...................................................................... 4-203 4.11.3.6 Main pump & main valve signals..................................................... 4-204 4.11.3.7 Failure codes................................................................................... 4-204 4.11.3.8 Throttle help information ................................................................. 4-205 4.11.3.9 Language selection ......................................................................... 4-205 4.11.3.10 System clock setup ....................................................................... 4-206 4.11.3.11 GPS information ............................................................................ 4-207 4.11.3.12 System setup ................................................................................ 4-208 4.11.3.13 Machine configuration ................................................................... 4-208 4.11.3.14 Service hour setup ....................................................................... 4-209 4.11.3.15 Machine configuration setup ......................................................... 4-210 4.11.3.16 Hydraulic oil temperature ...............................................................4-211 4.11.3.17 Screen brightness setup ................................................................4-211 4.11.3.18 System lockout (level 1) ................................................................ 4-212 4.11.3.19 System lockout (level 2) ................................................................ 4-212 司
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4-4
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4 STRUCTURE AND FUNCTIONS 4.1 Engine and Cooling System 4.1.1 Engine-related parts
1
M6
2
M6
In Ma t rk er n et a in ti o g n De al pt .
Ⅱ
俁 2
Ⅰ
4
3
I
4
司
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Ⅱ
Coupling installation
5
6
4×M18×60-10.9
Tightening torque 320N•m
2×M16
Tightening torque 120N•m
AA-6HK1XQA
7
W365413091
Fig. 4-1 (1) (2) (3) (4) (5) (6) (7)
Air cleaner Muffler AS Air cleaner Damper Flywheel Coupling Plunger pump
Specification Engine oil capacity: 35 L
Shop Manual - April 2014
4-5
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.1.2 Radiator and intercooler 3 4
1
In Ma t rk er n et a in ti o g n De al pt .
5
2
6
7
司
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W365413092
Fig. 4-2 (1) (2) (3) (4) (5) (6) (7)
4-6
Coolant tank Water inlet pipe Water outlet pipe Air intercooler Condenser Oil radiator Water radiator
Specification
Radiator AS: H1260×460×1100-S105Y100Z30 Aluminum ribbon-tublar radiator
Tank capacity: 8.4 L
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.2 Power Train 4.2.1 Overview 2
1
In Ma t rk er n et a in ti o g n De al pt .
3
4
5
6
司
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7
8
9
10
ZX365-1304003
Fig. 4-3 (1) (2) (3) (4) (5)
Swing motor (M5×180CHB-10A-3NA/265) Swing reducer (RG20D25G2-140) Swing bearing Idler Swivel joint
(6) Accumulator (7) Main control valve (KMX32NA/P45001) (8) Travel reducer (F80/121/OM/MB) (9) Plunger pump (K5V160DTH1×4R-9T06-V) (10) Engine (AA-6HK1XQP-01)
Shop Manual - April 2014
4-7
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.2.2 Travel reducer AS
7
6
In Ma t rk er n et a in ti o g n De al pt .
10
司
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1
9
8
2
3
4
5
11
12°
12
Fig. 4-4 4-8
Shop Manual - April 2014
ZX335-1002050
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
(1) (2) (3) (4) (5) (6)
Gear hub No.1 planetary gear No.1 planetary carrier pin No.1 sun gear No.1 planetary carrier No.2 planetary gear
(7) No.2 planetary carrier pin (8) No.2 sun gear (9) No.2 planetary carrier (10) Motor (11) Check port (12) Filler/drain port
Check item
13
Clearance between No.2 planetary gear and gear hub
14 15 16
Criteria 0.100 ～ 0.356
Remedy 1.10
In Ma t rk er n et a in ti o g n De al pt .
No.
Clearance between No.1 planetary gear and gear hub
0.133 ～ 0.386
1.00
Clearance between No.1 sun gear and No.1 planetary gear
0.05 ～ 0.286
1.10
Clearance between No.2 sun gear and No.2 planetary gear
0.076 ～ 0.304
1.00
Replace
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Shop Manual - April 2014
4-9
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.2.3 Swing reducer mechanism
9
19
In Ma t rk er n et a in ti o g n De al pt .
20
21
8
24
22 10
6
23 11 12
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5
26
7
4
13
14
3 2
15
1
17 16 18 28 ZX335-1002004
Fig. 4-5
4-10
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
(1) Plug (2) Oil seal (3) Self-aligning bearing (4) Gear ring (teeth: 66) (5) No.2 planetary carrier (6) No.1 planetary carrier (7) No.2 sun gear (teeth: 18) (8) No.1 sun gear (teeth: 15) (9) Swing motor (10) No.1 planetary gear (teeth: 25)
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)
No.2 planetary gear GP No.2 planetary gear (teeth: 23) Spring pin Screw plug Grease fitting Self-aligning bearing Bearing seal Pinion gear Dipstick Oil-filling tube
In Ma t rk er n et a in ti o g n De al pt .
Specification
Reduction ratio: 25.2
No. 21 22 23 24 25 26 27 28
Check Item
Criteria
Clearance between swing motor shaft and No.1 sun gear
Clearance between No.1 sun gear and No.1 planetary gear Clearance between No.1 planetary gear and gear ring Clearance between No.1 planetary carrier and No.2 sun gear Clearance between No.2 sun gear and No.2 planetary gear Clearance between No.2 planetary gear and gear ring Clearance between No.2 planetary carrier and swing pinion gear Clearance between swing pinion gear and swing bearing
Standard clearance
Clearance limit
0.18- 0.28
—
0.16- 0.50
1.00
0.18- 0.59
1.10
0.39- 0.71
1.20
0.16- 0.50
0.90
0.18- 0.59
1.00
0.07- 0.23
—
0.22- 1.32
2.00
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Shop Manual - April 2014
Remedy Replace
Replace
4-11
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.2.4 Swing bearing b ●
●
●
a
A
In Ma t rk er n et a in ti o g n De al pt .
A
1
2
司
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927±103 Nm
927±103Nm
A-A
ZX335-1002005
Fig. 4-6 (1) Inner race (teeth: 78) (2) Steel ball (3) Outer race
Specification Reduction ratio: 78/11= 7 Grease volume filled: 27±1 Kg
a. Location S (soft zone of inner race) b. Location S (soft zone of outer race)
4-12
3
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Check Item
Remedy
Standard clearance
Clearance limit
0.5-1.6
3.2
Replace
In Ma t rk er n et a in ti o g n De al pt .
Bearing axial clearance (Mounted on chassis)
Criteria
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Shop Manual - April 2014
4-13
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.3 Undercarriage Travel System 4.3.1 Track frame and tensioning mechanism 2
3
4
In Ma t rk er n et a in ti o g n De al pt .
1
11
9
8
7
6
5
Ɣ
10
12
司
X
公
销 营
X
ZX365-1304006
Fig. 4-7 (1) (2) (3) (4) (5) (6) (7) (8) (9)
Idler Track frame Carrier roller Sprocket Track roller Track Long guard Short guard Guide seat
4-14
● Dimension and number of track rollers may vary depending on the machine model, but their basic structures are the same. ● Number of track rollers on one side: 9
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Unit: mm No.
Check Item
10
Vertical width of idler guide
11
Standard
Horizontal width of idler guide
Standard size Track frame
123
Idler support
120
Track frame
266
Idler support
261
Remedy Tolerance
Standard size
+3 — -1 ±0.5 — +4 — -1 0 — -0.5 Repair limit
Free length × Outer diameter
Installation length
Installation load
Free length
Installation load
1225x 262
655
{21280kg} 208.5KN
795
—
In Ma t rk er n et a in ti o g n De al pt .
12
Repair limit
Tension spring
Standard track shoe
Build-up welding or replace
Replace
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Model
SY365H-9/SY365BH-9
Item Shoe width (mm)
Link pitch (mm) Number of track shoes on one side
600
216 49
Shop Manual - April 2014
4-15
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.3.2 Idler
5 6 4 3 7
8
In Ma t rk er n et a in ti o g n De al pt .
9
157~255 Nm
1
2
司
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ZX215-1002010
Fig. 4-8
4-16
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Unit: mm No.
Check item
1
Protrusion outer dia.
2
Criteria
Remedy
Standard size
Repair limit
635
—
Tread outer dia.
590
578
3
Tread thickness
30
24
4
Tread difference
22.5
26
5
Overall width
190
—
6
Tread width
44
—
8
9
Clearance between shaft and bushing
Shaft
φ80
—
Hole
Standard clearance
Clearance limit
—
—
—
In Ma t rk er n et a in ti o g n De al pt .
7
Tolerance
Standard size
Build-up welding or replace
Interference between idler and bushing
Clearance between bushing and support (Sum of clearances at both sides)
Tolerance
Standard size
Shaft
Hole
Standard interference
Interference limit
φ86
—
—
—
—
Standard clearance 司
Replace bushing
Clearance limit
公
销 营
0.5-1.0
Shop Manual - April 2014
—
4-17
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.3.3 Carrier roller
5
3
In Ma t rk er n et a in ti o g n De al pt .
8
4
6
7
2
1
司
公
销 营
ZX215-1002011
Fig. 4-9 No.
Check item
Criteria
Remedy
Standard size
Repair limit
190
—
Tread outer dia.
150
136
3
Tread width
57
—
4
Tread thickness
39
32
5
Flange width
16
—
6
Clearance between shaft and bushing
Standard size
Shaft
65
—
Interference between carrier roller and bushing
Standard size
1
Flange outer dia.
2
7
8 4-18
Carrier roller axial clearance
72
Tolerance Hole
Standard clearance
Clearance limit
—
—
—
Standard interference
Interference limit
—
—
Tolerance Shaft Hole —
—
Standard clearance
Clearance limit
0.44-0.76
—
Shop Manual - April 2014
Unit: mm
Replace
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.3.4 Track roller 10
3
9
2
1
In Ma t rk er n et a in ti o g n De al pt .
8
549±59 Nm
5
7
6
4
司
ZX215-1002012
公
销 营
Fig. 4-10 No. 1 2 3 4 5 6 7 8
Check item
Criteria
Standard clearance
Repair limit
216
—
Tread outer dia.
180
168
Tread thickness
51.5
40.5
Overall width
250
—
Tread width
50.5
—
Flange width
27
—
Inner width
95
Flange outer dia.
Clearance between shaft and bushing
Standard size
Tolerance Shaft Hole
70
—
—
Tolerance Shaft Hole
Standard clearance
Clearance limit
—
—
Standard interference
Interference limit
—
—
9
Interference between track roller and bushing
Standard size
Standard clearance
Clearance limit
10
Clearance between bushing and collar (Sum of clearances on both sides)
0.5 - 1.0
—
77
—
—
Shop Manual - April 2014
Unit: mm Remedy
Build-up welding or replace
Replace bushing
Replace
4-19
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.3.5 Track
1
In Ma t rk er n et a in ti o g n De al pt .
4
20
22
8
16
24
司
公
销 营
12
13
5
11
21
25
23
7
10
6 15
18
2
17
Fig. 4-11
4-20
3
9
Shop Manual - April 2014
19
14
ZX215-1002013
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Unit: mm No. 1
Check item
Criteria
Link pitch Bushing outer diameter
3
Bushing metal thickness
4
Link height
5
Link metal thickness (bushing pressfitting portion)
6 7 8 9
10 11
Standard size
Repair limit
216
219
Standard size
Reverse
66.9
60.23
11.1
—
Standard size
Repair limit
116
104.4
30.65
22.5
Reverse or replace
Repair or replace
In Ma t rk er n et a in ti o g n De al pt .
2
Remedy
12
178.4
Shoe bolt pitch
140.4 76.2
Link
Inside width
102
Overall width
23.2
Tread width
21.3
Pin protrusion
4.2
Adjust or replace
司
公
销 营
13 14 15 16 17 18 19
Bushing protrusion Overall length of pin Overall length of bushing Spacer thickness Press-fitting force
5.3
242
158.9 —
Bushing
88.2 -245 kN{9-25 ton}
Regular pin Master pin
127.4 -274.4 kN{13-28 ton} 78.4 -147 kN{8-15 ton}
Shop Manual - April 2014
—
4-21
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Unit: mm No.
Check item a. Regular link
20
Shoe bolt b. Master link
Interference between bushing and link
Remedy
Tightening torque(Nm{kgm}) Retightening angle (deg) 1100±55 Tri-grouser 120±10 track shoe {112.2±5.6} Tightening Lower torque torque limit Retightening angle (deg) (Nm) (Nm{kgm}) — — —
Retighten
Tolerance
Standard size
Shaft Hole +0.46 +0.074 +0.41 0 +0.19 –0.188 +0.09 –0.20 Tolerance Shaft Hole +0.19 +1.35 +0.09 +0.85
66.5
22
23
Interference between pin and link Clearance between pin and bushing
44.6
Standard size 44.6
司
公
销 营
4-22
Standard interference
In Ma t rk er n et a in ti o g n De al pt .
21
Criteria
Shop Manual - April 2014
0.36-0.464
0.285-0.485
Standard clearance 0.18-0.83
Adjust or replace
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.3.6 Tri-grouser track shoe
5
1
6
7
8
4
2
In Ma t rk er n et a in ti o g n De al pt .
3
ZX215-1002014
Fig. 4-12
No. 1 2 3 4 5 6 7 8
Check item
Height
司
公
销 营
Criteria
Standard size
Repair limit
30
20
Thickness
Unit: mm Remedy
11
29
Length of base
24
Build-up welding or replace
22
Length at tip
16 22
Thickness
Standard size
Repair limit
41
31
Shop Manual - April 2014
4-23
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4 Hydraulic System, Part 1 2
4.4.1 Deployment of hydraulic parts (1) Bucket cylinder (2) Arm cylinder (3) Boom cylinder (4) Hydraulic tank (5) Hydraulic oil filter (6) Main control valve
In Ma t rk er n et a in ti o g n De al pt .
(7) Main pump (8) Radiator
(9) Accumulator
(10) Left travel motor
(11) Right travel motor
1
(12) Swing motor
(13) Hydraulic lockout control (14) Left pilot valve
司
公
销 营
(15) Central swivel joint (16) Right pilot valve
(17) Travel pilot valve
(18) Solenoid valve AS
18A. Hi/Lo travel speed shift solenoid valve
18B. Negative flow solenoid valve (front pump)
ZX335-1002007
Fig. 4-13
18C. Negative flow solenoid valve (rear pump) 18D. Pilot lockout solenoid valve
4-24
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4
5
6
8
7
In Ma t rk er n et a in ti o g n De al pt .
3
司
公
销 营
A
10 11 12 13 14 16
17
9
18F18E
A 18D 18C 18B 18A
15 18 W365-1304008
Fig. 4-14 Shop Manual - April 2014
4-25
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.2 Hydraulic tank and filter 1
2
B
In Ma t rk er n et a in ti o g n De al pt .
6<++&
B
B-B
4
3
5
6
7
司
公
销 营
W365-1304009
Fig. 4-15
4-26
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
(1) Hydraulic tank (2) Level gauge (3) Filter element (oil drain) (4) Filler cap (5) Breather valve (6) Filter element (oil suction) (7) Filter element (oil return) Specification
In Ma t rk er n et a in ti o g n De al pt .
Tank capacity: 340 L Breather valve
Filter fineness: 10μm
Ambient temp: -30℃ -100℃
Pressure setting: Air inlet side → 0.005 MPa
Air outlet side → 0.05 MPa
司
公
销 营
Shop Manual - April 2014
4-27
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.3 Hydraulic pump Type: K5V160DTH1×4R-9T06-V B1
a5(16N·m)
a2(36N·m)
In Ma t rk er n et a in ti o g n De al pt .
a1(36N·m)
1
2
Dr1(170N·m)
B3
Dr4(170N·m)
司
公
销 营
PH1
5
4
A2
A3
Dr2(170N·m)
PH2
Psv2
A1
a3(36N·m)
Dr4(170N·m)
Psv1
3 a4(36N·m)
Fig. 4-16 4-28
Shop Manual - April 2014
ZX335-1002010
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.3.1 Outline ● This pump consists of 2 variable swash plate plunger pumps, 2 adjustors, and 1 pilot gear pump. a1: Main pressure detection port (front pump) a2: Main pressure detection port (rear pump) a3: Regulator pressure detection port (front pump) a4: Regulator control pressure detection port (rear pump)
In Ma t rk er n et a in ti o g n De al pt .
a5: Delivery pressure detection port (pilot gear pump)
PH1: Pressure sensor mounting port (front pump) PH2: Pressure sensor mounting port (rear pump) A1: Oil delivery port (front pump) A2: Oil delivery port (rear pump)
司
公
销 营
A3: Oil delivery port (pilot gear pump)
Psv1: Regulator control port (front pump) Psv2: Regulator control port (rear pump) Dr1: Drain plug (front pump) Dr2: Drain plug (rear pump) Dr4: Oil drain port
B1: Oil suction port (pump)
B3: Oil suction port (pilot gear pump) (1) 1: Front pump (2) 2: Rear pump (3) 3: Pilot gear pump (4) 4: Regulator (front pump) (5) 5: Regulator (rear pump)
Shop Manual - April 2014
4-29
Structure and Functions
2
3
13
SY365(B)H-9 Crawler Hydraulic Excavator
6
7
14
8
9
16
10
1
In Ma t rk er n et a in ti o g n De al pt .
15
4
5
12
11
ZX215-1002019
Fig. 4-17
司
公
销 营
(1) (2) (3) (4) (5) (6) (7) (8)
Front shaft Min. delivery adjusting screw Front casing Swash plate Slipper Plunger Cylinder block Oil distributor
4-30
(9) End cap (10) Rear shaft (11) Rear casing (12) Gear pump (13) Piston (14) Max. delivery adjusting screw (15) Gear pump shaft (16) Driving pin
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
1
6
13
7
8
In Ma t rk er n et a in ti o g n De al pt .
B
18
4
A
5
18
17
ZX215-1002020
Fig. 4-18
司
公
4.4.3.2 Function
销 营
● The torque of the engine is transmitted to the pump shaft (1), and drives cylinder block (7) to rotate. At the same time, nine plungers (6) slide along the oil distributor (8). Plunger (6) moves back and forth inside cylinder block (7) and pressurized oil is sucked in and discharged alternatively.
● Swash plate (4) has flat surface (A), and slipper (5) is always pressed against this surface while sliding in a circular movement.
● It is possible to change the displacement by changing the swash plate angle.
● Plunger (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).
4.4.3.3 Structure
● Cylinder block (7) is supported to shaft (1) by spline (17).
● Shaft (1) is supported by front and rear bearings (18). ● Tip of plunger (6) is shaped as a concave ball and slipper (5) is caulked to it to form one unit. ● Plunger (6) and slipper (5) constitute the spherical bearing.
● Swash plate (4) conducts high pressure oil to cylinder surface (B), and forms a static pressure bearing when it slides.
● Cylinder block (7) seals the pressurized oil to oil distributor (8) and carries out relative rotation. ● This surface is designed so that the oil pressure balance is maintained at a suitable level. ● The oil inside the respective cylinder chambers of cylinder block (7) is sucked in and delivered through oil distributor (8).
Shop Manual - April 2014
4-31
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.3.4 Operating principle ● Cylinder block (7) rotates together with shaft (1), and slipper (5) slides on flat surface (A).
1
4
7
5 A
● When this happens, swash plate (4) moves along cylindrical surface (B), so angle (a) between central line (X) of swash plate (4) and the axial direction of cylinder block (7) changes.
a X B
● (a) stands for the angle of the swash plate.
ZX215-1002021
Fig. 4-19
In Ma t rk er n et a in ti o g n De al pt .
● With central line (X) of swash plate (4) at a swash plate angle (a) in relation to the axial direction of cylinder block (7), flat surface (A) acts as a cam in relation to slipper (5).
4
A
● In this way, plunger (6) slides on the inside of cylinder block (7), so a difference between volumes (E) and (F) is created inside cylinder block (7). ● A single plunger sucks and discharges the oil by the amount (F) – (E).
6
5
F
a
X
E ZX215-1002022
司
公
销 营
7
Fig. 4-20
● As cylinder block (7) rotates and the volume of chamber (E) becomes smaller, the pressurized oil is discharged.
● On the other hand, the volume of chamber (F) grows larger and, in this process, the oil is sucked in. ● As central line (X) of swash plate (4) overlaps the axial direction of cylinder block (7) (swash plate angle (a) = 0), the difference between volumes (E) and (F) inside cylinder block (7)becomes 0.
F
● Suction and discharging of pressurized oil is not carried out in this state. Namely pumping action is not performed. (In reality, however, the swash plate angle is not set to 0)
E 4
Fig. 4-21
4-32
Shop Manual - April 2014
7
ZX215-1002023
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.3.5 Oil delivery control
13
16
F
● If swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and pump delivery (Q) increases. ● Piston (13) is used for changing swash plate angle (a). ● Piston (13) makes linear reciprocal movement under the control of the regulator.
a
● This linear motion is transmitted to swash plate (4) via drive pin (16). The sliding of the swash plate changes the swash plate angle and changes the displacement of the main pump.
E
In Ma t rk er n et a in ti o g n De al pt .
4
ZX215-1002024
Fig. 4-22
司
公
销 营
Shop Manual - April 2014
4-33
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.4 Pilot pump 435
433
710
700
354
351
434 310
355
311 312
In Ma t rk er n et a in ti o g n De al pt .
732
309
307
308
434
850
466
725
435
361
353
ZX215-1002025
Fig. 4-23
司
公
销 营
307: Valve stem 308: Valve base 309: Retainer 310: Spring 311: Adjusting screw 312: Nut 351: Body 353: Gear shaft 354: Gear shaft 355: Filter element
361: Body 433: Screw 434: Screw 435: screw 466: Plug 700: Washer 710: O-ring 725: O-ring 732: O-ring 850: Washer
Function The engine drives the main pump shaft and the pilot pump shaft through the gearbox. The pilot pump is operated through gear engagement.
4-34
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.4.5 Regulator 755
541
545 543
ൟো TYPE ᑣ߫ো SERIAL NUMBER
Pm E-E
E
铭牌 DETAIL OF STAMP FOR TYPE AND SERIAL NUMBER
601
E 642
753
467,727
F
B
496
757 413 438
656
F向
In Ma t rk er n et a in ti o g n De al pt .
D-D
418
079
439
646
438
D
司
公
销 营
D
B
722
543
755 545
755 438 466
541
724
C向
897
876
874
A
412 612
730
643
708
725
644
645
924 728
801
B-B
A-A
734 755 653 655 858 641
654 836 651 652
601
624
615 814
614
629
630 628 802
C
613 A
611 875
627 631
753
898
756
732
763
733 622
621
623
625
626
887 W365P130701
Fig. 4-24 Shop Manual - April 2014
4-35
Structure and Functions
Part name
Material
Quantity
Part code
Remark
—
Regulator
Alloy steel
1
412
Screw, socket head
Alloy steel
2
60150559
JIS B1176 M8-50
413
Screw, socket head
Alloy steel
2
60150560
JIS B1176 M8-70
418
Screw, socket head
Alloy steel
2
60150556
JIS B1176 M5-12
438
Screw, socket head
Alloy steel
10
60150557
JIS B1176 M6-20
439
Screw, socket head
Rolled steel
3
60150558
JIS B1176 M6-35
466
Plug
Rolled steel
1
60008724
G1/4
467
Plug
Carbon steel
1
60008507
G3/8×M8
496
Plug
Alloy steel
15
60008728
497
Plug
Alloy steel
4
Seat
Alloy steel
2
60008884
Stopper 1
Alloy steel
2
60008885
Steel ball
Bearing steel
2
Housing
Cast iron
1
60197213
Feedback rod block
Alloy steel
1
60075481
Lever（1）
Alloy steel
1
60008532
Lever（2）
Alloy steel
1
60008522
Pivot pin Compensation piston In-cavity piston
Carbon steel
1
60008533
Carbon steel
1
60008534
Alloy steel
1
60008535
Piston shell
Cast iron
1
60008536
Compensation piece
Alloy steel
1
60008524
Spring seat（C）
Alloy steel
1
60008494
Outer spring
Spring steel
1
Inner spring
Spring steel
1
60075415
Adjusting ring（C） Carbon steel
1
60008526
Adjusting bolt（C） Carbon steel Aluminum alCover（C） loy Locknut Rolled steel
1
60008497
1
60008529
1
60008537
1
60150553
543 545 601 611 612 613 614 615 621 622 623 624 625 626 627 628 629 630
In Ma t rk er n et a in ti o g n De al pt .
No.
541
631
PF sleeve
641
Guide cover
642
司
公
销 营
1
60008510
Valve stem
Cast iron Aluminum alloy Carbon steel
1
B229900001021
643
Guid piston
Alloy steel
1
60008520
644
Spring seat（Q）
Alloy steel
1
60008495
1
60197211
645 4-36
SY365(B)H-9 Crawler Hydraulic Excavator
Adjusting ring（Q） Carbon steel
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
No.
Part name
Material
Quantity
Part code
Remark
646
Guide spring
Spring steel
1
651
Sleeve
Alloy steel
1
60008503
652
Spool
Alloy steel
1
60008538
653
Spring seat
Carbon steel
1
60008539
654
Reset spring
Spring steel
1
60008541
655
Adjusting spring
Spring steel
1
60008540
656
Cover plate
Cast iron
1
60008548
708
O-ring seal
NBR
1
60008694
JISB 2401
722
O-ring seal
NBR
3
60008707
JISB 2401
724
O-ring seal
NBR
8
725
O-ring seal
NBR
1
60008696
JISB 2401
727
O-ring seal
NBR
1
60008700
JISB 2401
728
O-ring seal
NBR
1
60008702
JISB 2401
730
O-ring seal
NBR
1
60008704
JISB 2401
732
O-ring seal
NBR
1
60008701
JISB 2401
733
O-ring seal
NBR
1
60221603
JISB 2401
734
O-ring seal
NBR
1
60008692
JISB 2401
753
O-ring seal
NBR
2
60008709
JISB 2401
755
O-ring seal
NBR
5
60008697
JISB 2401
756
O-ring seal
NBR
1
60008706
JISB 2401
757
O-ring seal
NBR
1
60008698
JISB 2401
763
O-ring seal
NBR
1
60039416
JISB 2401
801
Nut, hexagon
Rolled steel
2
60150561
JIS B1181 RN-M8
802
Nut, hexagon
Rolled steel
1
60008506
M10
814
Collar
Tool steel
1
60009938
JIS B 2B04 SR-10
836
Collar
Tool steel
1
60008748
858
Collar
Tool steel
2
60009937
JIS B 2B04 RR-15
874
Pin
Bearing steel
1
60008734
Φ4×11.7L
875
Pin
Bearing steel
2
60008733
Φ4×8L
876
Pin
Bearing steel
2
60008735
Φ5×8L
887
Pin
Carbon steel
1
60008546
897
Pin
Bearing steel
1
60008736
Φ5×19L
898
Pin
Bearing steel
1
60150562
Φ8.5×10L
924
Screw, socket head Pressure-reducing solenoid valve
Alloy steel
1
60008743
1
60125194
2
60117792
In Ma t rk er n et a in ti o g n De al pt .
JISB 2401
079
041
Check valve block
司
公
销 营
Shop Manual - April 2014
4-37
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Operating principle ● The regulator controls the flow of the main pup through various pressure signal commands, keeping the pump’s driving power lower than the engine power
Psv
1
A
2
● Pump 1 and pump 2 are each equipped with a regulator. Primary components of the regulator are electromagnetic proportional pressure-reducing valve (1), electrohydraulic converter valve (2), variable power regulator (3), positive flow regulator (4), servo piston (5) and servo directional valve (6). The regulator opens or closes the oil passage of servo piston (5) according to various pressure signal commands, change the inclination of swash plate, and control the flow of pump as a result.
6
P2
5 3
a3
In Ma t rk er n et a in ti o g n De al pt . 4
B
W365P130702
Fig. 4-25
Components of control mechanism
Electric current flow control: when normal
司
公
销 营
By changing the value I of command current flowing to the electromagnetic proportional pressure reducing valve, the inclination angle (output flow) of pump can be controlled freely. This is a regulator featured with positive flow control (forward control), in which the output flow Q increases with the value I of command current. With such a device, when you input a current necessary for flow required by corresponding operation, the pump only delivers a flow as desired and no power will be wasted. Power control (+ power shift): For emergency (with rod pulled out)
● In case of emergency, the power shift command pressure Pf is used to change the value of power setting. The power shift command pressure (secondary pressure P2 of electromagnetic proportional pressure reducing valve) is introduced via in-pump passage to the power control component of each regulator and shifted to respective similar power setting value. ● When power shifting is being performed, the rising of self-pump output pressure Pd1 automatically reduces the inclination (output flow) of the pump. As a result, the input torque is limited under certain value. (In case of constant speed, the input power becomes constant too.) ●
When power control is exercised, regulator of each pump is controlled to the same inclination (output flow). Therefore, power control is performed irrelevant to the load of both pumps. Overload of prime mover is prevented as a result. In addition, the normal pressure for power shift is 0 MPa. So the power control is inactive in normal hours.
● With this mechanism, optimum power can be achieved in butting operation. Although the regulator has the two control mechanisms described above, each control in joint action can put small inclination (flow) command to priority via mechanical calculation. 4-38
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Regulator adjustment ● Adjusting the adjusting screws (953, 954) at the pump body side can obtain the minimum flow and the maximum flow. Power control characteristics can be changed by adjusting the screw (C) (628) and the wheel (C) (627) of this adjustor. The flow control characteristics can be achieved by adjusting the socket-headed setscrew (924).
806
532
548 531
808
954
In Ma t rk er n et a in ti o g n De al pt .
953
司
公
销 营
ZX335-1002014
Fig. 4-26
531: Inclination pin 532: Servo piston
548: Feedback pin 806: Retaining nut 808: Retaining nut
953: Adjusting screw (min. flow)
954: Adjusting screw (max. flow)
Shop Manual - April 2014
4-39
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Output flow Q
Maximum flow adjustment (pump body side) ● Loosen the hex nut (808). Tighten (or loosen) socket-headed setscrew (954). No control characteristics except the maximum flow changes.
Command current I
In Ma t rk er n et a in ti o g n De al pt .
W365P130703
Fig. 4-27
● Loosen the hex nut (806). Tighten (or loosen) the socket-headed setscrew (953). Though this action is the same as the adjustment of maximum flow and all the other control characteristics do not change, power required for maximum output pressure (at relief) is likely to increase if overtightened. Be careful in this case.
Output flow Q
Minimum flow adjustment (pump body side)
司
公
销 营
Command current I W365P130704
Fig. 4-28
Input power
Loosen the nut (630) and tighten or loosen the screw (C) (628) to perform adjustment. When screw (C) (628) is tightened, the control line, as shown in the right figure, moves rightward. The input power increases. Moreover, When the screw (C) (628) is turned by N turns, inner spring (626) also changes along with its setting. So turn the adjusting wheel (C) (627) in the opposite direction by N×A turns. (For value of A “Annexed Table: Regulator adjusting values” on page 4-47.)
Output flow Q
1) Adjustment of the outer spring
Output pressure (Pd1) W365P130705
Fig. 4-29 4-40
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
2) Adjustment of inner spring Output flow Q
After hex nut (802) is loosened, tighten (or loosen) the adjusting roller (C) (627) to carry out adjustment. When adjusting roller (C) (627) is being tightened, the flow (as shown) will increase and input power will also increase.
In Ma t rk er n et a in ti o g n De al pt .
Output pressure (Pd1) W365P130706
Fig. 4-30
Loosen the hex nut (801) and tighten (or loosen) the socket-headed setscrew (924) for adjustment. When the setscrew (924) is being tightened, The control lines will move rightward as shown by the illustration.
Output flow Q
Adjustment of flow control characteristics
司
公
销 营
Command current I W365P130707
Fig. 4-31
Flow control
As shown in the illustration on the right, the outflow of pump can be controlled indefinitely via feedback pressure value.
Pump displacement Q
Operating principle
Command current I W365P130708
Fig. 4-32 Shop Manual - April 2014
4-41
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Increasing the flow Port C1 connected with head end of servo piston
652 646 613
B 876
D
F 897
875 611
A
643 C
In Ma t rk er n et a in ti o g n De al pt .
When the negative feedback pressure Pi2 reduces, the pilot plunger (643) will move in direction A until a relative balance between P2 and the resilient force of the guide spring (646) is achieved. The movement of the pilot plunger is transmitted to lever (2) (613) via pin (875) and rotates towards the arrow direction with B as the pivot. The movement of lever (2) is transmitted to the feedback rod (611)via pin shaft (897) and rotates in the same direction of B with C as the pivot. Along with this, the spool (652) connected to the feedback rod moves towards direction D. The spool moving in direction D connects port C1 with the oil tank port, and the pressure inside the large diameter end of the servo piston is relieved. As a result, the output pressure Pd1 inside the small diameter end moves the servo piston (532) in direction E and flow is increased. Since the feedback rod is connected with the servo piston and the spool, movement of the servo piston in direction E makes the feedback rod rotate with F as the pivot. In this way, the spool is moved to the original position. Through this movement, the opening portion between the spool and the valve block is closed slowly. The servo piston stops moving when the opening portion is completely closed.
532
E
W365P130709
Fig. 4-33
Psv
A
司
公
销 营
Pz
P2
Pd1
a3
B
W365P130710
Fig. 4-34
4-42
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Decreasing the flow Port C1 connected with head end of servo piston
613
652
G
646 H 876
J
L
875
897
611 I
643
K
In Ma t rk er n et a in ti o g n De al pt .
When the negative feedback pressure Pi2 rises, the pilot plunger (643) will move in direction G until a relative balance between P2 and the resilient force of pilot spring (646) is achieved. The movement of pilot plunger is transmitted to the feedback rod (611) via pin (897) and rotates in the same direction as H with I as the pivot. Along with this, spool (652) connected to the feedback rod moves in direction J. If the spool moves in direction J, output pressure Pd1 enters the large diameter end of the servo piston through the spool and port C1. On the other hand, output pressure Pd1 enters the small diameter end of the servo piston. As a result of the area difference, the servo piston moves in direction K and the inclination is reduced, and the flow is also reduced. Since the feedback rod, the servo piston and the spool form a whole unit, when the servo piston is moving in direction K, the feedback rod rotates with L as the pivot. This makes the spool move to its original position. As a result, the opening portion between the spool and the valve block is slowly closed. The servo piston stops moving when the opening portion is completely closed.
532
W365P130711
Fig. 4-35
Psv
A
Pz
司
公
销 营
P2
Pd1
a3
B W365P130712
Fig. 4-36
Shop Manual - April 2014
4-43
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Power control (for emergency)
Output flow Q
● As shown in the illustration, when load pressure increases, pump inclination is reduced to prevent the overloading of the prime mover. ● The action of power control is the same as that of the flow control. The following is a brief description.
In Ma t rk er n et a in ti o g n De al pt .
Output pressure (Pd1) W365P130713
Fig. 4-37
司
公
销 营
4-44
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Action against overloading (For emergency)
897 R
625 876 N 612 626
Port C1 connected with head end of servo piston
652 6 P
875
M
623
621
611 O
In Ma t rk er n et a in ti o g n De al pt .
When the self pump output pressure Pd1 increases, the output pressure Pd1 is acted onto the ladder portion of the offset piston (621) , and as a result, the offset rod (623) moves in direction M until the output pressure Pd1 balances the elastic forces of outer spring (625) and inner spring (626). The movement of the offset rod is transmitted to the lever (1) (612) via pin (875) and rotate in the arrow direction with N as the pivot. Then, the movement of lever (1) is transmitted to feedback rod (611) via pin (897) and rotates in the same arrow direction as N with O as the pivot. Along with this, spool (652) which is connected to the feedback rod moves in direction P. If the spool moves in direction P, output pressure Pd1 enters the large diameter end of the servo piston through the spool and port C1. However, output pressure Pd1 enters the small diameter end of the servo piston, and as a result of the area difference, the servo piston moves in direction Q. The inclination is reduced as a result and the flow is also reduced. Since the feedback rod, the servo piston and the spool is a whole unit, when the servo piston is moving in direction Q, the feedback rod rotates with R as the pivot. This allows the spool to move to its original position. Through this movement, the opening portion between the spool and the valve block is slowly closed. The servo piston stops moving when the opening portion is completely closed.
Q
532
W365P130714
Fig. 4-38
Psv
A
司
公
销 营
P2
Pd1
a3
B W365P130715
Fig. 4-39
Shop Manual - April 2014
4-45
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Action of flow recovery (For emergency)
625 876 897 T 612 626 X
Port C1 connected with head end of servo piston
S
652
J 875 623
V 621
611 U
W
In Ma t rk er n et a in ti o g n De al pt .
When the self pump output pressure Pd1 drops, elastic force offset rod (623) of outer spring (625) and inner spring (626) moves in direction S to a point where the elastic force of the outer spring and the inner spring balances the output pressure Pd1. The movement of the offset rod (623) is transmitted to lever (1) (612) via pin (875) and rotates in the arrow direction with T as the pivot. Then, the movement of lever (1) is transmitted to feedback rod (611) via pin (897) and rotates in the same arrow direction as T with U as the pivot. Along with this, spool (652) which is connected to the feedback rod moves in direction V. If the spool is moving in direction V, port C1 is connected with the tank port, and the pressure inside the large diameter end of the servo piston is relieved as a result. Servo piston (532) moves in direction W through the output pressure Pd1 of the small diameter end. The flow is increased in this way. Since the feedback rod, the servo piston and the spool is a whole unit, if the servo piston is moving in direction W, the feedback rod will rotate with X as the pivot. This allows the spool to move to its original position. Through this movement, the opening portion between the spool and the valve block is slowly closed. The servo piston stops moving when the opening portion is completely closed.
532
W365P130716
Fig. 4-40
Psv
A
司
公
销 营
P2
Pd1
a3
B
W365P130717
Fig. 4-41
Prior mechanism of small inclination (small flow) command ● As described above, though the inclination command of delivery control and power control is transmitted to the feedback rod (611) and spool (652) via lever (2) (613) and the big diameter end of lever (1) (612) respectively, pin (φ5) on the big hole (φ9) , as a protrusive structure, only contacts with the rod and pin at the small inclination side. It does not contact with the rod φ9 and pin (897) on the large inclination side. Through this mechanical option, the inclination command of the delivery control and power control is placed in priority.
4-46
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Power shift control (power control reduction) Output flow Q
● As shown in the right diagram, the power of the pump can be set freely through power shift pressure Pf. ● If the power shift pressure Pf is increased, compensating rod (623) will be pushed to the right side via pin (898) and the offset piston (621). Through the same action as described in the power control overloading prevention, the power set value can be reduced by reducing pump inclination. On the contrary, the power set value can be increased by reducing the power shift pressure Pf.
In Ma t rk er n et a in ti o g n De al pt .
Output pressure (Pd1) ZX335-1002029
Fig. 4-42
● When the pump is under normal condition, the power shift pressure Pf is 0 MPa. In an emergency, the power shift pressure Pf is 4.9 MPa.
司
公
销 营
Annexed Table: Regulator adjusting values Model of regulator
KR3K-9T06-V
RPM (min-1)
2100
Adjusting screw (954) screw-in (rotation)
+1/4
Max flow regulation Min flow regulation
Adjustment of input horse power
Adjustment of outer spring
Adjustment of inner spring
Adjustment of flow control characteristics
Delivery change (l/min-1)
6
Adjusting screw (953) screw-in (rotation)
+1/4
Delivery change (l/min-1)
+4.8
Adjusting screw (928) screw-in (rotation) Compensation control initial pressure change (MPa) Input torque change (N·m)
+1/4
+50.8
A
1.87
Adjusting wheel (627) screw-in (rotation)
+1/4
Flow change (l/min-1)
+10
Input torque change (N·m)
+39
Adjusting screw (924) screw-in (rotation) Flow control initial current change (mA) (Secondary pressure of proportional valve) Delivery change (l/min-1)
Shop Manual - April 2014
+1.88
+1/4 Around 35mA （+0.18） -19.4
4-47
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.5 Hydraulic system, Part 2 4.5.1 Main control valve 4.5.1.1 Overview XBp2
XBa1 PaL,Dra CCk
(P3)
(PTb)
XBtr Px
XBtL
XBs
XAb1 BbR XBc BcR XAa2 BaR
Pns Dr4 XAb2 Dr2 (P4) (XBo) BoR Pna1,Dr3
In Ma t rk er n et a in ti o g n De al pt .
+
Dr3
Rs1
Pna1
CCo
Rs2
(R4)
XBp1
As Atr
CT2 CP2 Pns Btr
MR
Dr4 Bs
XAtr
ে㸠䍄
LCs
XAs CCb
ಲ䕀
XBb2
ࡼ㞖2
(XAo) (Ao) XBa1
OPTION
Dr3
Dra
᭫ᴚ1 PaL
ARC
HVa Aa (ROD) LCa Pra1
XAtr
司
公
销 营
XBa2
R1
Ba1 (HEAD)
Py
Bb (ROD)
XAs
BtL CP1 CT1 CMR1 CMR2 AtL
Ꮊ㸠䍄
LCb
PbL,Drb
ࡼ㞖1
LCk
(PTb) XBtr
XAc
N1
LCAP2
XAtL Ab (HEAD) XBb1 PAcs
䫆᭫
ࡼ㞖2
P1 CUT
XBp2
(PTa)
Ⳉ㒓㸠䍄
(PTb)
Pns XBtL Dr4 XBb2 AbR XAb1 (XAo) AoR XBc Dra Bc Dr3 (HEAD) Pna1 XAa2 PaL XBa1 AaR XBp1 (Ba2) (HEAD)
P2
XAa1
XBp1
XBp1
A向
Drb
XBs PbL LCb2 XBb1 XAb2 Hvb A AcR (Bo) (XBo) Dr1
LCo
(R2)
XAa1
(PTa)
XAtL
XBtr
XAa1
P2 CUT
Ac (ROD) XBa2 XBp2
LCAT2
N2
PG
R3
P2 Pns,Dr4
P1 PH
(PTa) XAtr W365V130701
Fig. 4-43 4-48
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
P1
: Pump port (P1 side)
PAcs : Pilot port, bucket (DIG) travel limit
P2
: Pump port (P2 side)
Pna1 : Pilot port, arm 1 logic control valve
Aa
: Rod end port, arm cylinder (OUT)
Pns
: Pilot port, swing logic control valve
Ba1
: Head end port, arm cylinder (IN)
PG
: Pilot pressure source port
(Ba2) : Head end port, arm cylinder (IN)
PH
: Pilot pressure source port
: Head end port, boom cylinder (UP)
Pz
: Pilot pressure for boosting main relief valve
Bb
: Rod end port, boom cylinder (DOWN)
PaL
: Pilot port, lock valve (arm rod end )
Ac
: Rod end port, bucket cylinder (DUMP)
PbL
: Pilot port, lock valve (boom head end)
Bc
: Head end port, bucket cylinder (DIG)
Px
: Signal port used for work equipment
Atr
: Motor port, right travel
Py
: Signal port used for travel
Btr
: Motor port, right travel
Drl
: Oil drain port
XAc
In Ma t rk er n et a in ti o g n De al pt .
Ab
: Pilot port, bucket (DUMP)
(P3)
XBc
: Pilot port, bucket (DIG)
(P4)
: Motor port, left travel
Dr2
: Oil drain port
: Motor port, left travel
Dr3
: Oil drain port
: Motor port, swing
Dr4
: Oil drain port
: Motor port, swing
Dra
: Oil drain port
: Pilot port, right travel
Drb
: Oil drain port
: Pilot port, right travel
R1
: Oil return port
(R2)
: Oil return port
R3
: Oil return port
: Pilot port, swing
Rs1
: Oil refi lling port
: Pilot port, swing
Rs2
: Oil refi lling port
XBb1 : Pilot port, boom 1 (DOWN)
(Ao)
: Backup port
XAb1 : Pilot port, boom 1 (UP)
(Bo)
: Backup port
XBb2 : Pilot port, boom confluence (DOWN)
(XAo) : (Backup pilot port)
XAb2 : Pilot port, boom confluence (UP)
(XBo) : (Backup pilot port)
XBa1 : Pilot port, arm 1 (IN)
(PTa)
XAa1 : Pilot port, arm 1 (OUT)
(PTb)
XBa2 : Pilot port, arm 2 (IN)
(N1)
XAa2 : Pilot port, arm 2 (OUT)
(N2)
AtL BtL As Bs XAtr XBtr
XAtL : Pilot port, left travel XBtL : Pilot port, left travel XAs XBs
司
公
销 营
XBp1 : Pilot port, bypass stop valve spool (P1 side)
(R4)
XBp2 : Pilot port, bypass stop valve spool (P2 side)
Shop Manual - April 2014
4-49
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.5.1.2 Main valve structure B
A
XBp2
XBa1
N Right travel Py
C
Pns
Left travel
252
D
PbL
N
Swing Drb
102
Boom 1 P
273×4
+ (P3)
CCk
(P4)
Boom 2
P
991 992×2
D
Dr4
AbR Hvb
Rs1
E
AoR
CCo
Backup
Bucket
In Ma t rk er n et a in ti o g n De al pt .
E
101
Pz
C
PaL,Dra
M
971×6
C
MR
Straight travel
Q
AcR
F
Dra
Dr1
211
Arm 1
Arm 2
PaL
G
AaR
P2 stop
XBp2
H
Q
Pna1
G
252 103
PG
J
XBtr
L-L
L
PG
Direction J
167 151 541 542 554
司
销 营
XAa1
XBp1
351 152 168 公
R3
M
H
A
971×6
(R4)
Arm regeneration stop
B
(PTb)
Rs2
F
Dr3
Dra
PaL
167 151
151 167
166 543 151 167
Q-Q
L
515 521 551
P2
CCk
561 169 153 CCo 551 561 521 515
P1
A
PH
167 151
PbL Drb
MR Pz (PTa)
XAtr N-N
M-M P-P
W365V130704
Fig. 4-44
4-50
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
351
168 169 153
152 PH
PG
P2
XBtr
XAtr 271×2
271×2 XBs
XAs 271×2
271×2 XAb2
XBb2
271×2
271×2
(XBo)
In Ma t rk er n et a in ti o g n De al pt .
(XAo)
341 168
271×2
XAa1
XBa1
271×2
271×2
(R2)
153
(P4) 169 A-A
Rs1
Rs2
司
公
销 营
R3
P1
271×2 (PTb)
271×2
271×2
271×2
(PTa)
XBtL
XAtL
271×2
271×2
XBb1
XAb1
271×2
271×2
XBc
271×2 XAa2
271×2
272×2
272×2
XBa2
XBp2
XBp1
162
162 561 551
561 551 163 B-B W365V130705
Fig. 4-45
Shop Manual - April 2014
4-51
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
153 169 201 336 332 372 337 332 261 601 308 512 522 552 562 512 522
Right travel
（Pta）
XAtr
MR Py
301 511
CMR2
Atr
CMR1
CT2 CP2
521 551 561 561 551 521 511
In Ma t rk er n et a in ti o g n De al pt .
552 562 561 551
Straight travel
201 336 332 373 337 332 261
CT1
Btr
521 511
Px
263 203 169 153
XBtr
(PTb)
263 203
Section C-C 司
公
销 营
201 336 332 373 337 332 261 301 166 165 163
511 521
Left travel
Swing
XAtL
XAs
201 336 332 371 337 332 261 305 162
166
AtL
As
LCs
CP1
551 561 165 161
263 203
Pns
Bs
BtL
166 XBtL Section D-D
XBs
256 254
263 203
W365V130705
Fig. 4-46 4-52
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
201 336 332 373 337 332 261
Boom 1
511 521
XBb2 AbR
307
Hvb
165 163
Ab CCb
LCb
Lcb2
551 561 561
In Ma t rk er n et a in ti o g n De al pt .
551
Boom 2
XBb1
553 561 523 513 303
201 336 332 371 337 332 602 261
551 521
561
Bb
511
Dr2
602
BbR
XAb1
263 203
XAb2
263 203
Section E-E
555 563 204 342 336 332 371 337 332 261 602 304
153 169 201 336 332 371 337 332 261
司
公
销 营
Bucket
Backup
XBa2
(XAo)
PAcs
XAc AcR
166
162 164 165 163 511 521 551 561 164 161
309 605
AoR
275×4
(Ao)
Ac
LCk
264 213 511 521
LCo
551 561 264 （Bo） 213
Bc
275×4
605
166
602 BcR
XBc
BoR (XBo)
263
Section F-F
203 169 153
263 203
W365V130706
Fig. 4-47 Shop Manual - April 2014
4-53
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
201 336 332 375 337 332 261 306
Arm 2
201 336 332 371 337 332 261
Arm 1 XBa1
XBa2
302
Dra
Dr1 511 521 561 551
167 151 561 553 Hv6 LCa
523 513 Pna1
In Ma t rk er n et a in ti o g n De al pt .
276×4 LCAT2 285 266 214 531 522 514 Ba2 153 169 275×4 214 264 602 263 203 152 168 202 333 331 324 323 334 331 262 551 561
Ba1
BaR
255 253
261
XAa2
205
XAa1
司
公
销 营
Section G-G
P2 stop
Arm regeneration stop
XBp2
257 602
AaR
169 153
Aa
CCk
(N2)
310 310
CCo
R1
(N1)
153 169 561 551 262 331 334 323 324 331 333 202
(R2) 267 XBp1 P1 stop
Section H-H
Fig. 4-48 4-54
215 277×4
Shop Manual - April 2014
W365V130707
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Torque （N.m）
Part name
Qty
101 102 103
Valve body A Valve body B Valve body C
1 1 1
151
Oil plug
6
13~17
308
152 153 161 162 163 164 165 166 167 168 169 201 202 203 204 205 211 213 214
Oil plug Oil plug O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal Spring cap Spring cap Spool cap Spring cap Spool cap Plate Flange Check valve plate Pipeless opening cover plate Pipeless opening cover plate Lock valve selector GP Logic valve component, arm 1 Logic valve component, swing Logic control valve Stop valve GP, arm regeneration O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal O-ring seal Bolt, socket head Bolt, socket head Bolt, socket head Bolt, socket head Bolt, socket head Bolt, socket head Travel spool Spool GP, arm 1 Spool GP, boom 1 Bucket spool
2 10 4 6 9 2 4 12 6 3 10 9 2 9 1 1 1 2 1
34~39 69~78
275 216 252 253 254 255 257 261 262 263 264 265 266 267 271 272 273 275 276 277 301 302 303 304
No.
Part name
Qty
305 306 307
1 1 1
309 310 323 324 331 332 333 334 336 337 341 342 351 371 372 375 511 512 513
Swing spool Spool, arm 2 Spool, boom 2 Spool AS, straight travel Backup Spool, bypass stop Spring Spring Spring seat Spring seat Bolt with washer Stopper Bolt with washer Stopper Oil plug Piston 节流塞（φ0.7） Spring Spring Spring Cone valve Cone valve Cone valve
1 2 2 2 4 20 2 2 10 10 1 1 3 8 1 1 10 2 2
1
514
Cone valve
1
1
515
Cone valve
2
521
Spring
12
1
522
Spring
3
1
523
Spring
2
2
司
公
销 营
9.8~14
2
52~62
531
Spring seat
1
1
120~140
541
Steel ball
1
542 543 551 552 553 554 555 561 562 563 601 602 605 971 991 992
Spring seat Spring Oil plug Oil plug Oil plug Oil plug Oil plug O-ring seal O-ring seal O-ring seal Main relief valve Port relief valve Port relief valve Bolt, socket head Nameplate Rivet
1 1 17 2 2 1 1 19 2 1 1 6 2 12 1 2
11 2 9 3 1 1 1 40 4 4 12 4 4 2 1 1 1
52~62 25~34 210~260 140~180 25~34 83~110
Shop Manual - April 2014
Torque （N.m）
1
In Ma t rk er n et a in ti o g n De al pt .
No.
16~18 37~41 34~39 7.8~9.8
370~410 230~260 370~410 25~29 220~260
120~140 120~140 120~140 390~470
4-55
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.5.2 Hydraulic circuit (With bucket confluence function)
Travel (R)
Straight travel
In Ma t rk er n et a in ti o g n De al pt .
Travel (L)
Swing
Boom 1
Boom 2
司
公
销 营
Bucket
Backup
Arm 2
Arm 1
Bypass stop
W365V130703
Fig. 4-49 4-56
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Operating principle 1) When spool is neutral position (Main circuit) ● When all spools are in neutral position, the working oil from (front) hydraulic pump enters the pump port P1, is guided to the main oil passage (1), and returns to the oil tank via the return ports R1 and R3 by passing through the neutral bypass (2) (function of neutral M-shaped spool) of each spool in straight travel (308), left travel (301), boom 1 (303), bucket (304) and arm 2 (306).
In Ma t rk er n et a in ti o g n De al pt .
● The working oil from (rear) hydraulic pump enters the pump port P2, is guided to the main oil passage (3), and returns to the oil tank via the return ports R1 and R3 by passing through the neutral bypass (4) (function of neutral M-shaped spool) of each spool in right travel (301), swing (305), boom 2 (307), backup (309) and arm 1 (302).
司
公
销 营
Shop Manual - April 2014
4-57
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
R3
(1)
P1
(2) (PTb)
(PTa)
XBtL
XAtL
XAb1
XBb1
In Ma t rk er n et a in ti o g n De al pt .
XBc
XAa2
XBa2
XBp1
XBp2
司
公
销 营
(p3)
PH
P2
PG
(3)
(4)
XAtr
XBtr
XAs
XBs
XBb2
XAb2
(XAo)
(XBo)
XBa1
(R2)
(p4)
Rs1
Fig. 4-50 4-58
Shop Manual - April 2014
Rs2
WJV3651305
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
2) Travel (Pilot circuit) ● When switched to left travel spool or right travel spool, the side oil passage closes and the pressure in port Py (travel signal port) rises. (Main circuit) ● When pressure is present in pilot port XBtL used for left travel spool (301), the neutral bypass (2) at the side of boom 1 closes. The working oil fed from (front) hydraulic pump is delivered through port BtL to the left travel motor.
In Ma t rk er n et a in ti o g n De al pt .
● Likewise, when pressure is present in pilot port XBtr used for right travel spool (301), the neutral bypass (2) at the side of arm 1 closes. The working oil fed from (rear) hydraulic pump is delivered through port Btr to the right travel motor. ● On the other hand, the oil returning from both the left and right travel motors via port AtL (Atr) passes the left (right) travel spool and goes back to the oil tank via return ports R1 and R3. ● When operating travel in the opposite side (pressurizing the pilot ports XAtr and XAtL), the above principle also applies.
司
公
销 营
XAtL
AtL
XBtL
BtL
Travel motor WJV3651306
Fig. 4-51
Shop Manual - April 2014
4-59
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3) Arm Arm-out operation (Pilot circuit) ● When switched to the arm 2 spool (302), the side oil passage closes and the pressure in port Px (work equipment signal port) rises. (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When performing the arm-out operation, the pilot oil is fed to port XAa1 and port XAa2. When pilot oil is delivered to the two sides of port XAa1 and port XAa2, arm 1 spool and arm 2 spool are switched to the left, as shown in Fig. 4-52. As a result, the working oil from port P2 is introduced into the neutral bypass (4) via the main passage (3). The neutral bypass is cut off by switching the arm 1 spool (302). Therefore, the working oil in the parallel passage pushes open the cone valve (253) of the logic valve, and enters the arm 1 spool (302) via the U passage. The oil from arm 1 spool (302) is then delivered to the rod end (R) of arm cylinder. ● On the other hand, the working oil coming from port P1 is guided to the neutral bypass (2) via the main oil passage (1). The neutral bypass is cut off by switching the arm 2 spool (306). Therefore, the working oil in the parallel passage pushes open the cone valve (514) of logic valve, and working oil from neutral bypass pushes open the cone valve (511) of the check valve and flows into the arm 2 spool (306) via the U passage. The oil then comes into confluence with oil from port Aa in the passage of neutral bypass (306) and is fed to the rod end (R) of the arm cylinder. 司
公
销 营
● Return oil from the arm cylinder head end (H) via port BaI flows respective tank circuits of arm 1 and arm 2, and returns to working oil tank via tank ports R1 and R3.
4-60
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
511
514
(Ba2)
LCAT2
BaR
Dr1 XBa2
In Ma t rk er n et a in ti o g n De al pt .
XAa2
XBa1
Dra
XAa1
司
公
销 营
LCa
Aa
Ba1
253
Pna1
R
H WJV3651307
Fig. 4-52
Shop Manual - April 2014
4-61
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Arm-in operation (Pilot circuit) ● When switched to the arm 1 spool (302), the side oil passage closes and the pressure in port Px (work equipment signal port) rises. Pressurized oil is fed to the port PaL at the same time. Relief signal is sent to the lock valve selector GP (252). (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When performing the arm-in operation, pilot oil is fed to ports XBa1 and XBa2. When pilot oil is delivered to the two sides of port XBa1 and port XBa2, arm 1 spool and arm 2 spool are switched to the right as shown in Fig. 4-53. As a result, working oil from P2 is guided to the neutral bypass (4) via the main passage (3). The neutral bypass is cut off by switching arm 1 spool (302). Therefore, the working oil in the parallel passage pushes open the cone valve (253) of the check valve and flows to the arm 1 spool (302) via the U passage. Then, it flows to the periphery of arm 1 spool (302) and is delivered to the arm cylinder head end (H) via port Ba. ● On the one hand, the working oil from port P1 is guided to the neutral bypass (2) via the main passage (1). The neutral bypass is cut off by switching the arm 2 spool (306). Therefore, the working oil in the parallel passage pushes open the cone valve (514) of the arm 2 check valve, and the working oil from neutral bypass pushes open the cone valve (511) of the check valve and flows to the arm 2 spool (306) via the U passage. Then, it comes into confluence with oil from port BaI in the internal passage of arm 2 spool (306). 司
公
销 营
● On the other hand, the oil returning from the arm cylinder rod end (R) and the working oil whose pressure rises due to the dead weight of arm goes back to the port Aa. The working oil returned to the port Aa flows into the valve spool via the holes (a) on the periphery of arm 1 spool (302), pushes open the cone valve (302-317) only under light load, and comes into confluence in the peripheral holes with oil from port BaI. ● If the pressure at the arm cylinder head end and in the U passage rises, arm regeneration check valve spool (257-103) switches to the left, as shown in Fig. 4-54, and closes due to the back pressure of the cone valve (302-317) in the spool. In this way, the arm regeneration function is deactivated and return oil from the arm cylinder rod end (R) flows to the spool via the hole (a) on the periphery of arm 1 spool (302). Then, it flows into arm regeneration stop valve (257) via hole (c) on the periphery of arm 1 spool (302), and returns to the working oil tank via tank ports R1 and R3.
4-62
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Light load
(Ba2) LCAT2
BaR
Dr1
XAa2
In Ma t rk er n et a in ti o g n De al pt .
XBa2
(302-317)
(a)
XBa1
XAa1
(b)
Dra
司
公
销 营
Aa
LCa
Ba1
Pna1
Arm dead weight
R
H WJV3651308
Fig. 4-53
Shop Manual - April 2014
4-63
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● When pressure in arm cylinder head end (H) rises
(Ba2) LCAT2
BaR
Dr1 XBa2
In Ma t rk er n et a in ti o g n De al pt .
XAa2
(a)
(302-317)
(c)
XBa1
XAa1
司
公
销 营
Dra
LCa
Aa
Ba1
Pna1
(257-103)
R
H WJV3651309
Fig. 4-54
4-64
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4) Boom Boom-up operation (Pilot circuit) ● When switched to the boom 1 spool (307), the side passage is closed and the pressure in port Px (work equipment signal port) rises. (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When boom-up operation is performed, the pilot oil is fed to port XAb1 and boom 1 spool (303) moves to the left as shown in Fig. 4-55. The working oil from port P1 is introduced to the neutral bypass (2) via the main passage (1). The neutral bypass is cut off by switching boom 1 spool (303). In this way, the working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows to the boom 1 spool (303) via the U passage. It then flows to the periphery of boom 1 spool (303) and is delivered to the boom cylinder head end (H) via port Ab. ● At the same time, the pilot oil is also fed to port XAb2 and boom 2 spool (307) moves to the left as shown in Fig. 4-55. The working oil from P2 flows the parallel passage. As the switching boom 2 spool (307) cuts off the neutral bypass, the working in the parallel passage flows into boom 2 spool (307) via the U passage. The oil then pushes open the cone valve (511) of the check valve, comes into confluence with the oil from port Ab, and is fed to the boom cylinder head end (H). (This is called the boom confluence function.) 司
公
销 营
● On the other hand, the oil flows to the periphery of boom 1 spool (303) via port Bb from oil return side of the boom cylinder rod end (R) and goes back to the working oil tank via the ports R1 and R3.
Shop Manual - April 2014
4-65
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
H
R
511
In Ma t rk er n et a in ti o g n De al pt .
513
LCb
Ab
Bb
BaR
司
公
销 营
XBb1
XBb2
XAb1
XAb2
Dr2
AbR
511
511
WJV3651310
Fig. 4-55
4-66
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Boom-down operation (Pilot circuit) ● When switched to the boom 1 spool (303), the side passage is closed and the pressure in port Px (work equipment signal port) rises. Pressurized oil is fed to the port PbL at the same time. Relief signal is sent to the lock valve selector GP (252). (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When boom-down operation is performed, the pilot oil is fed to port XBb1 and boom 1 spool (303) moves to the right as shown in Fig. 4-56. The working oil from port P1 is introduced to the neutral bypass (2) via the main passage (1). The neutral bypass is cut off by switching boom 1 spool (303). In this way, the working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows to the boom 1 spool (303) via the U passage. It then flows to the periphery of boom 1 spool (303) and is delivered to the boom cylinder rod end (R) via port Bb. ● On the other hand, the oil returning from the head end (H) of boom cylinder flows to the hole (a) and periphery of boom 1 spool (303). ● The pressure of return oil rises due to the dead weight of boom. To maintain sufficient pressure, with the help of the oil passage inside the spool, the cone valve (303-317) in spool is pushed to the right, as shown in Fig. 4-56, and the oil flows out of the spool. As the working oil for boom-down operation, the pressurized oil is again delivered to the boom cylinder rod end (R) (which is called boom regeneration function). The return oil entering the internal passage of spool via the hole (a) partially goes back to the oil tank via the hole (b). 司
公
销 营
H
R
513
511
LCb
Ab
Bb
BbR
XAb1
XBb1
(b)
(a)
(303-317)
WJV3651311
Fig. 4-56
Shop Manual - April 2014
4-67
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
5) Bucket Bucket-dig operation (Pilot circuit) ● When switched to the bucket spool (304), the side passage is closed and the pressure in port Px (work equipment signal port) rises. The pressure oil is fed to port XBp2 at the same time. (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When bucket-dig operation is performed, the pilot oil is fed to the port XBc and the bucket spool (304) moves to the left as shown in Fig. 4-57. The working oil from port P1 is guided to the neutral bypass (2) via main passage (1). As the neutral bypass is cut off by switching bucket spool (304), the working oil in the parallel passage pushes open the cone valve (511) of the check valve, and flows to the bucket spool (304) via the U passage. It then flows to the periphery of bucket spool (304) and is fed to the bucket cylinder head end (H) via port Bc. ● On the other hand, return oil from the bucket cylinder rod end (R) flows in via port Ac. It then goes back to the oil tank via the ports R1 and R3 from the periphery of spool. ● When boom-up and bucket-dig operations are performed at the same time, the pilot oil is led to the port PAcs. Therefore, the travel of bucket spool is not restricted to the end, but can be held in a position on the way. As a result, bucket cylinder passage is throttled and working oil flows to boom 1 spool (303) via bucket spool (304). In this way, boom-up operation have the priority. 司
公
销 营
H
R
511
AC
LCk
AcR
PAcs
Bc
BcR
XAc
XBc
Confluence
Fig. 4-57
4-68
Shop Manual - April 2014
WJV3651312
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Bucket-dump operation (Pilot circuit) ● When switched to the bucket spool (304), the side passage is closed and the pressure in port Px (work equipment signal port) rises. The pilot oil is also fed to the port XBp2 at the same time. (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When bucket-dump operation is performed, the pilot oil is fed to the port XAc and bucket spool (304) moves to the right as shown in Fig. 4-58. The working oil from port P1 is led to the neutral bypass (2) via the main passage (1). The neutral bypass is cut off by switching bucket spool (304). Therefore, the working oil in the parallel passage pushes open the cone valve (511) of the check valve and flows to the bucket spool (304) via the U passage. It then flows to the periphery of bucket spool (304) and is fed to the bucket cylinder rod end (R) via the port Ac. ● On the other hand, return oil from the bucket cylinder head end (H) enters via the port Bc, passes the spool periphery of spool, and goes back to working oil tank via the ports R1 and R2.
H
R
司
公
销 营
511
LCk
Ac
Bc
AcR
XAc
BcR
PAcs
Confluence
XBc
WJV3651313
Fig. 4-58 Bucket confluence ● When bucket-dig or -dump operation is performed, the pilot oil is fed to the port XBp2 and the neutral bypass stop valve spool (310) is switched. Working oil from port P2 is led to the neutral bypass (4) via the main passage (3). The neutral bypass is cut off by switching neutral bypass valve spool (310). Therefore, working oil pushes open the check valve (515) and comes into confluence with bucket spool (304) via the internal passage and the U passage. Shop Manual - April 2014
4-69
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
6) Swing When swing operation performed separately (Pilot circuit) ● When switched to the swing spool (305), the side passage is closed and the pressure in the port Px (work equipment signal port) rises. (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When swing is operated separately, the pilot oil is fed to the port XAs (or XBs) and swing spool (305) is switched. Working oil from port P2 is led to the neutral bypass (4) via the main passage (3). Neutral bypass is cut off by switching swing spool (305). Therefore, working oil in the parallel passage pushes open the logic cone valve (254-101) of the swing logic component and flows to the swing spool (305) via the U passage. It then flows to the periphery of swing spool (305) and is delivered to the swing motor via port As (or Bs). ● On the other hand, return oil from the swing motor flows in via port Bs (or port As). Then, it flows into tank ports R1 and R2 from the periphery of spool and goes back to the working oil tank. Swing motor 司
公
销 营
Pns
As
LCs
Bs
(254-101)
XAs
XBs
WJV3651314
Fig. 4-59
4-70
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
7) Priority function ● This function enables the working oil from port P to be sufficiently allocated to the work equipment under higher load in order to improve the operability when the arm-in operation is performed along with swinging operation. ● The following shows the priority of swinging operation relative to the arm-in operation. (Main circuit) ● When pressure oil is applied to the port Pna1 of the logic control valve (255), the piston (255356) and spool (253-107) move upward. The lifting distance of cone valve (253-101) is limited.
XBa1
In Ma t rk er n et a in ti o g n De al pt .
● In this way, the passage from the parallel passage to the U passage is throttle. As a result, oil from the arm 1 spool has the priority to go to the swing spool, giving the priority to the boomup operation.
XAa1
司
公
销 营
LCa
Aa
Ba1
(253-101)
(253-107)
Pna1
(255)
(255-356
WJV3651315
Fig. 4-60
Shop Manual - April 2014
4-71
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
8) Backup The backup spool is used to control attachment such as hydraulic shear. Backup operation (Pilot circuit) ● When switched to the backup spool (309), the side passage is closed and the pressure in port Px (work equipment signal port) rises. (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When the backup is operated, the pilot oil is fed to the port XAo (or XBo) and the backup spool (309) is switched. Working oil from port P2 is fed to the neutral bypass (4) via the main passage (3). Neutral bypass is cut off by switching backup spool (309). Therefore, working oil in the parallel passage pushes open the cone valve (511) of the check valve and flows to the backup spool (309) via the U passage. Then, it flows into the periphery of backup spool (309) and is supplied into the attachment via port Ao (or Bo). ● On the other hand, return oil from the attachment flows in via port Bo (or port Ao). Then, it flows into tank ports R1 and R2 from the spool periphery and returns to the working oil tank. R
H
司
公
销 营
511
Ao
LCo
Bo
BoR
XAo
XBo
Confluence
WJV3651316
Fig. 4-61 Backup confluence To achieve backup confluence, pilot oil is also fed to port XBp1 and the bypass stop valve spool (310) is switched. Working oil from port P1 is introduced into neutral bypass (2) via main passage (1). Neutral bypass is cut off by switching bypass valve spool (310). Therefore, working oil pushes open the cone valve (515) of check valve and comes into confluence with backup spool (309) via the internal passage and the U passage. 4-72
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
9) Straight travel When travel spool (301) is operated along with other spools at the same time. The following case shows when travel spool (301) and swing spool (305) are operated at the same time. (When pilot oil is delivered to the ports XAtL, XAtr and Xas) (Pilot circuit) ● Close the side passage of right/left travel spool (301) and the downstream side passage of swing spool (305). Pilot oil from port PG is fed to port PTa in order to switch the straight travel spool (308). (Main circuit)
In Ma t rk er n et a in ti o g n De al pt .
● When straight travel spool (308) is switched, the port P2 and the right/left travel spool (301) are interconnected through for priority. The port 1 and the parallel passage of swing - boom 2 - backup - arm 1 oil circuit / boom 1 - bucket/ - arm 2 circuit are interconnected through for priority. Therefore, the working oil from port P2 is mainly delivered to the ports Atl and Atr and distributed evenly to the two travel motors. ● On the other hand, the working oil from port P1 is delivered to the swing motor via port As. ● When oil pressure in the port P2 is lower than that in the port P1, the working oil form port P1 will be partially delivered to the port P2. In this way, sudden drop of travel speed can be prevented. 司
公
销 营
P1
R3
P2
(PTa)
XAtL
(PTb)
XBtL
WJV3651317
Fig. 4-62
Shop Manual - April 2014
4-73
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
10) Function of lockout valve The lockout valve selector module (252) is mounted between the arm cylinder rod end (R) and the arm 2 spool (302) and arm 2 spool (306). It is used to reduce the internal leakage of the spool due to cylinder pressure. Likewise, lockout valve selector module (252) is also mounted between the boom cylinder head end (H) and the arm 1 spool (303) and boom 2 spool (307) to reduce the internal leakage of he spool due to cylinder pressure. The figure below shows the case of boom cylinder head end (H). (Similar case applies to the arm cylinder rod end (R).) Spool in neutral position
In Ma t rk er n et a in ti o g n De al pt .
● When boom 1 spool (303) and boom 2 spool (307) are in a neutral position, the spool (252-511) inside the lockout valve selector module is pressed against the seat of the body (252-101) of the lockout valve selector module, as shown in Fig. 4-63, by the preload of spring (252-512). ● In this position, working oil in the boom cylinder head end (H) flows in via hole (a) and flows out from hole (b) through the periphery of the lockout valve selector module spool (252-511), pressing the cone valve (513) against the seat of the valve block via hole (b). By this means, oil leakage is reduced. (252-512)
司
公
销 营
(252-511)
Drb
(b)
(252-101)
(a)
PbL
513
Ab
LCb
Bb
(RH)
BbR
XBb1
XAb1
WJV3651318
Fig. 4-63
4-74
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Boom-down operation In boom-down operation the pilot oil is fed to the ports PbL, XBb1 and XBb2. Spool (252-511) inside the lockout valve selector module is pushed to the top by the pilot oil as shown in Fig. 4-64. Due to the movement of spool (252-511) inside the lockout valve selector module, hole (a) is cut off and working oil from boom cylinder head end (H) does not go to spring chamber (RH). In addition, oil in the spring chamber (RH) enters the oil leak circuit via the hole (b). In this way, the cone valve (513) is pushed open by the pressure in boom cylinder head end (H) and the function of the lockout valve selector module (252) is deactivated.
In Ma t rk er n et a in ti o g n De al pt .
(252-512)
Drb
(252-511)
(b)
(252-101)
(a)
511
513
PbL
司
公
销 营
Ab
LCb
Bb
(RH)
XBb1
BbR
XAb1
WJV3651319
Fig. 4-64 Boom-up operation In boom-up operation the pilot oil is fed to the ports XAb1 and XAb2. The cone valve (513) is pushed open by the oil from boom 1 spool (303) and boom 2 spool (307). The working oil goes to the port Ab as a result.
Shop Manual - April 2014
4-75
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
11) Function of main relief valve The main relief valve is mounted on the valve block A (101). It has the following functions: ● Working oil fulfils the cavity (a) through the hole in valve post housing (601-101) and valve post (601-511). The valve post (601-511) is therefore pressed against the housing (601-101). Reliable sealing has formed as a result. ● When pressure in passage (P) exceeds the preload of spring (601-521), the cone valve (611) opens. Therefore, the working oil passes through the gap between the housing (601-101) and valve pocket (601-102) from the periphery of cone valve (601-401) and goes to the low pressure passage (R).
In Ma t rk er n et a in ti o g n De al pt .
● Opening of cone valve (601-401) causes pressure drop in cavity (a). So the valve post (601511) is opened. In this way, working oil in passage (P) flows to the low pressure passage (R) directly. ● When pressure oil higher than 3MPa is fed to the port Pz, it pushes plunger (601-302) to the left. The preload of spring (601-512) increases as a result and pressure boosts at the moment.
(601-101)
(601-401)
(601-512)
(601-102)
司
公
销 营
P
R
(601-511)
(a)
(601-302)
Pz
WJV3651320
Fig. 4-65
4-76
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
12) Function of port relief valve The port relief valve, mounted between the oil tank port and low pressure passage, can prevent cavitation as an oil compensation check valve except working as a port relief valve. Functions of the valve are given below: Functioning as a relief valve ● Working oil fulfils into cavity (B) via the hole (A) on plunger (301). Valve post (511) is pressed against valve seat (541), and valve seat (541) is pressed onto the seat of the valve block, forming a reliable sealing. (B)
541
In Ma t rk er n et a in ti o g n De al pt .
(A)
P
R
司
公
销 营
301
511
WJV3651321
Fig. 4-66
● When pressure in passage (P) exceeds the preload of spring (621), cone valve (611) is pushed open. Therefore, working oil flows through hole (C) via the periphery of cone valve (611) and enters the low pressure passage (R).
(C)
P
R 611
621 WJV3651322
Fig. 4-67 Shop Manual - April 2014
4-77
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Opening of cone valve (611) causes pressure in cavity (B) to drop and valve post (511) is opened. In this way, working oil in passage (P) goes to the low pressure passage (R) directly.
(B)
In Ma t rk er n et a in ti o g n De al pt .
P
R
511
611
WJV3651323
Fig. 4-68
司
公
销 营
Functioning as oil complement check valve against cavitation
When negative pressure is formed in passage (P), working oil is fed from passage (R). When pressure in passage (R) exceeds the pressure in passage (P), valve seat (541) moves to the right direction. Therefore, working oil is delivered from passage (R) to passage (P) via the periphery of valve seat (541). Cavitation is prevented as a result.
P
R
541 WJV3651324
Fig. 4-69
4-78
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6 Hydraulic System, Part 3 4.6.1 Swing motor
In Ma t rk er n et a in ti o g n De al pt .
Type: M5X180CHB-10A-3NA/265
L
SH
PG
PB
B
IP
PA
A
司
公
销 营
M
1
DB
2
ZX215-1002081
Fig. 4-70
A: Main oil port B: Main oil port M: Makeup port PA: Pressure detection port PB: Pressure detection port DB: Lubricant port PG: Brake release port SH: Brake command port L: Level stick IP: Gear oil feed port (1) Safety valve (2) Anti-swing valve
Specifications
Model Theoretical displacement Safety valve press. setting Max swing speed Brake release pressure
Shop Manual - April 2014
M5X180CHB-10A-3NA/265 180.1 cm3/rev 26.0 MPa 1470 rpm 2.7-4.9 MPa
4-79
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
7
In Ma t rk er n et a in ti o g n De al pt .
6
A-A
A
8
9
5
A
司
公
销 营
4
10
11
3
12
2
13
1
ZX215-1002082
Fig. 4-71 (1) (2) (3) (4) (5) (6) (7)
Spacer Housing Disc Brake spring Shell Spring Check valve
4-80
(8) Oil distributor (9) Cylinder barrel (10) Brake piston (11) Plate (12) Piston (13) Drive shaft
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.2 Swing holding brake ● Port PG is directly connected with the pilot gear pump and it is always under a pressure of 3.9MPa.
M a
Pump
1 Main valve
7
PX
PG
In Ma t rk er n et a in ti o g n De al pt .
6
SH
5
ZX215-1002083
Fig. 4-72
● Port SH is in connection with port (PX) of the main control valve. In case of any operation (except travel) is performed by the main control valve, Port (PX) will be put under pressure. This pressure establishes connection between PG and chamber (a) below piston (7). The pressurized oil pushes the brake piston upward to compress spring (1) and separate disc (5) from plate (6). The brake is released. 司
公
销 营
M
a
Pump
1
Main valve
7
PX
PG
6
SH 5
ZX215-1002084
Fig. 4-73 ● Otherwise, without pressure acting upon the port (PX), the connection between (PG) and chamber (a) below piston (7) is blocked. Brake spring (1) pushes the brake piston to press disc (5) against plate (6). The brake is engaged. Shop Manual - April 2014
4-81
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.3 Relief valve section Structure ● The relief valve section consists of relief valves (1) and (2) and check valves (3) and (4). Function ● When the machine is in the swing holding mode, control valve (5) closes the motor outlet circuit, but the motor rotation is continued due to inertial force. The motor output is, therefore, abnormally increased, which could damage the motor.
In Ma t rk er n et a in ti o g n De al pt .
● In order to prevent the motor from being damaged, the relief valve relieves the abnormally high pressure oil to port (M) from the outlet side (high-pressure side) of the motor. Operating principle
From oil port M
1
1. When starting swing (suppose pressurized oil is delivered to port A)
2
● When the swing control lever is set to the right- swing, pressurized oil from the pump is delivered to port (A) via control valve (5).
● The pressure at port (A) rises, the starting torque is generated in the motor, and the motor starts to rotate.
司
公
销 营
3
● The pressurized oil from the outlet port of the motor passes from port (B) through the control valve (5) and returns to the tank.
C
A
B
5
Fig. 4-74
4-82
4
Shop Manual - April 2014
ZX215-1002085
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
2. When swing is stopped
From oil port M
1
● When the swing control lever is set neutral, the supply of pressurized oil from the pump to port (A) is stopped. ● The pressurized oil from the motor outlet can't return to the tank since the returning circuit to the tank is closed from control valve (5). Thus, the pressure on port (B) increases.
2
4
3
● Swing resistance is generated on the motor and hence the brake starts working.
C
In Ma t rk er n et a in ti o g n De al pt .
● Pressurized oil will be relieved when the pressure on port (B) rises to the set pressure of relief valve (2).
A
5
● A high braking torque acts on the motor, thereby stopping the motor. ● When relief valve (2) is being actuated, the relieved oil and the pressurized oil from port (M) are fed to port (B) via check valve (4).
B
ZX215-1002086
Fig. 4-75
司
公
销 营
● The above prevents the formation of cavitation on port (B).
Shop Manual - April 2014
4-83
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.4 Anti-jerk valve 4.6.4.1 Operation diagram A
T1
T2
B 2
3
Valve body Spool (side A) Spring (side A) Plug Spool (side B) Spring (side B) Plug
4
In Ma t rk er n et a in ti o g n De al pt .
1
(1) (2) (3) (4) (5) (6) (7)
7
6
5
Swing motor
B
T
A 司
公
销 营
Swing Control Valve
Fig. 4-76
ZX215-1002087
4.6.4.2 Effect illustration
: With antiswing valve
：Without antiswing valve
Reversing pressure
Pressure MA
Suppressing pressure
Reversing pressure
Pressure MB
First reversing Second reversing
Motor speed
Start
Brake
Reverse
Time
Fig. 4-77 4-84
Shop Manual - April 2014
ZX215-1002088
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Outline
A
● The inertia of the swing body, the counteraction and rigidity of the mechanical system, or the compressibility of the hydraulic oil can cause shaking of machine during swing operation. The anti-jerk valve is able to reduce such impact. It is effective in preventing collapsing of load when the swing is stopped and in reducing the cycle time (by better positioning performance and quicker movement for next operation).
T
c e
D4 a D3
D1 d 㔎ষ D2 % b f 7
In Ma t rk er n et a in ti o g n De al pt .
ZX215-1002089
Fig. 4-78
Operation
$
1. When braking pressure is generated at port (B)
● Pressure (MB) is conducted to chamber (d) via the notch. The pressure compresses spring (6) by use of the difference in areas of circles (D1 > D2) of spool (5) and moves the spring (6) to the left side. Port (B) and chamber (e) will be interconnected. Since pressure (A) is lower than the set pressure of spring (3), spool (2) does not move and the pressurized oil is stopped by spool (2). Thus the braking force is ensured.
T
F H
' D '
司
公
销 营
' G 㔎ষ '
%
E I
T
ZX215-1002090
Fig. 4-79
2. When motor is stopped
A
● The motor rotation is reversed by the closing pressure generated at port (B). (1st reversing) Reversing pressure is generated on port (A) under the above condition. Pressure (A) is conducted to chamber (a), and spool (2) moves spring (3) to the right side, and A and B is interconnected. At this time, b is interconnected with f via the orifice on spool (5), and reversing pressure on port A is bypassed to port T in order to prevent second reversing.
T
5 d
a 2
3
B b f T ZX215-1002091
Fig. 4-80 Shop Manual - April 2014
4-85
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.5 Central Swivel Joint 12 11
9 10 8
15
E
E 7
D
In Ma t rk er n et a in ti o g n De al pt .
D
C
C
B
B
6
A
A
5 4
司
公
3
销 营
2
13，14
1
W365R130401
Fig. 4-81 (1) (2) (3) (4) (5) (6) (7) (8)
Bolt O-ring Cap O-ring Washer Collar Rotary seal (CSI) Housing
4-86
(9) O-ring (10) Swivel shaft (11) Rotor (12) Plug (13) Bolt, socket-head (14) Flat washer (15) Dust boot
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.6 Travel motor Type: MAG-170VP-3800E View of motor before installation Motor positioning cut Φ200H7
Z Bre
X
Y
S
B
In Ma t rk er n et a in ti o g n De al pt .
T
Hexagon bolt 2-M20×40 Torque 358Nm
Bolt hole for motor installation 2-M20
Oil inlet of brake M12×1.5
Oil inlet of brake
Y向
Z向
X
B
Bre
A
MA
Direction B
司
公
销 营
Oil inlet, level M18×1.5
MB S
Drain port M18×1.5
W365T130401
Fig. 4-82
A, B: Working oil port T: Oil drain port
MA, MB: Test port S: Oil compensation port X: Control pressure port Bre: Oil port for releasing external brake
Shop Manual - April 2014
4-87
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Table 1 - Motor Specifications Unit
Specifications
Max input torque
N·m
546
Max input speed
r/min
4788
Max output torque
N·m
69309
Max output speed Basic braking torque (without back pressure) Starting pressure
r/min
37.7
N·m
730
bar
18
Max withstanding pressure
bar
50
In Ma t rk er n et a in ti o g n De al pt .
Item
Oil refilling capacity
L
8.5
Speed ratio
-
126.94
Weight
kg
400
Brake disc
Disc type brake
Lubricant oil
220（40℃）industrial application
司
公
销 营
4-88
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.7 Reducer Type: GFT80
15 3 20 5 21 6 19 48 47 8 12 13 14 13 18 11 16 53 55 59 54 58 89 91 93 66 90 94 67 92 200 199
In Ma t rk er n et a in ti o g n De al pt .
105
司
公
销 营
38 37 38 35 36 35
23 22 39 1 28 26 32 31 25 44 46 30 29 27 4 99 100 17 49 52 88 87
69 70 51 103 W365T130402
Fig. 4-83
Shop Manual - April 2014
4-89
Structure and Functions
No.
Code
SY365(B)H-9 Crawler Hydraulic Excavator
Description
Qty
No.
Code
Description
Qty
E001
R988011946
Support shaft
1
E048
R913006477
Bolt, hexagon
24
E003
R988012090
Drive shaft
1
E049
R988010958
Gear ring
1
E004
R988011553
Planetary carrier
1
E051
R988011457
End cover
1
E005
R988012073
Bearing seat
1
E052
R988011597
Sun gear
1
E006
R916452282
Collar
1
E053
R988011951
Planetary carrier
1
E008
R916452408
Collar
1
E054
R988011483
Planetary gear
3 3
Planetary gear
5
E055
R988012459
E012
R916411696
Cylidrical roller bearing
10
E058
2916650023
Collar
3
E013
R988012373
Collar
10
E059
R913003909
Collar
1
E014
R916452254
Collar
5
E066
R988012492
Ring
1
E015
R988013065
Float seal
1
E067
R913006441
Bolt, hexagon
12
E016
2916650025
Elastic collar
5
E069
R913003865
Plug
2
E017
R988011192
Sun gear
1
E070
R916462052
Washer
2
E018
R916452068
Elastic collar
1
E087
R988011630
Sun gear
1
E019
R988011289
Round nut
1
E088
R988012341
Collar
1
1
E089
R988011188
Planetary carrier
1
E090
R988011840
Planetary gear
3 3
E011
In Ma t rk er n et a in ti o g n De al pt .
R988011587
Cylindrical roller bearing
E020
R916412778
E021
R916412722
Tapered roller bearing Tapered roller bearing
1
司
公
销 营
E022
R988012516
O-ring
1
E091
R988012458
Cylindrical roller bearing
E023
R913006409
Bolt, hexagon
2
E092
R916452026
Collar
3
E025
R988011598
Piston
1
E093
R916462507
Collar
6
E026
R988012185
Collar
1
E094
R916452244
Collar
6
E027
R988012320
Collar
2
E099
R988012398
Deep-grooved ball bearing
1
E028
R916452300
Collar
1
E100
R916462138
Collar
1
6
E103
R988012357
Cylidrical roller
1
5
E105
R902165278
Motor
1
Friction disc, outside Friction disc, inside
E029
R988012929
E030
R988012931
E031
R916423354
Spring
18
E199
R988012436
Rivet
4
E032
R916423355
Spring
18
E200
R909830326
Nameplate
1
E035
R988012913
Collar
2
E036
R988012397
Spring sleeve
1
E037
R988012404
X -ring
1
E038
R988012914
X -ring
2
E039
R902602007
Plug
1
E044
2917890148
Pin
2
E046
R988012493
O-ring
1
E047
R988011215
Bearing seat
1
4-90
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.8 Travel motor (Nabtesco) Type: GM60VA
In Ma t rk er n et a in ti o g n De al pt .
Pi
Nabtesco
Dr
MA
Nabtesco
MB
A
B
26XM20
18XM24
司
公
销 营
FILL lEVEL
Filling port
DRAIN
Drain port
ZX305-1102601
Fig. 4-84
A: Main oil port B: Main oil port
Am: Pressure detection port Bm: Pressure detection port Pi: Two-speed pilot tubing port Dr: Oil drain port
Shop Manual - April 2014
4-91
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Unit
Specifications
Input flow
L/min
280
Relief valve pressure setting
Mpa
34.3
Motor displacement
2
cm /rev
290.7/170.1
Reduction ratio
—
40.67
Total displacement
2
cm /rev
—
Theoretical output torque
KN·m
64.3/37.6
Theoretical output speed
r·p·m
23.8/40.7
Braking torque
KN·m
1.17
Brake release pressure
Mpa
1.54
Auto switching pressure
Mpa
26.5
Operating temperature range
℃
-20~90
Total weight
kg
399
In Ma t rk er n et a in ti o g n De al pt .
Item
司
公
销 营
4-92
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.9 Operating principle of the basic components 4.6.9.1 Double-balanced valve Function: ● When external load makes the plunger motor tend to go faster than the rated rotating speed of feed flow (hereunder referred to pump effect), this valve controls motor speed and prevents over-speed of the motor in relation with the feed flow. ● The double-balanced valve and the relief valve constitute the braking circuit. The braking circuit applies braking force onto the swing of plunger motor and stops the motor gradually.
In Ma t rk er n et a in ti o g n De al pt .
● This valve can serve as a shuttle valve for high pressure selection to release the brake under its own pressure. ● The structure of a standard double-balanced valve is shown below. The following information describes the operating principle of a standard double-balanced valve. A. When stopped
● When the main valve is neutralized (motor stopped), port M1 and port M2 are shut off by spool (1) and check valve (2) since no pressure is generated at port P1 and port P2. The motor is not rotating. 司
公
销 营
8-1
8
8-2
Oil circuit B Oil circuit C2
Oil circuit C1
M2
M1
Orifice D3
Orifice D1
Damper chamber A2
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2 Spring chamber1 P2
P1
6-1
6-2
7-2
7-1
5-1
3
4-1
2-1
1
2-2
4-2
5-2
ZX215-1002094
Fig. 4-85 Shop Manual - April 2014
4-93
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
B. When motor is started
In Ma t rk er n et a in ti o g n De al pt .
● When the hydraulic oil from the main pump enters port P1 of the double-balanced valve, spring (3) is pushed to the left by check valve (2-1), opening circuit C1. The hydraulic oil enters the plunger motor via port M, trying to make the motor rotating. At the same time, return oil from the plunger motor enters the counterbalance valve via port M2, but it is stopped by check valve (2-2). The output pressure of the main pump increases as a result, and the hydraulic oil works on the inside of spring chamber (1) and damper chamber (A1) via orifice (4-1) and check valve (5-1). The force generated in this way pushes spring (7-2) on the other side and moves plunger (1) to the right. At this time, return oil from port M2 passes through circuit of the notch on the periphery of plunger (1), and through port P2 when pressure is generated at port M2, and enters the tank via the main valve finally. The motor starts rotating at this time.
8-1
8
8-2
Oil circuit B
司
公
Oil circuit C2
销 营
Oil circuit C1
M1
M2
Orifice D3
Orifice D1
Damper chamber A2
Damper chamberA1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
P2
P1
6-2
6-1
7-2
7-1
5-1
3
4-1
2-1
1
Fig. 4-86
4-94
Shop Manual - April 2014
2-2
4-2
5-2
ZX215-1002095
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
C. Counterbalance function
In Ma t rk er n et a in ti o g n De al pt .
● When the engine runs at an excessively high speed because of external force applied on it, the motor may lose control. At this time, port P1 serves as the inlet side, and the pressure drops. Pressure in spring chamber (1) and damper chamber A1 also drop. As a result, plunger (1) moves to the left under the force of spring (7-2), closing circuit B. Circuit at the suction side is also closed at the same time when the circuit at return side is closed. When circuit B is closed, pressure at port P1 rises due to hydraulic oil from the main pump, moving plunger (1) to the right again. In this way, when external load generates pump effect, slight movement of plunger (1) keep circuit B open. The rotation speed of the motor keeps in line with fuel supply of the main pump, and the motor will not lose control because of the vacuum in the hydraulic system.
司
公
销 营
Shop Manual - April 2014
4-95
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
D. Braking of motor ● The double-balanced valve and the relief valve forms the braking circuit. ● When the main valve is in neutral position, hydraulic oil from the main pump is cut off, and pressure at port P1 and P2 is the same. As a result, plunger (1) moves to the neutral position, and the opening area of circuit B decreases. ● At the same time, because of the inertia of external force, the motor does not stop rotating (pump effect), and pressure at port M2 rises and serves as the braking force of motor rotation.
In Ma t rk er n et a in ti o g n De al pt .
● When the pressure at port M2 reaches the set pressure of relief valve (8), cone valve (8-1) at port M1 overcomes the force of spring (8-2) and moves to the left, and hydraulic oil flows to the port M1. In this way, the impacting force due to inertia at port M2 is under control, and vacuum at port M1 is avoided.
8-1
8
8-2
Oil circuit B
司
公
销 营
Oil circuit C2
Oil circuit C1
M2
M1
Orifice D3
Orifice D1
Damper chamber A2
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
P2
P1
6-1
6-2
7-1
5-1
7-2
3
4-1
2-1
1
2-2
4-2
5-2
ZX215-1002096
Fig. 4-87
4-96
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
E. Shuttle valve function for high pressure selection ● The double-balanced valve can function as a shuttle valve to release travel brake. ● When hydraulic oil is fed to port P1, plunger (1) moves to the right, as shown in fig. 4. At this time, drain passage F of motor housing is cut off, and passage D leading to cylinder chamber E for travel braking is opened. ● Hydraulic oil flows to passage G via the orifice, and enters travel brake cylinder chamber E to release the travel brake. In addition, plunger (1) moves to neutral position, as shown in fig 5 when motor stops. Passage D is closed and drain passage F of motor housing is opened.
In Ma t rk er n et a in ti o g n De al pt .
● Hydraulic oil in travel braking cylinder chamber E is conducted to the drain passage of motor housing, and travel brake is applied. 1
Passage D
Passage D
Orifice Passage F
Passage F Passage D
Passage G
司
公
销 营
Passage G
Cylinder chamber E
ZX215-1002097
Fig. 4-88
1
Passage D
Passage D
Passage F Passage D
Orifice Passage F
Passage G
Passage G
Cylinder chamber E
ZX215-1002098
Fig. 4-89
Shop Manual - April 2014
4-97
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.9.2 Operation of parking brake 1) When starting travel ● As the travel lever is operated, pressurized oil from the pump activates back pressure valve spool (10), opens the parking brake circuit, and flows to chamber A of brake piston (12). Pressurized oil overcomes the force of spring (11) and pushes piston (12) toward the left.
10
In Ma t rk er n et a in ti o g n De al pt .
● Since the pushing force to plate (13) and disc (14) disappears, plate (13) is separated from disc (14) and the brake is released.
Travel control valve
11
14
13 12
A
M
22
ZX215-1002099
Fig. 4-90
2) When travel is stopped
司
公
销 营
● As the travel lever is placed in neutral, back pressure valve spool (10) returns to the neutral position and closes the parking brake circuit. T
10
● he pressurized oil in chamber (A) of brake piston (12) passes through the orifice of the brake piston and is drained to the motor casing. Brake piston (12) is pushed to the right by spring (11).
● Plate (13) and disc (14) are pushed against each other, and the brake is applied. As brake piston (12) returns, a time delay is formed by making the pressurized oil pass through a throttle valve in the slow return valve (22). This time delay ensures an active brake after the machine is stopped.
4-98
Travel control valve
11
14
13 12
A
M
22
ZX215-1002100
Fig. 4-91
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.9.3 Operation of braking valve
Travel control valve
PA
● The brake valve consists of a suction safety valve (8A) and a counterbalance valve (18). As shown in the illustration on the right, functions and operations of respective components are described below.
PB
8A
18
MB
In Ma t rk er n et a in ti o g n De al pt .
MA
ZX215-1002101
Fig. 4-92
1. Counterbalance valve and check valve
Travel control valve
PA
Function
● When traveling downhill, the weight of the machine tends to make the travel speed faster than the motor speed. If the machine travels with the engine at low speed, the motor may rotate at zero load, resulting in runaway and inviting a very dangerous situation. These valves are used to avoid such a situation by controlling the machine to travel according to the engine speed (pump flow).
司
公
销 营
PB
8B
8A
19
MA
MB
ZX215-1002102
Fig. 4-93
Operation when pressurized oil is supplied
● Operating the travel control lever conducts the pressurized oil from the control valve to port (PA). The pressurized oil opens suction safety valve (8A) and then flows to motor outlet port (MB) via motor inlet port (MA). The motor outlet side is closed by suction safety valve (8B) and spool (19), so the pressure at the supply side rises, as shown in the right illustration.
Shop Manual - April 2014
4-99
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● The pressurized oil on the supply side flows to chamber (S1) via orifice (E1) and orifice (E2) of the spool (19). As the pressure in chamber (S1) goes above the spool shift pressure, spool (19) is pushed toward the right. Port (MB) and port (PB) are connected, the motor outlet port side opens and the motor starts rotating, as shown in the right illustration.
Travel control valve
PB
PA
S1
19 MB
In Ma t rk er n et a in ti o g n De al pt .
MA
E1 E2
ZX215-1002103
Fig. 4-94
Brake operation in downhill travel
● If the machine goes out of control while travelling downhill, the motor will be caused to rotate without load to decrease the inlet side oil pressure. Pressure in chamber (S1) drops via orifices (E1) and (E2). As the pressure in chamber (S1) goes below the spool shift pressure, spool (19) is returned to the left by spring (20) and outlet port (MB) is throttled. The pressure at the outlet port side rises, generating rotation resistance on the motor to prevent the machine from losing control. On the other hand, the spool moves to a position where the pressure on outlet port (MB) can be balanced against the machine's own weight and the inlet port pressure. Oil flow from the outlet circuit is reduced to ensure the travel speed corresponded to the pump delivery, as shown in the right illustration.
4-100
Travel control valve
PB
PA
20
司
公
销 营
S1
19
MA
E1
Fig. 4-95
Shop Manual - April 2014
E2
MB
ZX215-1002104
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
2. Safety valve Function
In Ma t rk er n et a in ti o g n De al pt .
● When the machine travel is stopped (or it is travelling downhill), the double-balanced valve closes the inlet and outlet circuits of the motor. Since the motor is rotated by inertial force, pressure in the motor outlet port side is abnormally increased, potentially resulting in damages on the motor and piping. The safety valve relieves this abnormal pressure to the inlet port side of the motor in order to prevent damages to the equipment. Operation
1) When travel is stopped (or when travelling downhill or swinging to the right)
● Reduction of the pressure at motor inlet (PA) decreases the pressure in chamber (S1). When it drops beyond the spool shift pressure, the spool is returned to the left by spring (20), throttling the oil outlet passage (B1). At this time, the motor continues rotating due to its inertial force, thus pressure on the outlet port (MB) is increased, as shown in the right illustration.
Travel control valve
PB
PA
20
司
公
销 营
S1
MA
MB
A1
B1 ZX215-1002105
Fig. 4-96
● When the pressure rises above the set pressure of the suction safety valve (8A), the spool opens. The pressurized oil passes through notch (A1) of the counterbalance valve spool (19) into chamber (MA) of the circuit at the opposite side, as shown in the right illustration.
Spool MB
MA ZX215-1002107
Fig. 4-97
Shop Manual - April 2014
4-101
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
2) When starting travel (or traveling normally) Travel control valve
● As the travel control lever is operated, the pressurized oil from the pump moves the counterbalance valve spool (19) toward right. In this case, the passage to the suction safety valve functions as a circuit which passes through notch (B2) of spool (19), producing large differential pressure. The pump pressure rises, providing a large tractional force to the valve, as shown in the right illustration.
PB
PA
8B
8A
S1
19 MB
In Ma t rk er n et a in ti o g n De al pt .
MA E1
B2
ZX215-1002106
Fig. 4-98
3. Overload relief valve
● The structure of the relief valve is shown in the right figure. This valve is an areadifferential and direct-acting relief valve. It has impact damping function during starting and braking.
司
公
销 营
ZX365-1304108
Fig. 4-99
A. Operating principle and function
● When the main control valve makes the motor to start or brake, front pressure of cone valve (2-9-2) rises above the set pressure and the force of spring (2-9-5), and moves cone valve (2-9-2) to the right and off the valve seat (2-9-3). Pressurized oil in the front of cone valve (2-9-2) is bypassed to the low pressure side. The impact due to inertia energy at the high pressure side is put under control and vacuum is prevented from occurring at the low pressure side through bypassing pressurized oil to the low pressure side. 4-102
2-9-2
2-9-5
2-9-3
ZX365-1304109
Fig. 4-100
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
B. Damping function ● When the relief valve begins to function, damping piston (2-9-9) moves to the left. As a result, low pressure is maintained in spring chamber D. At this time, the loaded area of cone valve (2-9-2) is S1, and generally it is much larger than the set loaded area S1-S2 of the relief valve. So, when damping piston (2-9-9) is moving, the functional pressure of relief valve is maintained at 1/3 of normal set pressure in order to absorb the impact at the high pressure circuit side due to inertial energy. When the movement of damping piston stops, pressure in spring chamber D rises. Pressure at both side of cone valve (2-9-2) is the same, and the relief valve is working at normal set pressure. In this way, the relief valve reduces the impact during motor starting and braking by a two-stage action to provide excellent performance.
2-9-2
Area S2
2-9-5
2-9-3 Area S1
2-9-9
Spring chamber D ZX365-1304110
In Ma t rk er n et a in ti o g n De al pt .
Fig. 4-101
司
公
Pressure (P)
销 营
O
Damping form
time (T) ZX215-1002111
Fig. 4-102
Shop Manual - April 2014
4-103
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Table 2 Repair standard of motor components Components
Check item
1. Boot sliding surface 1-4-2 Plunger 2. Plunger outer diameter assembly
Remedy
Grind the boot sliding surface. Replace the Roughness 0.8a or surface roughcylinder block assembly ness, scratch 0.02mm+ if the scratch cannot be corrected. Roughness 1.2a or surface roughness, scratch 0.02mm+ Replace the cylinder Clearance 0.060. block assembly. Clearance 0.4.
In Ma t rk er n et a in ti o g n De al pt .
3. Plunger outer diameter and cylinder block inner diameter 4. Boot head clearance
Allowable limit
Grind the boot sliding surface. Replace the 1. Valve leaf and sliding sur- Roughness 0.8a or surface roughcylinder block assembly face ness, scratch 0.02mm+. if the scratch cannot be corrected. Roughness 1.6a or surface rough1-4-1 Cylinder 2. Shaft hole inner diameter ness, scratch 0.02mm+. block 3. Shaft hole inner diameter Replace the cylinder and 4-2 plunger assembly Clearance 0.060. block assembly outer diameter Roller distance below 38.749 4. Spline at shaft joint (measuring pin diameter φ3.333(V1=2.80)); or damaged Grind the sliding surface. 1-21 Oil distriRoughness 0.8a, scratch 0.02mm+ Replace the valve sheet 1. Sliding surface bution plate on sliding surface or burned sign if the scratch cannot be corrected. 1-4-3 Retainer Roughness 0.8a, scratch 0.02mm+ Replace the retaining 1-4-4 Retain- 1. Sliding surface on sliding surface or sign of burning plate or the retainer. ing assembly Grind the sliding surface. Roughness 0.8a, abrasion on sling Replace the valve sheet 1. Sliding surface surface or scratch 0.02mm+ if the scratch cannot be corrected. 1-5 Swash Roughness 1.6a. plate 2. Hole for assembling steel Scratch on spherical surface ball Replace the swash plate. 0.02mm+ or surface roughness 3. Hole for assembling steel Ball depth 14.5 ball 司
公
销 营
4-104
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Components
1-3 Shaft
Check item
Allowable limit
Remedy
1. Oil seal sliding portion outer Roughness 1.6a, rough surface, or Replace the swash diameter scratch 0.02mm+ plate. Stick spans below 47.380 (testing 2. Cylinder block matching pin diameter φ3.00), or the stick spline breakage. Replace the shaft. Stick spans below 30.498 (testing 3. Drive gear connection pin diameter φ3.33), or the stick breakage. 1. Dimension Height 38.2 Roughness 2.5a Scratch 0.02mm+ or rough surface
Replace the brake piston.
In Ma t rk er n et a in ti o g n De al pt .
1-15 Brake pis- 2. Sliding surface ton 3. Appearance 1. Dimension
1-13 Disc plate
2. Appearance
1-8 Ball bearing 1. Rolling surface 1-9 Ball bearing 2. Action
Thickness 3.2 Deep scratch on sliding surface or friction material peeling Peeling or fracture Abnormal rotation (noise•uneven rotation)
Replace the disc plate. Replace the ball bearing.
Grind the sliding surface. Replace the Roughness 1.6a, rough surface, or flange plate parts if 1. Boot sliding surface scratch 0.02mm+ the scratch cannot be corrected 1-7 Plunger asRoughness 1.2a, rough surface, sembly 2. Plunger outer diameter scratch 0.02mm+ Replace the flange 3. Plunger outer diameter and Gap 0.040. plate parts. flange part inner diameter 4. Boot head clearance Clearance 1.0 Roughness 0.8 a, scratch 0.02mm+ 1. Plunger outer diameter or rough surface 1-2-2 Plunger Replace the valve assembly sheet. 2. Plunger outer diameter and Clearance 0.060. valve sheet inner diameter 1. Assemble the plunger as- Roughness 0.8 a, scratch 0.02mm+ sembly hole or rough surface 2. Valve sheet inner diameter Clearance 0.060 and plunger outer diameter 3. Valve spool assembly instal- Roughness 0.8 a, scratch 0.02mm+ 1-2-1 Valve Replace the valve lation hole or rough surface sheet sheet and the parts. 4. Spool valve sheet inner diameter and valve spool outer Clearance 0.060. diameter 司
公
销 营
5. Movable plunger sliding part Scratch 0.02mm+ or surface roughand seat of the relief valve ness
Shop Manual - April 2014
4-105
Structure and Functions
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
4-106
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Components
1-2-9 Spool assembly 1-2-7-9 Movable plunger 1-2-7-1 Case
Allowable limit
1. Valve spool out diameter 2. Valve spool outer diameter and valve sheet inner diameter 1. Sliding portion of valve sheet and valve seat 1. Sling portion of the movable piston (outer diameter) 1. Dimension
Roughness 0.8 a, scratch 0.02mm+ or surface roughness
Free length 61.0
2. Appearance
Deformation and surface damage
Clearance 0.060.
Remedy
Replace valve sheet and parts
Scratch 0.02mm+ or surface roughness
Replace relief valve Scratch 0.02mm+ or surface rough- assembly ness
In Ma t rk er n et a in ti o g n De al pt .
1-4-7 Spring
Check item
1-18 Spring 1-20 Spring
1-2-4 Spring
1-2-10 Spring
O-ring and oil seal
1. Dimension
Free length 39.0
2. Appearance
Deformation and surface damage
1. Dimension
Free length 41.5
2. Appearance
Deformation and surface damage
1. Dimension
Free length 48.5
2. Appearance
Deformation and surface damage
1. Dimension
Free length 28.3
2. Appearance
Deformation and surface damage 司
公
销 营
When removed
Shop Manual - April 2014
Replace o-ring and oil seal
4-107
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.10 Control system 8
9
7
In Ma t rk er n et a in ti o g n De al pt .
6
4
1
2
5
4
5
3
11
9
10
7
6
12
司
公
销 营
8
10
13
3
11
2
12
1
ZX365-1304112
Fig. 4-103
4-108
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
(1) Pilot valve (travel) (2) Control lever (left travel) (3) Control lever (right travel) (4) Pilot valve (Right) (5) Control lever (right work equipment) (6) Accumulator (7) Block (8) Hydraulic pump (9) Main control valve (10) Solenoid valve (11) Control lever (left work equipment) (12) Relay Control lever positions 1
HOLD
2
Boom UP
3
Boom DOWN
4
Bucket DUMP
5
Bucket DIG
6
HOLD
7
Arm IN
8
Arm OUT
9
Right swing
10
Left swing
11
Neutral
12
Travel BACKWARD
13
Travel FORWARD
司
公
销 营
Shop Manual - April 2014
4-109
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.11 Manual pilot valve P3
P2
A T
P
2
3 P
In Ma t rk er n et a in ti o g n De al pt .
1
4
P4
A
P1
19~22Nm
64~73.5Nm
司
公
销 营
ZX365-1304113
Fig. 4-104 P: From pilot pump relief valve P1: Left pilot valve: Arm OUT / Right pilot valve: Boom DOWN P2: Left pilot valve: Arm IN / Right pilot valve: Boom UP P3: Left pilot valve: Swing LEFT / Right pilot valve: Bucket DIG P4: Left pilot valve: Swing RIGHT / Right pilot valve: Bucket DUMP T: To tank 4-110
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
6 7
5
In Ma t rk er n et a in ti o g n De al pt .
8
4
9
3
司
公
销 营
10
2
1
A-A
ZX215-1002114
Fig. 4-105 (1) (2) (3) (4) (5)
Plunger Adjusting spring Center spring Piston Disc
(6) Nut (for control lever connection) (7) Connector (8) Plate (9) Retainer (10) Valve body
Shop Manual - April 2014
4-111
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Operation 1. When in neutral ● Ports (A) and (B) of the control valve and ports (P1) and (P2) of the pilot valve are connected to drain chamber (D) via orifice (f) in plunger (1).
D f
2. During fine control (Neutral to fine control)
T
1
● When piston (4) is pushed by disc (5), retainer (9) is pushed, plunger (1) is also pushed by adjusting spring (2), and moves down.
In Ma t rk er n et a in ti o g n De al pt .
P
● When orifice (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP). Pilot pressurized oil of the control pump is led to port (A) from port (P1) via orifice (f). When the pressure at port (P1) becomes higher, plunger (1) is pushed back and orifice (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1). As a result, plunger (1) moves up and down until the force of adjusting spring (2) is balanced with the pressure at port (P1).
● The relationship of the position of plunger (1) and body (10) [orifice (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts plunger (1). Adjusting 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. In this way, the control valve plunger moves to a position where the pressure of chamber (A) (same as pressure at port (P1)) and the force of the return spring of the control valve plunger are balanced.
Pilot pump
P1
M
A
P2
Control valve
M
B
ZX365-1304115
司
公
销 营
Fig. 4-106
D
f
T
1
P
Pilot pump
A
P1
M
P2
Control valve
M
B ZX365-1304116
Fig. 4-107 4-112
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3. Fine control (When control lever returns) ● When disc (5) starts to return, plunger (1) is pushed up by the force of center spring (3) and the pressure at port (P1). ● Because of this, orifice (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.
D f
● If the pressure of port (P1) is lowered excessively, plunger (1) is pushed down by adjusting spring (2).
T
1 P
In Ma t rk er n et a in ti o g n De al pt .
● Orifice (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP). Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. ● When the plunger of the control valve returns, the oil in drain chamber (D) flows in from orifice (f) in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
Pilot pump
P2
PP
M
A
司
公
销 营
P1
f1
Control valve
M
B ZX365-1304117
Fig. 4-108
4. At full stroke
● Disc (5) pushes down piston (4), and retainer (9) pushes down plunger (1).
● Orifice (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). ● Therefore, the pilot pressure oil from the self pressure reducing valve passes through orifice (f) and flows to chamber (A) from port (P1) to push the control valve plunger.
● The oil returning from chamber (B) passes from port (P2) through orifice (f) and flows to drain chamber (D).
D
f
T
1
P
f1 Pilot pump
A
P1
M
P2 PP
Control valve
M
B ZX215-1002118
Fig. 4-109 Shop Manual - April 2014
4-113
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.12 Travel pilot valve A
T
In Ma t rk er n et a in ti o g n De al pt .
T
P
P
P5
A
P5
P2
P4
P1
2
1
4
3
P6
司
公
销 营
P3
ZX215-1002119
Fig. 4-110
P: From pilot pump P1: L.H. reverse P2: L.H. forward P3: R.H. reverse
4-114
P4: R.H. forward P5: Travel signal P6: Travel signal T: To tank
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
37~30Nm
B
65~45Nm 1
8~6Nm
3 4 5 6 7
In Ma t rk er n et a in ti o g n De al pt .
2
C
C
2，4
1，3
B-B
司
公
销 营
B
13~11Nm
C-C
8~6Nm
ZX215-1002120
Fig. 4-111 (1) (2) (3) (4)
Plate Body Piston Collar
(5) Center spring (6) Adjusting spring (7) Valve
Shop Manual - April 2014
4-115
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.12.1 Operating principle 1) When in neutral ● Ports (A) and (B) of the control valve and ports (P1) and (P2) of the pilot valve are connected to drain chamber (D) via orifice (f) in spool (1).
D f T
2) Fine control (Neutral to fine control)
P
● When piston (4) is pushed by lever (5), retainer (9) is pushed, and plunger (1) is also pushed by adjusting spring (2), and moves downward.
1 Pilot pump
P2
In Ma t rk er n et a in ti o g n De al pt .
P1
● When orifice (f) is shut off from drain chamber (D), it is almost simultaneously interconnected to pump pressure chamber (PP).
A
Fig. 4-112
司
公
销 营
5 4 9
● As a result, plunger (1) moves up and down until the force of adjusting plunger (2) is balanced with the pressure at port (P1). ● The relationship of the position of plunger (1) and body (10) [orifice (f) is in the middle between drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) contacts plunger (1).
f
T
P
1
Pilot pump
P1
A
PP
P2
Control Valve
10
B
ZX215-1002122
Fig. 4-113
● In this way, the control valve spool moves to a position where the pressure of chamber (A) (same as pressure at port (P1)) and the force of the return spring of the control valve spool are balanced.
4-116
D
2
● Adjusting 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.
B
ZX215-1002121
● Pilot pressurized oil of the control pump is led to port (A) from port (P1) via orifice (f).
● When the pressure at port (P1) becomes higher, plunger (1) is pushed back and orifice (f) is shut off from pump pressure chamber (PP). At almost the same time, it is connected to drain chamber (D) to release the pressure at port (P1).
Control Valve
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3) Fine control (When control lever returns) ● When lever (5) starts to return, plunger (1) is pushed up by the force of center spring (3) and pressure at port (P1).
5
● Because of this, orifice (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.
3
D
2 f
● If the pressure of port (P1) is lowered excessively, plunger (1) is pushed down by adjusting spring (2).
T P f’ 1
● Orifice (f) is shut off from drain chamber (D), and it is almost simultaneously interconnected to pump pressure chamber (PP).
Pilot pump
PP P1
In Ma t rk er n et a in ti o g n De al pt .
P2
A
● Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position.
● When the spool of the control valve returns, the oil in drain chamber (D) flows in from orifice (f) in the valve on the side that is not working. The oil passes through port (P2) and enters chamber (B) to replenish the chamber with pressurized oil.
Control Valve
B ZX215-1002123
Fig. 4-114
司
公
销 营
4) At full stroke
● Lever (5) pushes down piston (4), and retainer (9) pushes down plunger (1).
● Orifice (f) is shut off from drain chamber (D), and is interconnected to pump pressure chamber (PP). ● Therefore, the pilot pressure oil from the self pressure reducing valve passes through orifice (f) and flows to chamber (A) from port (P1) to push the control valve spool.
5 4
D
9 f
T
P
f’
1 PP
Pilot pump
● The oil returning from chamber (B) passes from port (P2) through orifice (f) and flows to drain chamber (D).
P1 A
P2
Control Valve
B ZX215-1002124
Fig. 4-115
Shop Manual - April 2014
4-117
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.13 Solenoid valve
P2
T
A1
A2
2
P1
In Ma t rk er n et a in ti o g n De al pt .
1
3
4
5
6
7
8
W365-1304125
Fig. 4-116
(1) Solenoid valve block
P1: To pilot fi lter 司
公
销 营
(2) Accumulator
P2: To main valve port G
(3) High-speed travel solenoid valve
T: To oil tank
(4) Backup valve
A1: To swivel joint port X
(5) Backup valve
A2: To pilot oil circuit block P
(6) Bucket confl uence solenoid valve (7) Backup
(8) Pilot pressure solenoid valve
4-118
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.14 PPC accumulator (1) Gas plug
1
(2) Shell (3) Poppet 2
(4) Holder (5) Bladder (6) Oil port
In Ma t rk er n et a in ti o g n De al pt .
3
4
Specifications
Gas capacity: 300 cc (for PPC)
5
6
司
公
销 营
ZX215-1002126
Fig. 4-117
Shop Manual - April 2014
4-119
Structure and Functions
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
4-120
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.15 Pilot oil filter K 1 K Model
2
Pressure Precision
3
In Ma t rk er n et a in ti o g n De al pt .
4
5
6
司
公
销 营
3
ZX215-1002127
Fig. 4-118 (1) (2) (3) (4) (5) (6)
Nameplate Head cover O-ring Seal ring Filter Casing
Specifications Max. delivery: 40 L/min Filter fineness: 10 um Operating pressure: 20 Mpa Max. operating pressure: 40 Mpa Pressure loss: 0.05 Mpa Max. allowable pressure difference: 1 Mpa Specification of inlet/outlet port O-ring: 30×3.1
Shop Manual - April 2014
4-121
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.16 Hydraulic cylinders Boom cylinder
1
2
7960N·m
3
56.9±10.7N·m
In Ma t rk er n et a in ti o g n De al pt .
367N·m
ZX335-1002035
Fig. 4-119
Arm cylinder
2
1
司
公
销 营
22200N·m
3
96.6±18.2N·m
711N·m
ZX335-1002036
Fig. 4-120
Bucket cylinder
2
1
9550N.m
3
56.9±10.7N.m
367N.m
ZX335-1002037
Fig. 4-121 4-122
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.6.16.2 Lubrication at every 100 service hours Unit: mm
1
2
3
Check Item Cylinder
Standard size
Boom
100
Arm
120
Bucket
100
Boom
100
Clearance between piston rod and bushing
Clearance between piston rod support pin and bushing
Criteria Tolerance Shaft Hole -0.012 +0.222 -0.034 +0.047 -0.012 +0.222 -0.047 +0.047 -0.012 +0.258 -0.034 +0.048 -0.036 +0.25 -0.071 +0.05 -0.036 +0.25 -0.071 +0.05 -0.036 +0.25 -0.071 +0.05 -0.036 +0.25 -0.071 +0.05 -0.036 +0.25 -0.071 +0.05 -0.036 +0.25 -0.071 +0.05
Remedy Standard clearance
Clearance limit
0.083-0.312
0.412
0.083-0.312
0.412
0.078-0.334
0.434
0.086-0.321
1.0
In Ma t rk er n et a in ti o g n De al pt .
No.
Clearance between cylinder bottom support pin and bushing
Arm
110
Bucket
90
Boom
90
Arm
110
Bucket
90
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
Replace the bushing.
Replace the pin or bushing.
司
公
销 营
4.6.16.1 Lubrication at every 500 service hours No.
1
2
3
Check Item
Clearance between piston rod and bushing
Clearance between piston rod support pin and bushing Clearance between cylinder bottom support pin and bushing
Criteria
Cylinder
Standard size
Boom
100
Arm
120
Bucket
100
Boom
100
Arm
110
Bucket
90
Boom
90
Arm
110
Bucket
90
Tolerance
Shaft
Hole
-0.012 -0.034 -0.012 -0.047 -0.012 -0.034 -0.036 -0.071 -0.036 -0.071 -0.036 -0.071 -0.036 -0.071 -0.036 -0.071 -0.036 -0.071
+0.222 +0.047 +0.222 +0.047 +0.258 +0.048 +0.25 +0.05 +0.25 +0.05 +0.25 +0.05 +0.25 +0.05 +0.25 +0.05 +0.25 +0.05
Standard clearance
Clearance limit
0.083-0.312
0.412
0.083-0.312
0.412
0.078-0.334
0.434
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
0.086-0.321
1.0
Shop Manual - April 2014
Unit: mm Remedy
Replace the bushing.
Replace the pin or bushing.
4-123
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.7 Work Equipment 4.7.1 Component dimensions
F D C G
In Ma t rk er n et a in ti o g n De al pt .
A
E
J
,
K
司
公
销 营
B
H
ZX365-1304500
Fig. 4-122
4-124
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
1
3
A-A
G-G
D-D
J-J
5
2
4
B-B H-H
K-K
In Ma t rk er n et a in ti o g n De al pt . E-E
6
F-F
C-C
I-I
ZX285-1002022
Fig. 4-123
司
公
销 营
Lubrication
No.
Item
Bushing
Lube
material
interval
Std. size
1
Clearance between the pin and bushing connecting the boom with swing platform
Copper
500 h
Ф110
2
Clearance between the pin and bushing connecting the boom with arm
Copper
500 h
Ф110
3
Clearance between the pin and bushing connecting the arm with rocker
Steel
100 h
Ф90
4
Clearance between the pin and bushing connecting the arm with bucket
Steel
100 h
Ф90
5
Clearance between the pin and bushing connecting the linkage with bucket
Steel
100 h
Ф90
6
Clearance between the pin and bushing connecting the linkage with rocker
Steel
100 h
Ф90
Std. tolerance 轴
孔
Std. clearance
–0.036
+0.063
0.036 ～
–0.071
0
0.134
–0.036
+0.087
0.036 ～
–0.071
0
0.158
–0.036
+0.054
0.036 ～
–0.071
0
0.125
–0.036
+0.054
0.036 ～
–0.071
0
0.125
–0.036
+0.2
0.036 ～
–0.071
0
0.271
–0.036
+0.054
0.036 ～
–0.071
0
0.125
Unit：mm
Clearance limit
Remedy
1.0
1.0
1.0 Replace
Shop Manual - April 2014
1.0
1.0
1.0
4-125
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.7.2 Arm dimensions 9
19
B
11
12 A
5
A
13
C
D 6
B
10
14
D
C
In Ma t rk er n et a in ti o g n De al pt .
8
7
司
公
16
18
销 营
15
A-A
B-B
3
2
17
1 4
D-D C-C
ZX285-1002501
Fig. 4-124 4-126
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
单位：mm
No. 1 2 3
SY365H-9 Standard size φ100 131 345 φ90
5
473
Tolerance +0.087 0 +1.5 0 0 -0.5 -0.036 -0.071 ±1
Standard size φ100 131 316 φ110 602
Tolerance +0.087 0 +1.5 0 0 -0.5 -0.071 -0.036 ±0.8
In Ma t rk er n et a in ti o g n De al pt .
4
SY365BH-9
6
354
±1
215
±0.5
7
989
±1
976.6
±0.8
8
2914
±3
2906
±2
9
3018
±3
3071
±2
10
473
±1
458
±0.8
11
740
±0.3
770
±0.3
12
728
±0.5
728
±0.5
13
520
±0.5
513.6
—
14
1,661
1570
15
φ90
16
345
17
φ90 345
— -0.036 -0.071 0 -0.5 -0.036 -0.071 0 -0.5
329
— -0.036 -0.071 +1 0 -0.03 -0.06 0 -0.5
Arm body
司
公
销 营
φ90 346
φ90
18 When bushing is pressed on Minimum
345
—
344
—
2,395
—
1,990
—
19
4,145
—
3,275
—
Maximum
Shop Manual - April 2014
4-127
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.7.2.1 Bucket dimensions
2
In Ma t rk er n et a in ti o g n De al pt .
1
4
6
3
5
司
公
8
7
销 营
9
10 11 12
W365-1304502
Fig. 4-125 4-128
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Unit：mm No.
SY365H-9
SY365BH-9
Standard size
Tolerance
Standard size
Tolerance
1
520
±0.5
567
±0.5
2
1661
—
1714
—
3
R100
—
R130
—
4
R125
—
R130
—
5
1478
—
1451
—
6
1570
1889
7
φ90
— +0.2 0 +0.2 0 —
— +0.2 0 +0.2 0 —
9
In Ma t rk er n et a in ti o g n De al pt .
8
φ100
φ90 36
10
34
11
346
12
486
φ90 36
36
— +1 0 —
346
500
— +1 0 —
司
公
销 营
Shop Manual - April 2014
4-129
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8 Operator Station and Its Attachments 4.8.1 Air conditioner lines
In Ma t rk er n et a in ti o g n De al pt .
C
C
C
C
B
A
司
公
7
1
销 营
6
2
3
5 4
Fig. 4-126 4-130
Shop Manual - April 2014
ZX335-1002042
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
(1) Air conditioner (2) Hot water pumping line (3) Air compressor (4) Refrigerant line (5) Condenser (6) Hot water return line (7) Duct A: Fresh air
In Ma t rk er n et a in ti o g n De al pt .
B: Recirculated air C: Warm air / cool air
司
公
销 营
Shop Manual - April 2014
4-131
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.1 Layout of A/C components
2 1 4
In Ma t rk er n et a in ti o g n De al pt .
3
5
司
公
销 营
7
6
ZX215-1002138
Fig. 4-127 (1) (2) (3) (4) (5) (6) (7)
Sunlight sensor Control panel Air conditioning unit Condenser Compressor Fresh air sensor Recirculated air sensor
4-132
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.2 A/C control panel
1
2
3
4
5
OFF TEMP
FULL AUTO AIRCONDITION
MODE
AUTO
In Ma t rk er n et a in ti o g n De al pt .
A/C
6
8
7
W365413093
Fig. 4-128 (1) (2) (3) (4) (5) (6) (7) (8)
OFF switch Fan speed control switch Temperature control switch Air outlet mode switch Auto mode switch Fresh air/recirculation control LCD display A/C power
Remark:
司
公
销 营
When auto mode switch (5), fresh air/recirculation control (6) and A/C power (8) are turned on, indicator lights above these switches will light up.
Shop Manual - April 2014
4-133
5
2
3
FL1
3
8
RLCC
10
11
7
8
8
1.25L D
1.256
FURM
20A
1.25R
RLBM
10
15
2
12
12
RLCH
10 BLCM 3
200W
2RL 1.25RL MR
2G
M
10
10
4
BLC
1
G
8
13
13
8
FUM
5A
+B 6
14
13
16
SW
H OFF ACC ON START
15
16
18
12
22
22
21
SSD
16
B G1 G2 ACC M ST
13
19
19
19
13
20
15
3
RLCC RLCD RLBM
16
16
14
17
15
THAM THW THI THF
28 15
12
15
23
27 4
15
20
28
ACM
21
27
29
2
M
MRF
25
1
MV1
31 22 32
31
25
26
24 22 26
23
24
25
22
25
24
30
30
M
32
GND
FUCD 15A
RLCD
9
9
ECC 40W
15
M
REC Vz Pt
60A
FLZ 40A
MCD SPCD M 80W
RLCH
03
SPHL
0.5B
MAM
FFE
2
1
5 5
SW 6
02
2B
9
15
35
10
34
26
32
34 35 35 22
38
33
M
MV2
Fig. 4-129
2
CMB
BAT
02
司
公
销 营
1.25R
0.50
7
RCD RLCH
02
03
2B
1
1
ACC
D1
D2
1.25B
7
4 4
02
2B
0.85B
4
CMB CM 02
02
In Ma t rk er n et a in ti o g n De al pt . G
01
1.25B
RLSF
3
06
06
Shop Manual - April 2014
4-134
SY365(B)H-9 Crawler Hydraulic Excavator
Structure and Functions
4.8.1.3 Diagram of electrical circuit
ZX215-1002140
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Diameter/Color Wire Color Code B Black
Wire No.
Diameter/Color Wire Color Code 0.5VW Violet+white
Br(R)
Brown
0.5YB
Yellow+black
0.85W
White
0.5WO
White+orange
RL
Red+blue
0.5PB
Pink+black
G
Green
0.5VR
Violet+red
0.5BL
Black+blue
0.5BG
Black+green
0.5R
Red+blue
0.5WY
White+yellow
0.5Y
Yellow
0.5WR
White+red
0.5BR
Black+red
0.5BrW
Brown+white
In Ma t rk er n et a in ti o g n De al pt .
Wire No.
0.5BrY
Brown+yellow
0.5GO
Green+orange
0.5BY
Black+yellow
0.5Sb
Sky blue
0.5GW
Green+white
0.5OW
Orange+white
0.5LO
Blue+orange
1.25V
Violet
0.5PG
Pink+green
1.25RG
Red+green
0.5RY
Red+yellow
1.25RW
Red+orange
0.5BW
Black+white
0.85GL
Green+Blue
0.5LgR
Light green+red
Code
Name
司
公
销 营
Code
Name
Code
ACM
A/C amplifier
FUCD
Condenser fuse
RLCH
BAT
Battery
FUM
A/C main fuse
RLSF
BLC
Speed regulating resistor
Alternator
SSD
CMB
Battery relay
MAM
A/M servo motor
SPCD
Diode
MB
Blower motor
SPHL
Diode 1
MCD
SW
Diode 2
MRF
ECC
Compressor clutch
MV1
Condenser motor Fresh/recirculated air servo motor Air outlet servo motor
FL1
Fuse
MV2
FRONT outlet servo motor
THI
FL2
Fuse
RCD
Condenser resistor
THW
FUBM
Blower fuse
RLBM
Blower main relay
RLCC
Compressor relay
RLCD
Condenser relay
D D1 D2
G
Shop Manual - April 2014
THAM THF
Name
Condenser high speed relay Protective relay Sunlight sensor Condenser pressure switch Hi\Lo pressure switch
Switcher Recirculated air thermistor Anti-frosting thermistor Recirculated air thermistor Water temp thermistor
4-135
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.4 Operating principle Refrigeration cycle diagram
Expansion valve
Cool air
Lo temp\Lo press\Liquid (Mist)
Evaporator
Blower motor
In Ma t rk er n et a in ti o g n De al pt .
Air in cab
Out side fresh air
Hi-temp hi-pres gas
Lo-pres. side
Hi temp\Hi press\Liquid
Lo temp\Lo press\Gas
Cooling fan
Hi-pres. side
Reservoir
Compressor
司
公
销 营
Lo-pressure part
Hi-pressure part
Warm air
ZX215-1002141
Fig. 4-130
Heating cycle diagram
Water valve switch
Water tank radiator
Water pump
Warm air
Engine
Blower motor Air in cab
Low temp water High temp water
ZX215-1002142
Fig. 4-131 4-136
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.5 Compressor 3 1
4
2
16
In Ma t rk er n et a in ti o g n De al pt .
15 14
5
13
司
公
销 营
6
12
11
10
9
8
7
ZX215-1002143
Fig. 4-132
(1) Stator (2) Front radial bearing (3) Thrust bearing (4) Front radial bearing (5) Rear cylinder head (6) Safety valve (7) Rear cylinder block (8) Swash plate (9) Slipper (10) Front cylinder block (11) Piston (12) Front cylinder head (13) Shaft seal (14) Main shaft (15) Boss (16) Rotor
Operating principle
Compressor type: 10S15C. This compressor has 5 plungers in total with a piston at both sides of each plunger. The rotation of the swash plate drives the pistons to move back and forth and transforms the refrigerant sucked from the evaporator from low temperature and low pressure gas state to high temperature and high pressure state.
Shop Manual - April 2014
4-137
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Process1
Process2
HI press.end pipe LO press.end pipe
HI press.end pipe LO press.end pipe
Valve plate
Outlet valve disc
Intlet valve disc
In Ma t rk er n et a in ti o g n De al pt .
Main shaft and swash plate
Process6
Process3
HI press.end pipe LO press.end pipe
HI press.end pipe LO press.end pipe
司
公
销 营
Process5
Process4
HI press.end pipe LO press.end pipe
HI press.end pipe LO press.end pipe
ZX215-1002144
Fig. 4-133
4-138
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.6 Clutch ● The electromagnetic clutch is used to transmit moment of torsion. When the engine is operating, the compressor may not be working. The clutch controls the operation of the compressor only when the air conditioner is under refrigerating mode.
1 2 3 4
● Operating principle When the A/C power is turned on, the clutch coil with an electromagnet generates a magnetic field and attracts the metal piece. The stator and rotor of the clutch are engaged and bring the main shaft of the compressor into rotation.
In Ma t rk er n et a in ti o g n De al pt .
5
6
Fig. 4-134
司
公
销 营
ZX215-1002145
(1) (2) (3) (4) (5) (6)
Rotor Stator coil Clasp Ball bearing Stator Center piece
Shop Manual - April 2014
4-139
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.7 Condenser
1 2
4
In Ma t rk er n et a in ti o g n De al pt .
3
5
ZX215-1002146
Fig. 4-135
司
公
销 营
(1) (2) (3) (4) (5)
Condenser core Bracket Bolt with washer Refrigerant inlet Refrigerant outlet
4-140
Function
● The condenser changes high-temperature, high-pressure gas refrigerant (16Kg/cm², approx. 80 ℃ ) to high-temperature and high-pressure liquid refrigerant (16Kg/cm², below approx. 60℃ ) through radiating.
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.8 Expansion valve Operating principle
Evaporator
Refrigerant from the reservoir spurts out via the orifice, turns into low-temperature, lowpressure liquid (mist) after immediate expansion, and enters the evaporator.
2
In Ma t rk er n et a in ti o g n De al pt .
1
4
Reservoir
3
Compressor ZX215-1002147
Fig. 4-136
司
公
销 营
(1) (2) (3) (4)
Spring Diaphragm Probe Needle valve
4.8.1.9 Evaporator
Operating principle
The evaporator is a kind of heat exchanger that looks like a condenser. Warm air in the cab is conducted into the evaporator via the blower motor and undergoes heat exchange with the surface of the evaporator. Heat is absorbed and warm air turns into cool air, which flows into the cab through the air ducts. Evaporator surface absorbs heat → Refrigerant in the evaporator absorbs heat → Refrigerant evaporates . Evaporated refrigerant (gas) is absorbed by the compressor.
1
2
ZX215-1002148
Fig. 4-137 (1) Expansion valve (2) Evaporator
Shop Manual - April 2014
4-141
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.10 Dehydrator
2 1
Function ● Temporary storage of refrigerant ● Dehydration of refrigerant ● Removing dust from refrigerant 3
● Measuring the volume of refrigerant
In Ma t rk er n et a in ti o g n De al pt .
4
司
公
销 营
ZX215-1002149
Fig. 4-138
(1) (2) (3) (4)
4-142
Inlet Outlet Receiver/dehydrator Desiccant
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.11 Pressure switch Function
Pressure
● The pressure switch is installed between the reservoir and the expansion valve (hipressure pipe). It is a combination switch (Hi-Lo pressure combination switch).
1 7
2
6
● When pressure is excessively high, the compressor stops.
In Ma t rk er n et a in ti o g n De al pt .
● When pressure is excessively low, the lowtemperature condition disappears. 3
5
4
ZX215-1002150
Fig. 4-139
司
公
销 营
(1) (2) (3) (4) (5) (6) (7)
O-ring Mobile contact point Hood Plug and fixed contact Spring Chamber Diaphragm
Operating features:
Feature
DIFF
DIFF
ON
High pressure
Above 0.02 MPa
0.59±0.2 MPa
OFF Low pressure
0.196±0.02 MPa
2.94~3.19 MPa
0.196~0.250 MPa
ON Medium pressure
OFF 1.23±0.1 MPa
1.52±0.08 MPa
Shop Manual - April 2014
4-143
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.1.12 Fresh air sensor Fresh air temperature sensor is mounted beside the condenser or at the fresh air inlet. Consisting of thermistors, it is used to detect ambient temperature.
Resistance /Kȍ
12
Specification Item
Specification 4.4~5.6 V
Applicable temperature
-30~60 ℃
Storage temperature
-40~90 ℃
8 6 4
In Ma t rk er n et a in ti o g n De al pt .
Applicable voltage
10
Resistance
1700±85Ω
B Constant Permissible working current
3900±195 K
2
-10
10
20
30
40
AT
ZX215-1002151
Fig. 4-140
1.6 mA (MAX)
司
公
销 营
4-144
0
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.2 Refrigerant 1. General property ● High heat absorption and easy liquefaction ● Non-flammable, nonexplosive ● Stable chemical composition and quality ● Non-toxic ● Non-corrosive
In Ma t rk er n et a in ti o g n De al pt .
● No hazard to clothing
2. Refrigerant circulation
● After evaporation in the evaporator, refrigerant turns from gas into liquid via the compressor and the condenser, which finishes a refrigerant cycle.
司
公
销 营
Compressor IntakeėDischarge
Compressor LO press. side (inlet): LO temp?LO press.?Gas Pressure/Temperature:2Kg/cm²，approx. 8ć Evaporator Absorb heatėEmit cold air
Compress HI press. side(outlet): HI temp\HI press.\Gas Pressure/Temperature:16Kg/cm²ˈapprox. 80ć
Condensor (outlet): LO temp\LO press.\Mist Pressure/Temperature: 2Kg/cm²ˈapprox. 0~2ć
Condensor Via radiating:Gas refrigerantėLiquid refrigerant
Condensor (outlet)˖HI temp?HI pressure?Liquid Pressure/Tempterature˖16Kg/cm²ˈBelow 60ć
Shop Manual - April 2014
Expansion valve Hi pressureėLo pressure Hi tempėLo temp LiquidėMist
4-145
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Refrigerant cycle principle (pressure - enthalpy diagram)
lgp Liquefaction completed
Refrigerant cyclic curve Liquefaction starts
Condensor
Throttling point
Condensing process Liquid Expansion throttle
Compressing process
Compressor
In Ma t rk er n et a in ti o g n De al pt .
Expansion valve
Evaporating process Evaporator
Gas-liquid mixture
Gasification completed
司
公
销 营
h=u+Apv(kJ/kg)
UInternal energy
pPressure
VSpecial volume
AJoule equivalent
ZX215-1002152
Fig. 4-141
4-146
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3. Feeding of refrigerant ● Filling method and volume: 1) Refrigerant: HFC-134a 2) Feeding volume: 900±50 g (for reference)
In Ma t rk er n et a in ti o g n De al pt .
3) Feeding method: Feeding of liquid refrigerant from the low-pressure end is not allowed. If feeding operation fails, discharge the refrigerant that has been fed before re-feeding.
● Inspect the state of the refrigerant in the A/C circulation system through the sight glass: 1) Correct feeding: Foam is hardly observed when the refrigerant is flowing. When engine speed increases from idling to 1500 rpm, foam disappears and the refrigerant turns clear.
ZX215-1002153
Fig. 4-142
Sight glass
司
公
销 营
2) Over-feeding: No foam can be observed when refrigerant is flowing.
Proper filling
3) Under-feeding: Foam is always observed when refrigerant is flowing.
4. Evacuation
Inadequate filling
● Reason of evacuation
No moisture shall be mixed inside the air conditioning unit. Refrigerant (R134a) is soluble in water. Very small amount of moisture in the unit can cause the orifice of the expansion valve to ice up, or cause the valve of the compressor to rust. To avoid such problems, moisture in the system shall be removed before refrigerant is fed. To reduce the residual moisture in the system to the minimum, moisture in the system can evaporate through evacuating. No better means is available so far.
ZX215-1002154
Fig. 4-143
Shop Manual - April 2014
4-147
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Evacuating steps 1) Connection of manifold pressure gauge:
Valve Lo-pres. gauge
a) Close the high-pressure valve (HI) and low-pressure valve (LO) of the manifold pressure gauge.
Lo-pres.gauge above 750mmHg LO HI OFFOFF ON ON LO
HI
Hi-pres. gauge
Hi-pres. valve(ON)
Lo-pres. valve (ON) Green
b) Connect the air hose (red, blue) to the auxiliary valve of the compressor.
Red
D
Blue
Red hose——High pressure side (Mark D)
In Ma t rk er n et a in ti o g n De al pt .
S
Blue hose——Low pressure side (Mark S)
★ Connect the end of the air hose with a L to the auxiliary valve of the compressor. If connected inversely, the valve will not open. Besides, do not inversely connect the highpressure end and the low-pressure end.
Vacuum pump (running)
ZX215-1002155
Fig. 4-144
司
公
销 营
c) Connect the middle hose (green) to the vacuum pump. 2) Evacuating
a) Open the high-pressure valve (HI) and low-pressure valve (LO) on the manifold pressure gauge.
b) Turn on the vacuum pump and evacuate for about 15 minutes.
c) When negative pressure reading on the gauge (degree of vacuum) reaches above 750 mmHg, turn off the vacuum pump and close the Hipressure valve and the Lo-pressure valve on the gauge.
4-148
Compressor
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3) Air - proof check
Valve
a) Keep the Hi- and Lo-pressure valve of the manifold pressure gauge under closed state for more than 5 minutes, and make sure the pointer on the gauge does not return to zero.
Lo Hi Left at least OFFOFF for 5 minutes
Lo-press gauge backs to zero.
Lo-press gauge
Pointer backs to zero.
b) If the pointer returns to near zero, a leakage is available somewhere. Check and adjust the pipe joint. Tighten the joint and conduct another evacuating operation until no leakage is detected. 4) Leak check
Tighten the connector ZX215-1002156
In Ma t rk er n et a in ti o g n De al pt .
Fig. 4-145
Valve
a) Connect the air hose (green) that is previously connected to the vacuum pump to the fluorine cylinder.
b) Connect the other end of the hose (green) to the pressure gauge. Open the valve of the cylinder and press the vent valve of the pressure gauge. (Do not press the valve with naked hand to avoid frostbite caused by refrigerant). Release the air in the hose with the pressure of the refrigerant. (Release the vent valve when you hear a squeezing sound).
Lo Hi OFF OFF
Vent valve Release air
Open the valve
司
公
销 营
c) Add refrigerant until pressure reading on the Lo-pressure gauge is 1kgf/cm2. Hi-pressure valve of the gauge is open at this time. Close the Hi-pressure valve when feeding is finished.
d) Use a leak detector to check if leakage is present in the cooling system.
Blue
Air hose (green) Red
R134a
Fluorine cylinder
To compressor
ZX215-1002157
Fig. 4-146
Valve Lo
Hi
Lo-pres. gauge OFF ON reads1kg/cm2
Lo-pres.valve (OFF) Cylinder valve (ON)
Lo-pres. gauge reads1kg
1kg/cm2
Lo Hi OFFOFF
Open Hi-pres.valve
D
e) Make necessary repairs (tightening) if leakage is observed.
S R134a
Compressor
Fluorine cylinder ZX215-1002158
Fig. 4-147 Shop Manual - April 2014
4-149
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
5. Refrigerant filling operation
Performance testing
Air leak check
Fill refrigerant
normal
Air leak check
Pres. gauge
Fill refrigerant kg/cm2
Wait 5 min.
Air-proofness check
More than 15 min.
Evacuation ends
75cm-Hg or more
In Ma t rk er n et a in ti o g n De al pt .
Evacuation starts
● When evacuation is finished, fill refrigerant into the cooling system as per the following instruction:
Pres. gauge
Tighten pipe joint
(1) Compressor stopped, fill at hi pressure end
abnormal
Repair any leak.
(2)Compressor running, add at lo pressure end
● Fill from the hi-pressure side
1) Remove the air hose (green) of the manifold pressure gauge from the vacuum pump and connect it to the fluorine cylinder. 2) Open the valve of the cylinder and press the vent valve on the pressure gauge. Use the pressure of the refrigerant to release the air in the hose.
Valve Lo Hi OFFOFF
司
公
销 营
Vent valve
Open the valve
Loosen this nut
Blue
Release the vent valve when you hear a squeezing sound. Do not press the vent valve with naked hand to avoid frostbite.
Air hose (green)
Red
To compressor
R134a
Fluorine cylinder ZX215-1002159
Fig. 4-148
4-150
(Note) Refrigerant is released when squeaking is heard.
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3) With the engine stopped, open the high-pressure valve on the manifold pressure gauge and the fluorine cylinder valve and fill in one and a half cylinder of fluorine (approximate 600g).
Valve
Filling one cylinder
Lo Hi (about 600g) OFF ON
Lo
Hi
OFF OFF
(Never) ·Run the compressor ·Open the low-press valve
Do not run the compressor at this moment. Once the compressor is started, the refrigerant could flow back, causing the fluorine cylinder and hose to burst.
Lo press valve (OFF)
Open the high-press valve
Fluorine cylinder valve (ON)
D S
Operating the compressor without refrigerant will burn the compressor. Never run the compressor without refrigerant.
In Ma t rk er n et a in ti o g n De al pt .
R134a
ZX215-1002160
Fig. 4-149
Do not open the low-pressure valve on the manifold pressure gauge (liquid compression will occur, causing damage tot he compressor).
4) Close the high-pressure valve on manifold pressure gauge and the fluorine cylinder valve.
司
公
销 营
● Fill from lo-pressure side (additional filling) 1) Confirm the hi-pressure valve of the manifold pressure gauge is closed.
Manifold Press gauge
4) Adjust engine speed to 1300 – 1500 rpm.
ON
H I
2) Start the engine and open the cab door.
3) Turn on the air conditioner, and set Temperature control switch to minimum.
Hi-press valve (OFF)
(Note) Engine started Opening the high-pressure valve can cause the fluorine cylinder 1300~1500rpm to explode, resulting in serious ZX215-1002161 injury
Fig. 4-150
5) Open the Lo-pressure valve of the manifold pressure gauge and the valve of the fluorine cylinder, and fill refrigerant into the reservoir until no foam is observed.
Shop Manual - April 2014
4-151
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Note: Manifold pressure gauge reading (for reference): High pressure 13~17kg/cm2 (ambient temperature 30℃ ); Low pressure 1.5~2kg/cm2 (ambient temperature 30℃ ). 6) When refrigerant filling is finished, close the Lo-pressure valve of the manifold pressure gauge and the valve of the fluorine cylinder.
Valve
Fill until no foam is not observed via sight glass Lo Hi OFFOFF
In Ma t rk er n et a in ti o g n De al pt .
Lo Hi ON OFF Lo-pressure gauge (1.5~2.5kgf/cm2)
7) Check carefully for air leaks with a leak detector.
Never open the Hi-pressure valve of the manifold pressure gauge. If it is opened, high-pressure gas will counterflow and cause the air hoses and the fluorine cylinder to explode, resulting in serious injury.
Do not position the fluorine cylinder upside down (when engine is operating and filling in progress). If the cylinder is placed upside down, liquid refrigerant will be sucked directly into the compressor and cause liquid compression, resulting in damage to the compressor valve and the gaskets. Place the cylinder vertically and fill gas refrigerant.
Lo-pressure valve (open)
Compressor running
司
公
销 营
Fluorine cylinder (never placed upside down)
ZX215-1002162
Fig. 4-151
Valve
Fill until no foam is seen via the sight glass
Lo Hi ON OFF
Lo-pressure valve (open) Cylinder valve (open)
Warm water less than 40°C (Do not heat with hot water)
9) When ambient temperature is high
4-152
Hi-pressure valve (close) (Never open it)
Fluorine cylinder valve (open)
8) When ambient temperature is low When refrigerant filling can not be performed due to low ambient temperature, place the cylinder in water of less than 40 ℃ to increase the pressure of the refrigerant inside the cylinder. When ambient temperature is very high, cool the compressor with an electrical fan.
Hi-pressure gauge (13~17kgf/cm2)
Lo Hi OFF OFF
Hi-pressure valve (close)
Compressor running ZX215-1002163
Fig. 4-152
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Replace the fluorine cylinder Handle
When the refrigerant in a cylinder is used up, replace the cylinder as per the following instruction: 1) Close the Hi- and Lo-pressure valves of the manifold pressure gauge.
Air hose port Needle valve
2) Raise the needle and disc plate of the cylinder and remove the empty cylinder.
Gasket Disc plate Refrigerant cylinder
In Ma t rk er n et a in ti o g n De al pt .
3) Install a new cylinder onto the cylinder valve. 4) Release the air in the hose as per the following instruction:
Fig. 4-153
a) Tighten the valve of the fluorine cylinder, and then, loosen it a bit.
Valve Lo Hi Loosen Close
b) Open the Lo-pressure valve of the manifold pressure gauge a bit. c) Press the vent valve and allow a little refrigerant to come out. Immediately close the valve of the cylinder and the Lo-pressure valve of the manifold pressure gauge.
ZX215-1002164
Close the Lo-pressure valve immediately after the refrigerant squeaks.
司
公
销 营
★ Do not press the vent valve with naked hand to avoid frostbite by refrigerant.
5) Turn the handle of the cylinder valve to pierce the cylinder and continue filling operation.
Loosen the valve a bit
Lo-pressure valve
Green
Blue
Red
To compressor
R-134a
Refrigerant cylinder ZX215-1002165
Fig. 4-154
Shop Manual - April 2014
4-153
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
6. Troubleshooting with manifold pressure gauge After the engine has been preheated, read the pressure value on the gauge under the following conditions: 1) Temperature at air inlet: 30 – 35℃ 2) Engine speed: 1500 rpm 3) Fan speed: High 4) Temperature control: Minimum.
In Ma t rk er n et a in ti o g n De al pt .
5) Air mode: Recirculation
● Refrigerating system under normal condition Gauge reading:
Lo-pressure end 0.15~0.25 Mpa (1.5~2.5 Kg/ cm²)
Hi-pressure end 1.37~1.57 Mpa (14~16 Kg/ cm²)
司
公
销 营
04
3
4
06
6
2
07
{cmHg kgf/cm2} 8 0 8.5 -50
0
-76
-01
15
20
1
10
7
1
2
15
5
02
01
15
05
03
05
5
25
{cmHg kgf/cm2}
0
085
30
3
0
08
25
-76 35
-01
MPa
35
MPa
R134a
ZX215-1002167
Fig. 4-155
4-154
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Moisture in the refrigerating system Fault: Intermittent refrigeration to non-refrigeration
04
3
4
07
{cmHg kgf/cm2} 8 0 8.5 -50 -76
05
5
25
{cmHg kgf/cm2}
30 3
0 08
25
-76 35
In Ma t rk er n et a in ti o g n De al pt .
0
10
7
1
20
1
06
6
2
2
15
5
02
01
15
05
03
-01
15
0
085
MPa
-01
35
MPa
ZX215-1002168
Fig. 4-156
Symptom
Cause
司
公
Analysis
Remedy
销 营
● Replace receiver/ ● Moisture in the system ● Over-saturation of dedehydrator ● When the system is hydrator. ices up at the expan● Remove the moisoperating, pressure sion valve causing ● Moisture in the system at the Lo-pressure ture in the system temporary stop of ices up at the expanend unstable (somethrough constant circulation. When ice sion valve and hinders times vacuum, pumping. melts, the system bethe circulation of the sometimes normal) ● Add proper volume comes normal again. refrigerating system. of new refrigerant.
Shop Manual - April 2014
4-155
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Insufficient refrigeration Fault: Insufficient refrigeration.
04
3
4
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
7
1
-76 15
05
5
25
{cmHg kgf/cm2}
0
085
30 3
0 08
25
-76
35
-01
35
In Ma t rk er n et a in ti o g n De al pt .
-01
20
1
06
6
2
2
15
5
02
01
15
05
03
MPa
MPa
ZX215-1002169
Fig. 4-157
Symptom
Cause
Analysis 司
公
销 营
● Pressure at both Hi- and Ho-pressure ends very low
● Air leaks somewhere in the refrig● Foam is continuously oberating sysserved via the sight glass tem ● Insufficient refrigeration.
4-156
● Insufficient refrigerant in the system
● Leak of refrigerant
Shop Manual - April 2014
Remedy
● Check for air leakage with a leak detector. Make necessary repairs. ● Add proper amount of refrigerant. ● When connected with the gauge, if the reading is near zero, set the system under vacuum state after inspection and repair.
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Defective refrigerant circulation Fault: insufficient refrigeration
04
3
4
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
7
1
-76 -01
15
20
1
06
6
2
2
15
5
02
01
15
05
03
05
5
25
{cmHg kgf/cm2}
30
0 08 0
085
3
35
-01 35 MPa
In Ma t rk er n et a in ti o g n De al pt .
MPa
-76
25
ZX215-1002170
Fig. 4-158
Symptom
● Pressure at both Hi- and Lo-pressure sides very low ● Frosting on the piping between parts and reservoir
Cause
Analysis
Remedy
司
公
销 营
● Contaminant in the reservoir hinders the flow of refrigerant.
● Blocked reservoir
Shop Manual - April 2014
● Replace reservoir
4-157
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Refrigerant not circulating Fault: Non-refrigeration (intermittent refrigeration)
04
3
4
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
7
1
-76 15
05
5
25
{cmHg kgf/cm2}
30 3
0 08 0
085
25
-76
35
-01
35
In Ma t rk er n et a in ti o g n De al pt .
-01
20
1
06
6
2
2
15
5
02
01
15
05
03
MPa
MPa
ZX215-1002171
Fig. 4-159
Symptom
Cause
Analysis
司
公
销 营
● Vacuum at Lo-pressure side; pressure at Hi-pressure side extremely low
● Frosting or condensation on the pipes around the expansion valve or receiver/dehydrator
4-158
● Moisture or contaminant in the refrigerant hinders the flow of refrigerant.
● Refrigerant not circulating
● Air leak at the thermal pipe of the expansion valve hinders the flow of refrigerant.
Shop Manual - April 2014
Remedy
● Check the expansion valve and ERP. ● Blow the contaminant in the expansion valve or replace the expansion valve if necessary. ● Replace the receiver ● Release internal air and add refrigerant. If air leaks from thermal pipe, replace expansion valve.
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Over-filling of refrigerant or insufficient refrigeration of condenser Fault: Insufficient refrigeration
04
3
4
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
7
1
-76 15
05
5
25
{cmHg kgf/cm2}
30 3
0 08 0
085
25
-76
35
-01
35
In Ma t rk er n et a in ti o g n De al pt .
-01
20
1
06
6
2
2
15
5
02
01
15
05
03
MPa
MPa
ZX215-1002172
Fig. 4-160
Symptom
Cause
Analysis
Remedy
● Clean the condenser ● Excessive refrigerant in ● Pressure at both Hi● Over-filling of refrigersystem → Over-filling of ● Check the working and Lo-pressure condition of fan moant in the system. Rerefrigerant sides very high tor frigerating performance ● Insufficient refrigeration ● No foam can be obinadequate. ● If the two above of condenser → Raserved via the sight items are normal, ● Insufficient refrigeration diator fins of condenser glass even when check the volume of of condenser plugged or failure of fan engine speed drops. refrigerant. Add remotor frigerant as required. 司
公
销 营
Shop Manual - April 2014
4-159
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Air present in refrigerating system Fault: Poor refrigeration If refrigerant is added with no evacuation operation performed, the following gauge reading will appear:
04
15
05
03 3
4
02
20
1
06
6
10
25
25
In Ma t rk er n et a in ti o g n De al pt .
2
2
15
5
7
1
01
07
{cmHg kgf/cm2} 8 0 8.5 -50
0
-76
-01
15
05
5
{cmHg kgf/cm2}
30
3
0
08
0
085
MPa
-76 35
-01
35
MPa
ZX215-1002173
Fig. 4-161
司
公
销 营
Symptom
Cause
● Pressure at both Hi- and Lo-pressure ends very high ● Lo-pressure piping feeling hot
● Air enters the refrigerating system
Analysis
Remedy
● Air enters the refrigerant system
● Check if compressor oil is contaminated or inadequate.
● Insufficient evacuation
● Foam is observed through the sight glass
4-160
Shop Manual - April 2014
● Evacuate and add new refrigerant.
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Improper installation of expansion valve/ thermal pipe defect (wide opening) Fault: insufficient refrigeration
04
3
4
0
10
7
1
07
{cmHg kgf/cm2} 8 0 8.5 -50 -76 15
05
5
25
{cmHg kgf/cm2}
30 3
0 08 0
085
25
-76
35
-01
35
In Ma t rk er n et a in ti o g n De al pt .
-01
20
1
06
6
2
2
15
5
02
01
15
05
03
MPa
MPa
ZX215-1002174
Fig. 4-162
Symptom
Cause
Analysis
Remedy
司
公
● Pressure at both Hi- and Lo-pressure ends very high ● Frosting or condensation on Lo-pressure piping
销 营
● ● Improper installation of thermal pipe/defective thermal pipe (exces● sively wide opening)
● Check the installation of Excessive refrigerant in Lothermal piping pressure piping ● If thermal piping is normal, Expansion check the expansion valve. valve opening Replace expansion valve if too wide found defective.
Shop Manual - April 2014
4-161
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Compressing error Fault: No refrigeration
04
3
4
07
{cmHg kgf/cm2} 8 0 8.5 -50 0
10
7
1
-76 -01
15
20
1
06
6
2
2
15
5
02
01
15
05
03
05
5
{cmHg kgf/cm2}
0
085
-76 35 - 01
35
MPa
In Ma t rk er n et a in ti o g n De al pt .
MPa
30 3
0 08
25
25
ZX215-1002175
Fig. 4-163
Symptom
● Pressure at Lo-pressure side very high ● Pressure at Hi-pressure side very low
4-162
Cause
Analysis
Remedy
● Compressing fault;
司
公
销 营
● Compressor internal leakage
● Leaking or damaged valve, or missing parts
Shop Manual - April 2014
● Repair or replace compressor
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.8.2.1 Compressor oil
Oil shall be added into the A/C system for lubrication. Compressor oil is solved in the refrigerant and circulates in the system. When the air conditioning system is shut down, compressor oil will stay inside the components. If no compressor oil is added into the system when replacing components, inadequate lubrication will result. Add compressor oil according to the chart below:
Replaced component Condenser
Evaporator
See "NOTICE" below
40
40
ND8# (10P, 10PA, 10S series compressor)
In Ma t rk er n et a in ti o g n De al pt .
Volume (CC)
Compressor
Compressor oil grade
ND9# (TV series compressor)
NOTICE
● Add oil into a new compressor according to the required volume of the system. When the compressor is to be replaced, discharge the surplus oil in it. 司
公
销 营
● Filling of improper amount of compressor oil: Over-filling of compressor oil will reduce the refrigerating capacity. Short of compressor oil in the system will lead to an abnormal compressor. ● Keep the pipe connectors and O-ring seals free from contamination when disassembling the compressor.
Shop Manual - April 2014
4-163
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.9 Engine Control
5
4
Z
3
In Ma t rk er n et a in ti o g n De al pt .
1
2
6
9
7
8
司
公
销 营
Z
W365-1304503
Fig. 4-164 (1) (2) (3) (4) (5) (6) (7) (8) (9)
Battery relay Battery Start switch Fuel control dial Start motor Controller Fuel injection pump Throttle motor Shutdown device
Outline
● The engine is only started and stopped with the start witch (3). ● The engine controller (6) receives the signal from the fuel control dial (4) and transmits the drive signal to the throttle motor (8) to control the governor lever angle of fuel injection pump (7) in order to regulate engine speed. ● When the start switch (3) is turned to the OFF position, the shutdown device (9) closes the injection nozzle of the fuel injection pump to cut off the engine fuel supply. Then, the engine stops.
4-164
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.9.1 System operation 4.9.1.1 Engine starting
(Power supply) Engine Lo
Hi
Hi
Governor motor
(Start signal)
B BR
C
Alternator (Driving signal)
Shutdown device
When it happens, the engine controller detects the signal voltage sent from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.
P
Throttle ON
Start switch
Safety relay s B E C R
L B E
M
Throttle OFF
Lo
s E
(Potentiometer signal)
● When the start switch is turned to the START position, the starting signal is sent to the start motor. Then, the start motor starts the engine.
Start motor
Battery relay
Pilot switch Start relay
Shutdown relay
(Start signal)
Fuel control dial
Shutdown delay relay
Monitor - controller (Regulating signal)
(Start switch ON siganl)
ZX335-1002044
In Ma t rk er n et a in ti o g n De al pt .
Fig. 4-165
4.9.1.2 Engine speed control
(Power supply)
Engine
Lo
Shutdown device
司
公
销 营
Start switch
Safety relay s B E C R
(Start signal)
L BE
M P
Throttle ON
B BR
C
Alternator (Driving signal)
Hi
s E
(Potentiometer signal)
According to the signal voltage, the controller sends a driving signal to throttle motor in order to control the fuel injection pump, hence controlling the engine speed.
Lo Hi Governor motor
Throttle OFF
● The fuel control dial sends to the controller a signal voltage corresponding to its angle.
Start motor
Battery relay
Pilot switch Start relay
Shutdown relay
(Start signal)
Fuel control dial
Shutdown delay relay
Monitor - controller
(Regulating signal)
(Start switch ON siganl)
ZX335-1002045
Fig. 4-166
4.9.1.3 Engine shutdown
(Power supply)
Lo
Hi
Throttle OFF
● When the start switch is turned to the STOP position, the shutdown controller controls the shutdown device to stop fuel supply to the fuel feed pump. The engine is then stopped.
Governor motor
Start motor s E
(Start signal)
Start switch
Safety relay s B E C R
L B E
Throttle ON
Shutdown device
Battery relay
Shutdown relay
Monitor - controller
B BR
C
Alternator
Pilot switch Start relay
(Start signal)
Engine
Shutdown delay relay
(Start switch ON siganl)
ZX335-1002046
Fig. 4-167
Shop Manual - April 2014
4-165
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.9.2 System components 4.9.2.1 Fuel control dial
140° 9×10°
1
Gear position 1
25°
2 Leftmost position
5
Rightmost position
In Ma t rk er n et a in ti o g n De al pt .
3
4
Gear position 10
司
公
销 营
6
Yellow
1
2
1
2
3
3
Blue
Red
5V
VR
0V
ZX215-1002180
Fig. 4-168 (1) (2) (3) (4) (5) (6)
Knob Dial Spring Ball Potentiometer Plug
4-166
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Function ● Turning of the fuel control dial changes the resistance of the sliding rheostat inside the dial and the voltage signal collected by the controller. The controller calculates the collected signals and drives the governor motor via signal output and controls the injection of the fuel pump so that the engine can run at an optimal speed.
（%） Dial angle
100
● When throttle voltage is beyond the area, the controller sends out alarm code and the engine runs at low idle. The area under the sloping line is the abnormality detection area.
0
0.25 1.72
4.49 4.75 5（V） Voltage (V)
ZX215-1002181
In Ma t rk er n et a in ti o g n De al pt .
Fig. 4-169
Remark:
The leftmost position is 0%; and the rightmost position is 100%.
司
公
销 营
Shop Manual - April 2014
4-167
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.9.2.2 Controller
In Ma t rk er n et a in ti o g n De al pt .
SEHC-281A (Huaxing)
司
公
销 营
J1-2（40 pins）
J1-1（81 pins）
WT365-1304001
Fig. 4-170
Controller ports
........ ........ ........ ........
................... ................... ................... ...................
J1-2 Fig. 4-171
4-168
Shop Manual - April 2014
J1-1
W365K-1304002
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Controller signal distribution J1-1
J1-2 Signal name
1 2 3 4 5 11 13 15 23 28 30 31 34 38 39 40 41 42 48 49 50 51 52
Power ground Power ground Power ground Power（24V） Power（24V） Fuel level sensor signal GPS detecting signal Throttle position signal RX232 Air filter plugging sensor signal Water temp sensor signal Oil temp sensor signal Fuel control dial signal Engine speed signal 2RS RS TX232 2nd boost button signal Engine oil pressure signal L. travel pressure sensor Bucket-dig pressure sensor Boom-down pressure sensor Arm-in pressure sensor Rear pump principal pressure sensor Sensor power ground Sensor power ground Sensor power Monitor CAN low Calibrator CAN high Pilot switch Coolant temp high R. travel pressure sensor Swing pressure sensor Bucket-dump pressure sensor Boom-up pressure sensor Arm-out pressure sensor Front pump principal pressure sensor Sensor power ground Sensor power Sensor power Monitor CAN low Calibrator CAN high Engine shutdown signal Engine start signal
53 54 55 56 58 60 65 66 67 68 69 70 71 72 73 74 75 77 78 79 80
No.
I/O
82 88 89 98 99 100 101 105 113 114 115 116 117 118 119 120 121
Input Input Input Input Input Input Input Input
Signal name
I/O
High/low speed shift valve Front pump proportional valve Rear pump proportional valve Bucket confluence valve Engine start control Shutdown delay signal Bucket solenoid valve Throttle motor drive signal+ Throttle motor drive signalPower ground Power ground Power ground Power ground Power（24V） Power（24V） Power（24V） Power（24V）
In Ma t rk er n et a in ti o g n De al pt .
No.
Input Input Input Input Input
司
公
销 营
Input
Input Input Output
Input Input Input Input Input Input
Input Input Output Output
Shop Manual - April 2014
4-169
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10 Electrical Control System 4.10.1 Control function
Engine - pump combination control
In Ma t rk er n et a in ti o g n De al pt .
Pump control
Valve control
Dual-speed Travel control
Electrical control system
Engine preheat/overheat alarm
司
公
销 营
Low Engine oil pressure alarm
Auto deceleration/acceleration control
Engine speed calibration
Self-diagnostic function
4-170
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.2 Diagram of machine control system Battery relay drive
Battery
Fuel control dial
Power supply
Shutdown delay relay
Power supply
Preheating signal
Starting signal
Start switch
Energizing signal
Fuse
Power regulator valve signal 1
Monitor controller integration
Travel speed select signal
Right travel signal
CAN bus Working mode signal Travel speed select signal Auto deceleration signal Signal monitoring info
Left travel signal
In Ma t rk er n et a in ti o g n De al pt . Signal monitoring info
4
Boom-down siganl Arm-in signal
Fuel level sensor
2 3
Boom-up signal
Fuel level signal
11
5 6
Arm-out signal
7
Bucket-dig signal
8
Bucket-dump signal Swing signal
9 10
Controller HCU
司
公
销 营
R pump outlet press signal 12
F pump outlet press signal 13
F pump control signal
Start relay
14
Engine speed sensor Motor Engine oil pressure
Safety relay
Coolant temp signal Charge indicator
Battery charge signal
15
16
feedback signal
Starting signal
PPC lock signal
Real throttle position
Engine speed
Motor drive signal
R pump control signal
Potentiometer
Eng oil press sensor Eng coolant temp sensor Alternator
Engine
Air filter plugging switch
Start signal
Start motor Preheater relay
Electric air heater
Preheat signal
W365413081
Fig. 4-172 Shop Manual - April 2014
4-171
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
1
2
R. travel pressure sensor
3
L. travel pressure sensor
4
Boom-up pressure sensor
5
Boom-down pressure sensor
6
Arm-in pressure sensor
7
Arm-out pressure sensor
8
Bucket-dig pressure sensor
9
Bucket-dump pressure sensor
10
PPC valve
15
PPC basic pressure
13
Frong pump oil feed device
14
Work equipment rotating device
11
In Ma t rk er n et a in ti o g n De al pt .
Swing pressure sensor
司
公
销 营
12
PPC
16
lock valve
Rear pump Front pump Two-speed proportional proportional solenoid valve valve valve
Port for each action control valve
Power limit solenoid valve
Servo
F
Main valve
Swing motor
Servo
R
Swing motor
Main pump
Swing motor Rear pump oil feed device Work equipment rotating device
W365413082
Fig. 4-173 Note: The diagram above is a schematic diagram of electrical control. See the hydraulic section for more information on the hydraulic circuits.
4-172
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.3 Engine-pump combination control Cab
Pilot valve B
Travel
Travel
MAX Boom up/down Bucket dig/dump
Arm in/out Swing
F1
F2
Esc
F3
F4
MIN Fuel control dial
F5
Enter
Pressure sensor
In Ma t rk er n et a in ti o g n De al pt .
MC controller input H/S/L/B Cancel auto deceleration Shift travel speed Alarm output
Pilot oil pressure
A
司
公
销 营
Main control valve
Engine chamber
P1
Pressure sensor
P2
Controller
Engine feed regulation
Pump
Pump proportional pressure reducing solenoid valve
Throttle motor
Potentiometer
Motor
Control rear pump inclination Fuel, coolant temp & others Control front pump inclination Engine speed Control motor Actual throttle position feedback
W365413083
Fig. 4-174 Shop Manual - April 2014
4-173
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Function ● This function allows operator to select a working mode and change the engine power output according to the kind of job that the machine is to be engaged. The working modes include H, S, L and B. A selector button on the monitor is available for selection of a working mode.
10
● Pump controller controls the pump so that the pump is able to absorb all torques at engine output point. These torques are determined by the pump absorption torque specification, fuel control dial setting and real engine speed under each mode.
7
6
In Ma t rk er n et a in ti o g n De al pt .
1 9
Fig. 4-175
Technical specifications
H
Speed (rpm)
~1750
Power(KW)
143
1750~1900 1900~2180
司
公
销 营
S mode
159
174
Speed (rpm)
~1750
1750~2180
Power(KW)
133
166
L mode
S
Engine power KW
H mode
L
Engine speed N
ZX335-1002051
Speed (rpm)
~1850
Power(KW)
150
Fig. 4-176
H
Pump flow Q
S
L, B
Pump output pressure P ZX335-1002052
Fig. 4-177
4-174
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Mode control methods ● Mode H ● H mode matching point: Rated speed Engine torque T
184kW/2180rpm ● Engine speed decreases when pump load increases and the pressure rises. In this case, engine speed will be up to the proximity of matching point, allowing pump controller to reduce output. On the contrary, when pump load reduces and the pressure decreases, the pump controller will keep increasing pump output until engine speed reaches the proximity of matching point.
In Ma t rk er n et a in ti o g n De al pt .
Engine speed N
司
Engine power KW
Fig. 4-178
公
销 营
ZX335-1002053
Engine speed N ZX335-1002054
Pump flow Q
Fig. 4-179
Pump output pressure P ZX335-1002055
Fig. 4-180 Shop Manual - April 2014
4-175
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
● Power output percentage corresponding to each mode Mode Power output percentage
H
S
L
B
95%
90%
80%
80%
10
● The controller maintains the pump suction force along the stable horse power curve and controls engine speed through enginepump combination control.
7
6
1 9
In Ma t rk er n et a in ti o g n De al pt .
Fig. 4-181
H
Engine power KW
司
公
销 营
S L
Engine speed N
ZX335-1002051
Fig. 4-182
H
Pump flow Q
S
L, B
Pump output pressure P ZX335-1002052
Fig. 4-183
4-176
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.4 Pump control function
Engine Injection pump
Main pump Governor motor
Pressure sensor
F
M P
Speed sensor
Pressure sensor R
Servo
In Ma t rk er n et a in ti o g n De al pt .
Servo
Lo
(Engine speed signal)
Hi
(Control signal)
Fuel control dial
Valve
(Control signal)
Valve
司
公
销 营
Right travel signal
Left travel signal
Boom UP signal
Boom DOWN signal
Arm IN signal
Arm OUT signal
Bucket DIG signal
Bucket DUMP signal
Swing signal
Controller
W365413084
Fig. 4-184
Shop Manual - April 2014
4-177
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Pump 1 delivery amount Boom RAISE PPC pressure Pump 1 delivery amount
Pump 1 delivery amount
In Ma t rk er n et a in ti o g n De al pt .
Arm IN PPC pressure
Arm OUT PPC pressure
Pump 1 delivery amount
MAX
Corresponding delivery output
Bucket CURL PPC pressure
Pump 1 delivery amount
司
公
销 营
Bucket DUMP PPC pressure
Pump 1 delivery amount
Pump 1 delivery amount
Swing PPC pressure
L. Travel PPC pressure
ZX215-1002197
Fig. 4-185
4-178
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Pump 2 delivery amount Boom RAISE PPC pressure Pump 2 delivery amount Arm IN PPC pressure
In Ma t rk er n et a in ti o g n De al pt .
Pump 2 delivery amount
Arm OUT PPC pressure
Pump 2 delivery amount
MAX
Corresponding delivery output
Bucket CURL PPC pressure
Pump 2 delivery amount
司
公
销 营
Bucket DUMP PPC pressure
Pump 2 delivery amount
Boom LOWER PPC pressure
Pump 2 delivery amount
R. Travel PPC pressure
ZX215-1002198
Fig. 4-186 Function
Use the work equipment and swing pilot pressure signal directly as the hydraulic pump discharge control signal. Pilot pressure is applied on the valve stem and, on the other hand, is collected by the controller. The controller keeps the discharge amount of the hydraulic pump at the specified value of the corresponding pilot pressure according to the functional relation between the set hydraulic pump dis-
charge amount and pilot pressure. During combined operation, the set discharge amount of each operation shall be added. Operation When the work equipment is operating, the controller collects the signal of pilot pressure sensor, and determines the control discharge amount of pump 1 and pump 2 according to the pressure signal.
Shop Manual - April 2014
4-179
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.4.1 Constant power control Function ● It is mainly used to calculate the theoretical maximum displacement. The system employs constant power control. Two regulators are interconnected hydraulically, enabling synchronized operation of two actuators of the same specification at the same time. Change of pump flow is determined by the sum P ∑ of working pressures of both hydraulic pumps. So long as it satisfies 2P0 ≤ P ∑ ≤ 2 PMax, the sum of powers of both hydraulic pumps remains constant, exceeding not the power of diesel engine.
Flow
Q
PMax
Pump curve P-Q
P0
In Ma t rk er n et a in ti o g n De al pt .
PMax
Operation ● When work equipment is working, the controller collects throttle position signal and gives a constant current in order to control power of pump.
P
Pressure
ZX215-1002199
Fig. 4-187
司
公
销 营
4.10.4.2 ESS control Function
● Changing of the engine speed due to load change controls the pump power, and engine output can be used more efficiently. (This function can also prevent the engine from losing control when the machine is operating under harsh conditions (eg. high - altitude area). Operation
The engine control panel controls the target operating speed of the engine.
● The engine controller collects the actual speed signal from the speed sensor, and preform a loop control with the target operating speed. Then, the controller involves the output of loop control with the calculation of the solenoid valve control signal, and sends the final regulating current signal to the pump proportional solenoid valve. ● The solenoid valve controls pump flow by feeding pilot oil to the pump regulator according to the signal sent from the controller.
4-180
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.5 Valve control function
Bucket confluence
Swing priority
Main control valve Pressure sensor
Pressure sensor
Engine
Main pump
Governor motor
Injection pump
F
M P
Servo
Servo
Valve
Valve
司
公
Lo
(Control signal)
Hi
销 营
(Control signal)
Fuel control dial
(Engine speed signal)
(Motor drive signal)
(Throttle position feedback signal)
In Ma t rk er n et a in ti o g n De al pt .
Speed sensor
R
Controller
A
Right travel signal
Left travel signal
Boom UP signal
F5
Boom DOWN signal
F4
Arm IN signal
F3 Enter
Arm OUT signal
F2
Bucket DIG signal
F1 Esc
Swing signal
CAN bus
Bucket DUMP signal
B
W365413086
Fig. 4-188 ● Bucket fl ow control ● Swing priority control
Shop Manual - April 2014
4-181
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
1) Bucket flow control Swash plate angle
Function Control the pump swash plate angle according to the operation of bucket control lever.
Max
Operation
Min
When the bucket control lever is operated, the controller collects the signal from the bucket DUMP pressure sensor and bucket CURL pressure sensor, and controls the bucket confluence proportional valve.
Bucket joystick pilot pressure
ZX215-1002201
In Ma t rk er n et a in ti o g n De al pt .
Fig. 4-189
Bucket confluence valve current
450mA
400mA
司
公
销 营
Bucket joystick pilot pressure
ZX305-1002202
Fig. 4-190
2) Swing priority control Function
● Pressurized oil from pump 1 bypasses bucket 1 valve spool, and flows first to swing motor valve spool to activate swing first. Operation
● When signals from pump 1 pressure sensor, arm pressure sensor and swing pressure sensor meet the following conditions, the controller activates the solenoid valve. The solenoid valve conducts pilot pressure oil to arm flow controller and limits the alternate circuit of arm 1 valve spool. Swing valve spool first ensures swing motor power, preventing the counter acting force when the arm is retracting from affecting the positioning of the upper swing structure. Operating condition ● Swing pressure sensor: signal output available
4-182
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.6 Dual travel speed control
Travel Motor
Right travel pressure sensor
Main Control Valve
Governor Motor
Servo
Servo 司
公
销 营
(Control signal)
(Control signal)
(Throttle position feedback signal)
(Motor drive signal)
Main Pump R
F
M P
Hi
Travel Speed Solenoid Valve
Engine
Injection Pump
Fuel Control Dial
Lo
Regulator
In Ma t rk er n et a in ti o g n De al pt .
Left travel pressure sensor
Regulator
Controller
A
F1 Esc
F2
F3
B
F4
F5
Enter
(CAN Bus) W365413085
Fig. 4-191
Shop Manual - April 2014
4-183
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Function Travel mode control Operation ● When travel mode is set to LOW, the angle travel motor swashplate reaches its maximum and travel speed is slow.
In Ma t rk er n et a in ti o g n De al pt .
● When the controller receives signal from travel pressure sensor under the following condition, it activates the solenoid valve. The solenoid valve delivers pilot oil to the travel motor swashplate angle control valve in order to reduce the angle to its minimum and increase travel speed. Operating condition
Fast travel function on the monitor is on.
Note: When lifting the track on one side with the help of work equipment and running the track, the pump control pressure on the side increases to enable fast running of the track. When the machine is traveling under HIGH mode, the travel mode cannot be changed even if work equipment is operated (work equipment pressure sensor is turned ON).
4-184
司
公
销 营
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.7 Engine preheat/overheat alarm Start switch Heat
Main Control Valve
Preheat Relay
Engine
In Ma t rk er n et a in ti o g n De al pt .
Main Pump
Governor motor
F
Coolant Temp Sensor
R
M
A
B
司
公
销 营
(Control signal)
Lo
Servo
Servo
(Control signal)
Hi
(Throttle position feedback signal)
(Motor drive signal)
P
Controller
(CAN bus) F1 Esc
F2
F3
F4
F5
Enter
W365413087
Fig. 4-192
Shop Manual - April 2014
4-185
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
1) Engine preheating Function ● Preheat control Operation ● The excavator starts preheating when it is powered on. Operating condition ● Low temperature switch is closed; excavator is energized; auto preheating begins at starting.
Function
In Ma t rk er n et a in ti o g n De al pt .
2) Engine overheat alarm
● When coolant temperature is high (over 103℃ ) during operation, the monitor displays alarm. Operation
● The controller collects signal from coolant temperature sensor. If coolant temperature is too high, alarm message will be generated and sent to the monitor. Receiving the alarm message, the monitor will illuminate the alarm indicator light. 司
公
销 营
Operating condition ● Power on
● Coolant temperature greater than 103℃ 3) Alarm - low engine oil pressure Function
● The controller collects signal from engine oil pressure sensor. When engine speed is greater than 600 rpm and engine oil pressure is too low, alarm message will be generated and sent to the monitor. Receiving the alarm message, the alarm indicator lights up.
4-186
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.8 Auto deceleration/acceleration control
Right Joystick control Bucket
Boom
RIGHT LEFT
Swing
Arm
A
FWD BWD
Left travel
Travel Control Levers
Right travel
FWD BWD
(Throttle signal)
In Ma t rk er n et a in ti o g n De al pt .
Fuel Control Dial
Left Joystick Control
IN OUT
Engine throttle controller
DIG DUMP
DOWN UP
Engine
B
Controller 司
公
销 营
F1
Esc
F2
F3
F4
Enter
F5
CAN Bus
Control lever signal
ZX225-1002022
Fig. 4-193 Function
Speed (rmp)
● When all control levers are in the neutral position, lower engine speed in order to reduce fuel consumption and noise.
● When any control lever is operated, engine speed will be back to the setting of the fuel control dial.
Set speed
Drop 100 rpm
Auto deceleration
(1400rpm)
3.2S
0.5S
0.5S
0.2S
Operated
Control lever
Unoperated
Time (s)
Operated
ZX335-1002061
Fig. 4-194 Operation ● Engine speed will drop to the speed of gear position 1 (100 rpm lower than the set speed) 0.2 second after the control levers are placed in the neutral position. The engine will run at low speed (1400 rpm) after another three (3) seconds. This can reduce void flow of hydraulic system and wear of the engine, hence saving energy and reducing noise. When any control lever is operated to resume the operation, the engine speed will be restored. ● When any control lever is operated during engine deceleration, engine speed will increase immediately to the speed set by the fuel control dial. Shop Manual - April 2014
4-187
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.9 Engine speed calibration function
Bucket confluence
Swing pripority
Main valve
Injection pump
Pressure sensor
Pressure sensor
Engine
Main pump
Governor motor
F
M
Speed sensor
In Ma t rk er n et a in ti o g n De al pt .
P
R
Servo
Servo
司
公
（Control signal）
Lo
（Engine speed signal）
Hi
（Control signal）
销 营
Fuel control dial
R. Travel signal
L. Travel signal
Fig. 4-195
4-188
A
B
(CAN bus)
Boom UP signal
Boom DOWN signal
Arm IN signal
Arm OUT signal
Bucket DIG signal
Bucket DUMP signal
Swing signal
Controller
Shop Manual - April 2014
F1 Esc
F2
F3
F4
F5
Enter
W365413088
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Function Enter the maximum engine speed for each working mode as a criteria for engine speed control.
Throttle Help Info
Operation Current Gear
1. Auto calibration of engine speed requires starting the engine.
N：
Engine Speed rpm：
2. Call the interface of System Information and select Throttle Installation Aid.
Gear Position
A. Turn the fuel control dial to position 1.
V：
In Ma t rk er n et a in ti o g n De al pt .
Throttle Position V：
B. Press the key [F4] to start speed calibration process.
s
C. Turn the fuel control dial after calibration. D. Repeat step (2) to finish calibration of speed at all positions.
E. Press the key [F5] or [ESC] to end calibration.
AUTO
n/min
rpm
XP2051203013
Fig. 4-196
司
公
销 营
Shop Manual - April 2014
4-189
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.10.10 System parts and components 1) Pump pressure sensor
Connector
Housing
Pressure joint
B C
In Ma t rk er n et a in ti o g n De al pt .
A
Connection Diagram
Terminal No.
Signal Name
A
Power (+5V)
司
公
B
Ground
C
Output
销 营
W365-1304208
Fig. 4-197
Operation
(V)
● The illustration on the right shows the relationship between the pressure acting upon the sensor and the output voltage.
Ӵᛳ఼䕧ߎ⬉य़
(MPa)
⊍य़ ZX335-1002067
Fig. 4-198
4-190
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
2) Pilot pressure sensor
Connector
Housing
Pressure joint
B C
A
In Ma t rk er n et a in ti o g n De al pt .
Connection Diagram
Fig. 4-199
Terminal No.
Signal Name
A
Power (+5V)
B
Ground
C
Output
W365-1304208
司
公
销 营
Operation
(V)
● The illustration on the right shows the relationship between the pressure acting upon the sensor and the output voltage.
Ӵᛳ఼䕧ߎ⬉य़
(MPa)
⊍य़ ZX335-1002067
Fig. 4-200
Shop Manual - April 2014
4-191
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
3) Engine speed sensor
2
1
In Ma t rk er n et a in ti o g n De al pt .
ZX335-1002070
Fig. 4-201 Function
● Engine speed sensor is mounted on the gear ring of flywheel. It calculates the number of gear teeth passing before the sensor and sends the result to the controller. Note: If the engine speed sensor has not been tightened to the specific torque, it may fail to produce signal. Always tighten the engine speed sensor to the specific torque. 司
公
销 营
4) Engine oil pressure switch
1
2
W365413089
Fig. 4-202 (1) Pressure detector
Function
(2) Connector
Engine oil pressure switch is mounted on the delivery pipe of engine oil filter. It detects engine oil pressure and sends generated pressure signal or alarm signal to the controller.
4-192
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
5) Fuel level sensor 2
3
4
In Ma t rk er n et a in ti o g n De al pt .
1
ZX215-1002246
Fig. 4-203 (1) Float
(2) Lever (3) Shell
(4) Connector
司
公
销 营
Function
Signal from the sensor will be collected by the controller and displayed on the monitor. Resistance output sensors like hydraulic oil temperature sensor, fuel level sensor and coolant temperature sensor send signal to the controller. The controller collects, process and calculate voltage signals and converts it into related information that will be displayed on the monitor. Specifications
Electrical parameters:
● Total resistance: 100Ω ● Tolerance: ±5%
● Upper limit: Ru ≤ 9.6Ω ● Lower limit: Rd ≥ 86Ω ● Variation: Nonlinear
● Max. input volt: 12VDC Mechanical parameters: ● Rotor angle: 105° ● Vertical distance between upper and lower limits of the float (measurable range of fluid level): 500 mm Shop Manual - April 2014
4-193
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
6) Coolant temperature sensor
ZX335-1002071
Fig. 4-204 Function
The output resistance of engine coolant temperature sensor changes with the temperature. The controller collects signal and works out a cooling temperature.
4-194
司
公
销 营
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11 Monitoring System
Monitor
A
B
CAN signal
In Ma t rk er n et a in ti o g n De al pt .
Controller
F1
F2
Esc
F3
F4
F5
Enter
Each sensor
Power
司
公
销 营
Battery
ZX335-1002073
Fig. 4-205
● The machine condition is monitored by the sensors mounted on different locations of the machine. The controller processes the signals and transmits the signals to the monitor display, informing the operator of the machine condition.
● The monitor panel also contains mode selector, functional keys and machine operation control outputs.
● Information on the monitor display includes primarily: 1. Alert information in case of machine failure 2. Operating condition (coolant temperature, hydraulic oil temperature, fuel level, etc. )
Shop Manual - April 2014
4-195
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.1 Monitor SECD_5I7D
$
In Ma t rk er n et a in ti o g n De al pt .
%
F1
F2
Esc
F3
F4
F5
Enter
司
公
销 营
WX215-1204002H
Fig. 4-206 Outline
IMPORTANT
● The monitor is used to display monitoring information and select a working mode.
● The monitor has a CPU (Central Processing Unit) which processes, displays, and outputs information. ● The monitor uses a LCD (Liquid Crystal Display). Port I/O signals No.
Signal name
I/O
1 3 4 8 9 10 12
Digital input A CAN high CAN low Trigger power (24V) Power supply (24V) Ground Ground
Input
4-196
● Technical specification allows a screen to have not-more-than 10 dark spots (not illuminated) or bright spots. ● It is normal to have blue bright spots on the screen when the monitor is on for a quite period of time. ● It is normal to have blinking strips on the screen when the monitor initializes.
Shop Manual - April 2014
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.2 Monitor panel NOTICE
A
A
B
● Stop operation immediately when the alert indicator is on. Check and repair related parts. B
● The monitor does not display all working conditions of the machine.
In Ma t rk er n et a in ti o g n De al pt .
● Do not solely depend on what is displayed on the monitor when maintaining and checking the machine.
F1
The monitor panel performs the functions of monitoring and displaying, selecting a working mode, and switching on/off an electrical element.
C
Overview
The monitor consists of three parts:
Esc
F2
F3
F4
F5
Enter
XP235-13001
Fig. 4-207
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A: Alert indicators B: LCD display
C: Operation keys
4.11.2.1 Alert and signal indicators Alert indicator
When the excavator has a problem, the alert indicator flashes five times along with five buzzing. If the fault is still there, the indicator light A will be kept on, telling user to solve the problem.
$
%
XP235-13002
Fig. 4-208
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.2.2 LCD display When start switch of excavator is turned to the ON position, the monitor is energized by machine batteries and enters the initializing screen. As shown by the figure on the right, a fully displayed screen includes the following information:
Sany Hydraulic Excavator
1
S
1
10
2
(1) Working mode
C
H
E
F
(2) Coolant temperature gauge (3) Fuel level gauge
3
(4) Failure code
In Ma t rk er n et a in ti o g n De al pt .
4
(5) Total service hours
5 6
(6) Function icons
0032h25m
s
E101
11/11/01 09:32:24
9 8 7
AUTO
n/min
(7) Local time
XP235-13003
(8) Local date
Fig. 4-209
(9) GPS signal indication (10) Engine speed level
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Coolant temperature gauge
There are a total of 13 segments (yellow) for the full range from zero to 120 degrees. A: When the engine is just started.
B: When temperature is between zero and 110 degrees.
A
C: When temperature is over 110 degrees, the last segment turns red and the alert indicator is on at the same time. When the temperature goes back to a level under 110 degrees, the alert indicator goes off automatically.
B
C
Fig. 4-210 4-198
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XP235-13004
Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Fuel level gauge There are 13 yellow segments indicating a range from 0 to 100%. A: Fuel level is lower than 8%. There is no segment shown. Alert indicator is on at the same time.
A
B: Fuel level is over 8%. Alert indicator goes off.
In Ma t rk er n et a in ti o g n De al pt .
C: Fuel level is 100%.
B
C
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XP235-13005
Fig. 4-211
4.11.2.2 Operation keys
The operation keys include function keys and navigation keys. A: Function keys
B: Navigation keys
F1
A
Esc
F2
F3
F4
F5
Enter
B
XP235-13006
Fig. 4-212
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
Function keys There are five function keys, i.e. F1, F2, F3, F4 and F5. These keys are defined by the icons displayed above them. ● Function of the same key may vary as the icon above it changes. ● A key is disabled when no icon is displayed above it. Common icons and corresponding keys are given in the following table. Function keys
Icon displayed
F1
s
F3 F4
Display range
Change working mode.
H→S→L→B
In Ma t rk er n et a in ti o g n De al pt .
F2
Functions
AUTO
n/min
Shift to full speed/auto idling.
Full speed/auto idling
Shift to high/low travel speed.
High/low speed
Enter an option/setup item.
Same as the Enter key
View system information.
F5
Back to previous page.
——
Same as the ESC key
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Operation keys
Operation keys
Functions
Enter
Enter an option/setup item.
ESC
Back to previous page.
UP (The highlight goes to the bottom item after the top one.) Increase the value of digit at the cursor. DOWN (The highlight goes to the top item after the bottom one.) Decrease the value of digit at the cursor. LEFT (The highlight goes to the right most item after the left most one.) Move the cursor leftward. RIGHT (The highlight goes to the left most item after the right most one.) Move the cursor rightward.
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SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3 Monitor display and operation Sany Hydraulic Excavator
4.11.3.1 Default page S
Default page is shown during normal operation of the excavator. Operation
1 C
H
E
F
1. Working mode Press the key F1 to change working mode to H, S, L or B in a cycle manner.
0032h25m
H mode - Heavy-duty operation
s
11/11/01 09:32:24
AUTO
n/min
In Ma t rk er n et a in ti o g n De al pt .
S mode - Standard operation
E101
L mode - Light-duty operation
XP235-13007
Fig. 4-213
B mode - Breaker operation
NOTE: S is the default mode after the machine is powered on.
3. Selecting high/low travel speed
2. Selecting auto idling
Press the key F2 to disable/enable auto idling function.
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When the icon appears above the key F2 , press the key to disable auto idling; when the icon appears above the key F2 , press the key to enable auto idling. AUTO
n/min
n/min
NOTE: When the machine is powered on, auto idling is enabled as default.
● Auto idling is active as default. When all control levers are in neutral position for more than 0.2 seconds, engine speed will drop by 100 rpm immediately and then enter auto idling after another 3 seconds (controller will reduce engine speed to idling) in order to reduce fuel consumption and noise. ● In idling, if the controller detects any maneuver or gear change, engine speed will restore respective level.
Press the key F3 to switch between high and low travel speeds. When the symbol appears above the key F3 , press the key to select high speed travel; when the symbol appears above the key F3 , press the key to select low speed travel. NOTE: When the machine is powered on, low speed is the default travel speed. 4. Viewing failure information
When alert indicator of the monitor is on, a failure code will appear on bottom line of monitor screen. Meanwhile, a red tick appears above the key F4 . Press the key to see failure information. 5. Viewing system information Press the key F5 to see system information. NOTE: To see system information requires password. Please contact your Sany distributor.
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.2 Password entry to system information Press F5 on the default page to enter the password entry to system information. You need to enter the correct password prior to access to System Information.
System Information
Key operation Please enter password:
● Press F1 or or to increase or decrease the number on the digit with the cursor.
In Ma t rk er n et a in ti o g n De al pt .
● Press F2 or or to move the cursor to the left or right digit. ● Press F3 to enter System Unlock.
● Press F4 to enter Backlight Adjustment.
● Press F5 or ESC to return to the default page. ● Press Enter to check the validity of password. If the password is valid, you have access to the Main Menu.
XP235-13008
Fig. 4-214
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4.11.3.3 Main menu
Key in the correct password and press Enter on the password entry to access System Information.
Main Menu
This page contains a list of system functions. You can pick up an item and enter respective page.
Operating Information
Failure Information Throttle Help Info
Key operation
Language Selection
SYS Clock Setup
● Press F1 or or to scroll up or down the menu. When you scroll down the menu, the highlight returns to the top item after the bottom one.
GPS Information
Running parameters of engine, main pump and main valve.
● Press F2 or Enter to enter highlighted item. ● Press F4 to go to System Setup. ● Press F5 or ESC to return to the default page.
4-202
XP1251203007
Fig. 4-215
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.4 Engine & throttle signals Select Running information on the Main Menu and press F2 or Enter to see Engine & Throttle Signals.
Engine & Throttle Signals
This page contains operating parameters of engine and throttle signals.
Coolant Temp ℃：10 Fuel Level
Key operation
%：10
Eng Oil Press kPa：10
● Press F1 to see Pilot Pressure Signals.
Throttle Gear
● Press F5 or ESC to return to the Main Menu.
Engine Speed rpm：10 V：10
In Ma t rk er n et a in ti o g n De al pt .
Gear Position
N：10
Throttle Position
V：10
XP1251203008
Fig. 4-216
4.11.3.5 Pilot pressure signals
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Press F1 on the page of Engine & Throttle Signals to see Pilot Pressure Signals.
Pilot Press Signals
This page shows pilot pressure signals.
Boom UP kg：10
Key operation
Boom DOWN kg：10
● Press F1 to see Main Pump & Main Valve Signals.
Arm IN kg：10
Arm OUT kg：10
Bucket DIG kg：10
● Press F5 or ESC to return to the Main Menu.
Bucket DUMP kg：10 Swing kg：10
Left travel kg：10
Right Travel kg：10
XP2051203009
Fig. 4-217
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.6 Main pump & main valve signals Press F1 on the page of Pilot Pressure Signals to see Main Pump & Main Valve Signals. This page shows main pump and main valve signals.
Main Pump & Main Valve Pump_1 Main Press Kg：10 Pump_2 Main Press Kg：10
Key operation
Prop Valve_1 Current mA：10
● Press F1 to see Engine & Throttle Signals.
Prop Valve_2 Current mA：10 Bucket Confl valve
○
Swing Priority valve
○
Boom Priority valve
○
High/Low Speed Shift
○
In Ma t rk er n et a in ti o g n De al pt .
● Press F5 or ESC to return to the Main Menu.
XP2051203010
Fig. 4-218
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4.11.3.7 Failure codes
销 营
Select Failure Codes on the Main Menu and press F2 or Enter to enter the page. This page contains failure codes and failure information.
Failure Information
Current failure code：E101 E101：Controller failure
E102：Controller temp abnormal
Key operation
E103：Sensor power abnormal E202：Voltage high
● Press F1 to see next page of failure codes.
E203：Backup battery volt low
● Press F5 or ESC to return to the Main Menu.
H101：F. pump press abnormal
E401：CAN bus abnormal
E501：Fuel control dial abnormal H102：R. pump press abnormal
H105：F. pump valve current abnormal
H108：R. pump valve current abnormal H112：Backup pilot press abnormal
H201：Bucket-dig pilot press abnormal
H202：Bucket-dump pilot press abnormal H203：Arm-in pilot press abnormal
H204：Arm-out pilot press abnormal
H205：Boom-up pilot press abnormal
XP2051203011
Fig. 4-219
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SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.8 Throttle help information Select Throttle Help Info on the Main Menu and press F2 or Enter to enter the page. Throttle Help Info
This page contains help information for throttle installation.
Current Gear
Key operation
N：
● Press F2 to select auto idling or full speed.
Engine Speed rpm：
● Press F3 to select high or low speed travel.
Gear Position
● When SYFCS controller is used, the icon rpm will appear in blue or red color.
Throttle Position V：
In Ma t rk er n et a in ti o g n De al pt .
V：
● Press F5 or ESC to return to the Main Menu.
s
rpm
AUTO
n/min
Note: Only a SYFCS controller allows the change of rpm between blue and red colors.
XP2051203013
Fig. 4-220
4.11.3.9 Language selection
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Select Language Selection on the Main Menu and press F2 or Enter to enter the page.
This page is used to select a language for the system.
Language Selection
Key operation
中文系统
● Press F2 to select Chinese System ( 中文 系统 ).
English Systems
● Press F3 to select English System.
● Press F5 or ESC to return to the Main Menu. ● Press or to highlight a language up or down the list.
中文
Eng XP2051203014
Fig. 4-221
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.10 System clock setup Select System Clock Calibration on the Main Menu and press F2 or Enter to enter the page. This page is used to set up system clock.
SYS Clock Setup
Key operation
Local time and time zone：
● Press or to increase or decrease the number on the digit with the cursor.
1234·12·12 12:12：12 12W
Time and time zone setup：
● Press or to move the cursor to the left or right digit.
1234·12·12 12:12：12 12W
In Ma t rk er n et a in ti o g n De al pt .
● Press F1 or Enter to finish calibration. You will be prompted by “Calibration finished! Please restart your machine.”
Use [↑][↓][←][→] to set p system clock.
● Press F5 or ESC to return to the default page. NOTE: System clock can only be set up once after the machine is powered on. When the machine is powered on, the prompt of successful calibration remains on the screen if you press F1 or the Enter key.
4-206
XP2051203015
Fig. 4-222
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.11 GPS information Select GPS Information on the Main Menu and press F2 or Enter to enter the page. This page shows GPS monitoring information.
GPS Information
Key operation
Longitude °：121.0W
Press F5 or ESC to return to the default page.
Altitude m：28.79P
Latitude °：31.40N Velocity Km/h：4.037 Number of Satellites ：0006
Note:
Communication Indicator ：1023 Signal to noise ratio 1：
dB
Signal to noise ratio 2：
dB
In Ma t rk er n et a in ti o g n De al pt .
1. The letter “E” stands for East Longitude and “W” for West Longitude. 2. The letter “N” stands for North Latitude and “S” for South Latitude. 3. The letter “P” stands for a height above the seal level and “N” for a height below the seal level.
4. The signal-to-noise ratio ranges from 0 to 99, which is indicated by a bar. The value on the right of the bar is real S/N ratio.
Signal to noise ratio 3：
dB
Signal to noise ratio 4：
dB
XP20512003026
Fig. 4-223
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5. If the elevation value is not zero and no value is displayed for the longitude and latitude, GPS data are being received but the location has not been precisely defined yet. 6. When the communication signal is 1023, GPRS communication is regular. When it is 615, the GPRS communication is abnormal. 7. When the communication signal changes from 7 to 0, the SIM card or the antenna has a bad connection.
8. When the communication signal changes from 15 to 0, GPRS service is not available, the SIM card has insufficient fund, or GPRS network is abnormal. 9. When the communication signal changes from 31 to 0, the monitoring center is closed. 10. This page is required for remote system locking, remote system unlocking and remote downloading.
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.12 System setup Press the key F4 on the Main Menu to enter System Setup. System Setup
This page is used to configure your machine. Note: Access to System Setup requires entering the password. For method of entering password see “Password entry to system information” on page 4-202.
Machine Configuration Service Hour Setup Machine Configuration Setup Hydraulic Oil Temperature
Key operation
In Ma t rk er n et a in ti o g n De al pt .
● Press F1 or or to scroll up or down the menu. When you scroll down the menu, the highlight returns to the top item after the bottom one. ● Press F2 or Enter to enter highlighted item.
XP2051203016
● Press F5 or ESC to return to the Main Menu.
Fig. 4-224
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4.11.3.13 Machine configuration
Select Machine Configuration on the Main Menu and press F2 or Enter to enter the page.
This page shows machine configuration information.
Machine Configuration
Note: Access to System Setup requires entering the password. For method of entering password see “Password entry to system information” on page 4-202.
Machine Model： SY215C \V217
Key operation
HYD SYS Model： KPM_P
Machine S/N： 11SY0216 00008 Engine Model： CUMMINS_II
● Press F5 or ESC to return to System Setup.
Control SYS： KC-MB-001
Note: “V217” following machine model is software version. XP2051203018
Fig. 4-225
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SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.14 Service hour setup Select Service Hour Setup on the page of System Setup and press F2 or Enter to enter the page.
Service Hour Setup
This page is used to set up service hours of the machine.
Current Service Hours ： 100 h 50 m
Note: Access to System Setup requires entering the password. For method of entering password see “Password entry to system information” on page 4-202.
Service Hour Setup ： 100 h 50 m
In Ma t rk er n et a in ti o g n De al pt .
Key operation
● Press F1 or Enter to save the change after calibration. You will see on the screen “Calibration finished! Please restart your machine.”
Use [↑][↓][←] and [→] to set up service hours.
XP2051203021
Fig. 4-226
● Press F5 or ESC to return to System Setup.
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.15 Machine configuration setup Select Machine Configuration Setup on the page of System Setup and press F2 or Enter to enter the page.
Machine Configuration Setup
This page is used to set up machine configuration after monitor installation.
Machine Model：SY215C\GPS 32
Note: Access to System Setup requires entering the password. For method of entering password see “Password entry to system information” on page 4-202.
Engine Model：CUMMINS_II
Key operation
Machine S/N：11SY0216 00008
HYD SYS Model：KPM P
In Ma t rk er n et a in ti o g n De al pt .
Controller Model：KC-MB-001
● When “215” after machine model is blinking, each pressing of F1 will bring the number up by 10; when “32” after GPS is blinking, each pressing of F1 will bring the number up by 10.
Use [↑][↓][←] and [→] to change machine S/N.
Model Eng
Fig. 4-227
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● Press F4 to change controller model.
● Press F5 to save the change. You will see on the screen “Calibration finished! Please restart your machine.”
● Press or to increase or decrease the selected machine S/N by 100. ● Press or to increase or decrease the selected machine S/N by 1. Depress the key to increase S/N quickly. ● Press ESC to return to System Setup.
● Each pressing of the key Enter enables the number after machine S/N or model to blink. A blinking number can be modified using the keys.
4-210
Ctrl
XP2051203023
● Press F2 to change Engine Model.
● Press F3 to change Hydraulic System Model.
Hyd
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.16 Hydraulic oil temperature Select Hydraulic Oil Temp on the page of System Setup and press F2 or Enter to enter the page.
HYD Oil Temp
This page shows temperature of hydraulic oil. Hydraulic Oil Temp ℃：49
Key operation
In Ma t rk er n et a in ti o g n De al pt .
● Press F5 or ESC to return to System Setup.
XP2051203028
Fig. 4-228
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4.11.3.17 Screen brightness setup
销 营
Press F4 on the page of password entry to system information to enter the page. This page is used to adjust backlight brightness of the screen.
Screen Brightness Setup
Screen Brightness：20%
Key operation
● Press F1 to dim backlight.
● Press F2 to enhance backlight.
● Press F3 to safe brightness change.
● Press F5 to return to System Information.
Press F3 to save setup！
XP2051203029
Fig. 4-229
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Structure and Functions
SY365(B)H-9 Crawler Hydraulic Excavator
4.11.3.18 System lockout (level 1) When this page appear on monitor, it indicates that the excavator is locked out in level 1. System Lockout
Key operation ● Press F5 to enter the page for unlocking.
Machine Model：SY205C
NOTE: After 5 seconds according to the command, corresponding state (Level 1 lockout, level 2 lockout or no lockout) will be displayed. (Waiting for 5 seconds performs a function of filtration.)
Machine S/N：00008 Lockout State：Level 1
In Ma t rk er n et a in ti o g n De al pt .
Current time：12：12：11
System Locked
Contact your Sany distributor to unlock your machine.
XP2051203024
Fig. 4-230
4.11.3.19 System lockout (level 2)
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When this page appear on monitor, it indicates that the excavator is locked out in level 2.
System Lockout
Key operation
● Press F5 to enter the page for unlocking.
Machine Model：SY205C Machine S/N：00008
NOTE: After 5 seconds according to the command, corresponding state (Level 1 lockout, level 2 lockout or no lockout) will be displayed. (Waiting for 5 seconds performs a function of filtration.)
Lockout State：Level 2
Current time：12：12：11
System Locked
Contact your Sany distributor to unlock your machine.
XP2051203025
Fig. 4-231
4-212
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Structure and Functions
BLMaInt e r AkNe rn a tKi t i ng o PAD nal eGp tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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4-213
Structure and Functions
BLM In t aAr e kNe rn a tKi t i nP o gA n al DG ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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Shop Manual - April 2014
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Standard Values 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
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Shop Manual - April 2014
5-1
Standard Values
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
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5-2
Shop Manual - April 2014
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
5 TABLE OF STANDARD VALUES 5.1 Standard Values for Engine-Related Parts
Item
SY365(B)H-9
Engine
ISUZU AA-6HK1-XQP-01 Standard values for Repair limits new machine 2,250 ± 25 2,250 ± 25
Measurement condition
Unit
High idling
rpm
Low idling
rpm
1,050 ± 25
1,050 ± 25
In Ma t rk er n et a in ti o g n De al pt .
Engine speed
Applicable Models
Rated speed
rpm
2,000
2,000
Air cleaner outlet location Arm-in relief ＋ max rpm
kPa {mmH2O}
Min 133 {Min 1,000}
Min 133 {Min 1,000}
Valve clearance
At sudden acceleration At high idling Intake valve Exhaust valve
Bosch Index mm mm
Max 25 — 0.4 0.4
35 — 0.3– 0.5 0.3 – 0.5
Compression pressure
Oil temp：75℃ Engine speed 250 rpm
Mpa {kg/cm2}
Min 3.0 {31}
2.5 {26}
kPa {mmH2O}
Max 0.98 {Max 100}
1.96 {200}
High idling
MPa {kg/cm2}
Min 0.29 {Min 3.0}
0.25 {2.5}
Low idling
MPa {kg/cm2}
Min 0.10 {Min 1.0}
0.07 {0.7}
Engine oil temp
Full speed range (in oil pan)
℃
80 – 110
120
Fan belt tension
Between fan belt pulley and alternator belt pulley Deflection when pressed with finger force of 58.8 N {6 kg}
mm
8.5
Min 7，Max 10
Between fan belt pulley and compressor belt pulley A/C compressor belt tension Deflection when pressed with finger force of 58.8 N {6 kg}
mm
5–8
5–8
Intake pressure (Negative pressure) Exhaust color
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Blow-by pres- Coolant temp：working range armsure in relief ＋ max rpm
Engine oil pressure
Shop Manual - April 2014
5-3
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
5.2 Standard Values for Chassis-Related Parts Applicable Models category
Measurement Condition
Unit
Standard Value for New Machine
Permissible Value
● Engine coolant temperature: Within operational range ● Hydraulic oil temperature: Within operational range ● Engine running at high idle ● Heavy-load operating mode (H) ● Arm-in relief condition
rpm
2,050±50
2,050±50
2 pumps at relief + boosting (if available)
● Engine coolant temperature: Within operational range ● Hydraulic oil temperature: Within operational range ● Engine running at high idle ● Heavy-load operating mode (H) ● Arm-in relief condition + boost switch on
rpm
2,050±50
2,050±50
Speed when auto deceleration is operated
● Engine running at high idle ● Auto idling switch on ● All control levers neutral
rpm
1,350±50
1,400±100
mm
11.5±0.5
11.5±0.5
mm
9.5±0.5
9.5±0.5
mm
11.5±0.5
11.5±0.5
mm
9.5±0.5
9.5±0.5
Item
In Ma t rk er n et a in ti o g n De al pt .
Engine Speed
2 pumps at relief
Boom control valve Spool Stroke
SY365(B)H-9
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Raise
Lower ● Engine stopped In ● For measurArm control valve ing points see Out Control Valve Bucket control valve Curl/dump on page 3-10. Swing control valve Travel (L&R)
mm
9.5±0.5
9.5±0.5
mm
9.5±0.5
9.5±0.5
Travel control valve
mm
9.5±0.5
9.5±0.5
mm
85±10
85±10
● Engine stopped mm ● Control lever grip at center Bucket control lever ● Max. reading up to stroke end (except mm lever play in NEUTRAL position) Swing control lever mm Travel control lever mm ● Engine stopped ● Slightly push Work Equipment mm the control lever with your hand. Play of control lever Stop pushing when you feel clear resistance Travel mm ● Max. reading up to stroke end
85±10
85±10
85±10
85±10
85±10 115±12
85±10 115±12
Max 15
Max 20
Max 20
Max 25
Forward & Reverse
Boom control lever
Travel of Control Lever
Arm control lever
5-4
Shop Manual - April 2014
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Applicable Models
Standard Value for New Machine
Permissible Value
Boom control lever
Max 19.6 {Max 2.0}
Max 24.5 {Max 2.5}
Arm control lever
Max 19.6 {Max 2.0}
Max 24.5 {Max 2.5}
Bucket control lever
Max 15.6 {Max 1.6}
Max 21.6 {Max 2.2}
Max 15.6 {Max 1.6}
Max 21.6 {Max 2.2}
Max 30.4 {Max 3.1}
Max 39.2 {Max 4.0}
Max 93.1 {Max 9.5}
Max 107.6 {Max 11}
3.5 ± 1.0 {36 ± 10}
3.5 ± 1.0 {36 ± 10}
34.3 ± 1.0 {350 ± 10}
33.3 – 35.3 {340 – 360}
34.8 ± 1.0 {355 ± 10}
33.3 – 36.8 {340 – 375}
34.8 ± 1.0 {355 ± 10}
33.3 – 36.8 {340 – 375}
25.5 ± 1.0 {261 ± 10}
24.5 － 27.5 {250 － 280}
33.4 ± 1.0 {342±10}
32.4 – 34.4 {330 – 351}
3.9±0.2 {40±2}
3.7 – 4.1 {37 – 41}
Item
Measurement Condition
● Hydraulic oil temp：Within operational range ● Engine running at high idle Swing control ● Control lever grip at center ● Pedal at tip lever ● Max reading at stroke end Travel control lever
Unit
N {kg}
In Ma t rk er n et a in ti o g n De al pt .
Operating Force of Control Lever and Pedal
Category
SY365(B)H-9
Travel control pedal
● Hydraulic oil temp：Within operational range ● Engine running at high idle Unloaded ● Working mode：H pressure ● Hydraulic pump output pressure with all control levers in neutral position ● Hydraulic oil temp：Within opBoom relief erational range ● Operate corresponding control lever after the engine runs at Arm relief high idling speed. ● Working mode：H ● Hydraulic pump output pressure Bucket relief with all measurement circuits MPa relieved {kg/cm2} ● Hydraulic oil temp：Within opSwing relief erational range ● Operate corresponding control lever after the engine runs at high idling speed. ● Working mode：H Travel relief ● Hydraulic pump output pressure with all measurement circuits relieved ● Hydraulic oil temp：Within operational range Control circuit ● Engine running at high idle source pres● Self pressure reducing valve sure output pressure with all control levers in NEUTRAL position 司
公
Hydraulic Pressure
销 营
Shop Manual - April 2014
5-5
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Applicable Models
5-6
Measurement Condition
Unit
● ● ● ●
Hydraulic oil temp：Within operational range Engine running at high idle Working mode: H degree Swing circle misalignment amount when stopping mm after one turn ● For measuring posture see Swing 1 on page 3-10. ● Hydraulic oil temp：Within operational range 90° ● Engine running at high idle ● Working mode: H ● Time required for passing points 90° and 180° from starting point ● For measuring posture see Swing 180° 1 on page 3-10.
Standard Value Permissible for New MaValue chine
Max 100 (—)
Max 130 (—)
sec.
3.1 ± 0.3
Max 3.7
sec.
4.4 ± 0.4
Max 5.5
In Ma t rk er n et a in ti o g n De al pt .
Time taken to swing
Travel speed (unloaded)
Travel
Motor leakage
Hydraulic drift
Swing
Time taken to start swing
Swing brake angle
CateItem gory
SY365(B)H-9
● ● ● ●
Hydraulic oil temp：Within operational range Engine running at high idle Working mode: H Time required for 5 turns after making initial one turn ● For measuring posture see Swing 1 on page 3-10. 司
公
销 营
sec.
● Hydraulic oil temp：Within operational range ● Engine stopped ● Keeping the upper structure transverse on a grade of 15° . For more information see Swing 2 on page 3-10. mm ● Notching a mating mark on inner and outer races of the swing circle ● Mating mark misalignment amount during 5 minutes. ● Hydraulic oil temp：Within operational range ● Engine running at high idle ● Swing lockout switch: ON ml/min ● Leakage amount for one minute during swing relief ● Hydraulic oil temp：Within operational range Lo ● Engine running at high idle ● Working mode: H ● Time required for track shoes to make 5 turns after making one initial turn ● For more information on measur- Hi ing posture see Travel 1 on page 3-11. Shop Manual - April 2014
31
+4 -2
Max 35
0
0
Max 5
Max 10
11.8± 3
8.8-14.8
7.6 ± 3
4.6-10.6
sec.
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Applicable Models Item
Measurement Condition
Standard Permissible Unit Value for New Value Machine
● ● ● ● ●
Hydraulic oil temp：Within operational range Engine running at high idle Lo Working mode: H Level ground sec. Time required for traveling 10 m after 10 m trial run Hi ● For measuring posture see Swing 2 on page 3-10. ● ● ● ● ● ●
22 ± 2.5
19.5-24.5
14 ± 2.5
11.5-16.5
Hydraulic oil temp：Within operational range Engine running at high idle Working mode: H Travel Speed: Low Hard level ground mm Amount of deviation (χ) while traveling 20 m after initial 10 m trial run ● For measuring posture see Travel 2 and 3 on page 3-11.
Max 800
Max 900
● Hydraulic oil temp：Within operational range ● Engine stopped ● Park the machine on a grade of 12° , with the sprockmm et in the downhill direction ● Measure the sliding distance for 5 minutes ● For measuring posture see Travel 4 on page 3-12.
0
0
13.6
27.2
In Ma t rk er n et a in ti o g n De al pt . Deviation
Hydraulic drift Arm cylin- Boom Bucket cylinder der cylinder
Work Equipment
Bucket tips
Leakage amount of travel motor
Hydraulic drift
Travel
Travel speed (Actual run)
Category
SY365(B)H-9
司
公
销 营
● ● ● ●
Hydraulic oil temp：Within operational range Engine running at high idle Traveling with the sprocket locked mm Oil leakage amount for one minute with traveling in relief condition
● ● ● ●
mm
Max 600
Max 900
mm
Max 20
Max 27
mm
Max 20
Max 20
mm
Max 35
Max 40
Hydraulic oil temp: Within operational range Flat and level ground Bucket full of earth or with rated load (0.8m3: 1,440 kg) Boom horizontal, arm fully retracted and bucket cylinder fully extended ● Engine stopped ● Work equipment control lever in neutral position ● Measure total amount of falling for 15 minutes by measuring the falling every 5 minutes immediately after initial setting ★ Bucket tip lower distance ★ Boom cylinder: Cylinder retracting distance ★ Arm cylinder: cylinder extending distance ★ Bucket cylinder: cylinder retracting distance ● For measuring posture see Work Equipment 1 on page 3-12.
Shop Manual - April 2014
5-7
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Applicable Models Cate-
Item
gory
SY365(B)H-9
Measurement Condition
Unit
Standard Value for Permissible New Machine Value
● Hydraulic oil temp：Within operational range ● Engine running at high idle ● Working mode: H ● Time required for the bucket to raise from the ground to its stroke end
UP
● For measuring posture see Work Equipment 2 on page 3-12. ● Hydraulic oil temp：Within operational range
sec.
3.8 ± 0.3
Max 4.8
In Ma t rk er n et a in ti o g n De al pt .
Work Equipment Speed
Work Equipment
Boom
IN
sec.
3.5 ± 0.3
Max 4.5
OUT
sec.
3.0± 0.3
Max 3.5
DIG
sec.
3.1 ± 0.3
Max 3.4
sec.
2.0 ± 0.3
Max 2.3
● Engine running at high idle ● Working mode: H
Arm
● Time required from dumping stroke end to digging stroke end ● For measuring posture see Work Equipment 3 on page 3-13.
● Hydraulic oil temp：Within operational range
司
公
销 营
● Engine running at high idle
● Working mode: H Bucket ● Time required from dumping stroke end to digging stroke end DUMP ● For measuring posture see Work Equipment 4 on page 3-13.
5-8
Shop Manual - April 2014
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Applicable Models Category
Item
Measurement Condition
Unit
● Hydraulic oil temp：Within operational range ● Engine running at low idle ● Working mode: H ● Time required from maneuvering the joystick to the moment that the sec. bucket reaches the ground and begins to push the machine upward, within 50 mm off the ground ● For measuring posture see Work Equipment 5 on page 3-13. ● Hydraulic oil temp：Within operational range ● Engine running at low idle ● Working mode: H ● Average time required for operatsec. ing the control lever back and forth till the arm starts to move ● For measuring posture see Work Equipment 6 on page 3-14. ● Hydraulic oil temp：Within operational range ● Engine running at low idle ● Working mode: H ● Average time required for operatsec. ing the control lever back and forth till the arm starts to move ● For measuring posture see Work Equipment 7 on page 3-14. ● Hydraulic oil temp：Within operational range ● Engine running at high idle ml/min ● Leakage amount for one (1) minute with cylinder or travel measured at relief condition
Standard Value for New Machine
Judgement Criteria
Max 1.0
Max 1.2
Time Delay
In Ma t rk er n et a in ti o g n De al pt .
Work Equipment
Boom
SY365(B)H-9
Arm
Max 2.8
Max 1.0
Max 3.6
5
20
10
50
Max 200
Max 220
司
公
销 营
Internal Leakage
Bucket
Performance in Combined Operations
Max 2.0
Cylinders Central Swivel Joint
● Hydraulic oil temp：Within operational range ● Engine running at high idle Amount of devia● Working mode: H tion in simultane● Travel Speed: Low ous operation of ● Amount of deviation measured for work equipment 20 m after traveling about 10 m on and travel a hard level ground ● For measuring posture see Travel 2 and 3 on page 3-11.
mm
Shop Manual - April 2014
5-9
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Machine attitudes applicable to performance test and testing procedure of all machine models
In Ma t rk er n et a in ti o g n De al pt .
Control valve: Spool stroke
ZX335-1003002
Fig. 5-1
Swing 1: Swing brake angle, time taken to start swing and time taken to swing
司
公
销 营
ZX335-1003004
Fig. 5-2
Swing 2: Hydraulic drift of swing
15°
Sprocket ZX335-1003006
Fig. 5-3 5-10
Shop Manual - April 2014
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Travel 1: Travel speed (without load)
ZX335-1003003
In Ma t rk er n et a in ti o g n De al pt .
Fig. 5-4
Travel 2: Travel speed (actual run), Travel deviation
45°
司
公
销 营
ZX335-1003005
Fig. 5-5
Travel 3: Travel deviation
x 10m
ZX335-1003007
Fig. 5-6
Shop Manual - April 2014
5-11
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Travel 4: Hydraulic drift of travel
12°
ZX335-1003008
In Ma t rk er n et a in ti o g n De al pt .
Fig. 5-7
Work equipment 1: Hydraulic drift of work equipment
司
公
销 营
ZX335-1003010
Fig. 5-8
Work equipment 2: Boom speed
ZX335-1003012
Fig. 5-9
5-12
Shop Manual - April 2014
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Work equipment 3: Arm speed
ZX335-1003009
In Ma t rk er n et a in ti o g n De al pt .
Fig. 5-10
Work equipment 4: Bucket speed
司
公
销 营
ZX335-1003011
Fig. 5-11
Work equipment 5: Boom delay
ZX335-1003013
Fig. 5-12
Shop Manual - April 2014
5-13
Standard Values
SY365(B)H-9 Crawler Hydraulic Excavator
Work equipment 6: Arm delay
ZX335-1003014
In Ma t rk er n et a in ti o g n De al pt .
Fig. 5-13
Work equipment 7: Bucket delay
司
公
销 营
ZX335-1003015
Fig. 5-14
5-14
Shop Manual - April 2014
Standard Values
BLMaInt e r AkNe rn a tKi t i ng o PAD nal eGp tE.
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
Shop Manual - April 2014
5-15
Standard Values
BLM In t aAr e kNe rn a tKi t i nP o gA n al DG ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
5-16
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Testing and Adjusting 6 Testing and adjusting
6.1 Engine Speed - Test and Adjust............................................................................... 6-3 6.2 Exhaust Gas Color - Test ......................................................................................... 6-5 6.3 Valve Clearance - Adjust.......................................................................................... 6-7 6.3.1 Testing............................................................................................................ 6-8 6.3.2 Adjusting ........................................................................................................ 6-9 6.4 Compression force - Test ....................................................................................... 6-10 6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13 6.5.1 Testing.......................................................................................................... 6-14 6.5.2 Adjusting ...................................................................................................... 6-18 6.6 A/C Compressor Belt Tension - Test and Adjust .................................................... 6-19 6.6.1 Testing ......................................................................................................... 6-19 6.6.2 Adjusting ...................................................................................................... 6-19 6.7 Swing Bearing Clearance - Test ............................................................................ 6-20 6.8 Track Tensioner - Test and Adjust .......................................................................... 6-21 6.8.1 Testing.......................................................................................................... 6-21 6.8.2 Adjusting ...................................................................................................... 6-22 6.9 Oil in Hydraulic Circuits - Test and Adjust .............................................................. 6-23 6.9.1 Testing.......................................................................................................... 6-23 6.9.2 Adjusting ...................................................................................................... 6-25 6.10 Control Oil Circuit Pressure - Test and Adjust...................................................... 6-28 6.10.1 Testing........................................................................................................ 6-28 6.10.2 Adjusting .................................................................................................... 6-28 6.11 Solenoid Valve Output Pressure - Test ................................................................ 6-29 6.12 Pilot Valve Output Pressure - Test ....................................................................... 6-31 6.13 Work Equipment and Swing Pilot Valves - Adjust ................................................ 6-33 司
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销 营
Shop Manual - April 2014
6-1
Testing and Adjusting
Hydraulic Drift of Work Equipment - Test ............................................................. 6-34 Remaining Pressure in Hydraulic Lines - Relieve................................................ 6-36 Oil Leakage Amount - Test................................................................................... 6-37 Air in Each Component - Purge ........................................................................... 6-41
In Ma t rk er n et a in ti o g n De al pt .
6.14 6.15 6.16 6.17
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
6-2
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6 TESTING AND ADJUSTING 6.1 Engine Speed - Test and Adjust Testing Start the engine and keep the engine running until coolant temperature enters operational range. Key in the password on the monitor and check if the engine speed is normal in each gear position.
Main Menu Operating Information Failure Information Throttle Help Info
Testing Items:
In Ma t rk er n et a in ti o g n De al pt .
Language Selection SYS Clock Setup
1. Engine speed at low idle
GPS Information
2. Engine speed at fuel control dial position 11 (H and S modes)
Running parameters of engine, main pump and main valve.
3. Engine speed at relief, with fuel control dial in position 11 (H and S modes) 4. Engine speed at auto deceleration
司
公
销 营
XP1251203007
Fig. 6-1
Shop Manual - April 2014
6-3
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
Calibration 1. Preconditions for auto speed calibration: A. Start the engine. Throttle Help Info
B. Check the throttle position voltage for gear position 1 on the Throttle Help Info page on the monitor. Normal voltage should be 1.3±0.3V under normal speed range of 1050±50. If the voltage is out of the specified range, manually adjust the throttle pull rod. Otherwise abnormality would occur in speed calibration and a red question mark“?” would appear after Engine Speed on the Throttle Help Info page on the monitor.
Current Gear
N：
Engine Speed rpm： Gear Position
V：
In Ma t rk er n et a in ti o g n De al pt .
Throttle Position V：
s
2. Enter the speed calibration page.
Press F5 on the default page of monitor and key in the password to access the Main Menu. Choose Throttle Help Info on the Main Menu to enter the page like the figure on the right.
rpm
XP2051203013
Fig. 6-2
司
公
销 营
3. Speed calibration
Press F4 on the Throttle Help Info page to execute speed calibration. The system enters speed calibration (when the icon turns red) and it automatically shifts to full speed (when the icon turns red). 4. Successful calibration
If the calibration is done successfully, the icon for calibration indication turns blue. The switching to full deceleration requires pressing F2 to switch it manually.
6-4
AUTO
n/min
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.2 Exhaust Gas Color - Test ● Tools used for testing exhaust gas color No.
Part Name
1
Smoke meter
2
Opacimeter
CAUTION
In Ma t rk er n et a in ti o g n De al pt .
● Be careful not to touch any hot part when installing or removing a testing equipment. 1. Testing with smoke meter
A. Put the filter paper in the smoke meter.
B. Insert the waste gas intake pipe into the exhaust pipe. C. Start the engine and keep the engine running until engine coolant temperature is within the operational range.
司
公
销 营
D. When engine speed increases suddenly or is kept at high idle, direct exhaust gas through smoke meter to the filter paper.
ZX335-1004002
Fig. 6-3
E. Remove the filter paper from the smoke meter. Read the smoke value through the apparatus provided. F. Remove the testing tools after testing. Make sure the machine goes back to its normal state. 2. Testing with opacimeter A. Mount the opacimeter onto the exhaust pipe by clamping it to the pipe outlet.
ZX335-1004003
Fig. 6-4
Shop Manual - April 2014
6-5
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
B. Open the opacimeter and preheat it for about 15 minutes. C. Start the engine and keep the engine running until engine coolant temperature is within the operational range. D. When engine speed increases suddenly or is kept at high idle, use the opacimeter to read the smoke value of exhaust gas. E. Remove the testing tools after testing. Make sure the machine goes back to its normal state.
ZX335-1004004
In Ma t rk er n et a in ti o g n De al pt .
Fig. 6-5
司
公
销 营
6-6
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.3 Valve Clearance - Adjust ● Service Standard (Unit: mm) Location
Service Item
Standard Value
Limits
—
Valve clearance (with engine cold)
0.4
—
Correction method Adjust
● Special tools Symbol
Tool name and shape
Part Number
Application
In Ma t rk er n et a in ti o g n De al pt .
Flat-head screwdriver
MH060008
Adjustment of valve clearance (carried on machine)
ZX335-1004006
Check and adjust the valve clearance in cold state as per the following procedure: 司
公
销 营
Shop Manual - April 2014
6-7
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.3.1 Testing In cold state, valve clearance is to be checked and adjusted as per the following procedure: Aligning point
1. Remove the rocker arm cover. 2. Turn the No.1 piston or the No.6 piston to the top dead center (TDC) of compression stroke by following the steps below. ● Turn the engine until the TDC line on the crankshaft pulley is in line with the timing pointer.
In Ma t rk er n et a in ti o g n De al pt .
● Turn the No.1 piston or the No.6 piston to the TDC of compression stroke.
Note: When the rocker arm at the intake side and rocker arm at the exhaust side cannot be turned by hands, it is indicated that the piston has reached the TDC of compression stroke. Turning the engine by one more turn, the TDC of compression stroke of No.1 piston and No.6 piston swaps.
ZX335-1004007
Fig. 6-6
司
公
销 营
3. When the No.1 piston is at the TDC, adjust the valve clearance in a sequence marked with a black dot ( ● ). Cylinder Exhaust Intake
1
2
●
●
3
○
●
4
●
○
5
○
●
6
●
○
○
○
A. When a feeler gauge is used for such measurement, resistance to a moving feeler gauge in the clearance should be felt.
ZX335-1004008
Fig. 6-7
B. If the feeler gauge moves easily in the clearance, it is impossible to obtain accurate result. 4. If the measured value is out of specification, readjustment shall be performed according to the following method.
6-8
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.3.2 Adjusting 1. In adjustment of valve clearance, loosen the locknut before adjusting the adjusting screw. A standard clearance is achieved when slight resistance to the feeler gauge is felt when pulling it out from the clearance.
Adjusting screw
Locknut
2. After adjustment, hold the adjusting screw with a screwdriver to prevent it from turning, and tighten the locknut. Locknut: 21-30 N.m{2.1- 3.1 kgf.m}
In Ma t rk er n et a in ti o g n De al pt .
Valve clearance
3. Go on with the next step until all valve clearances marked with a black dot ( ● ) have been adjusted
ZX335-1004009
Fig. 6-8
4. Recheck the clearances with the feeler gauge. Readjustment should be made if deviation from the standard valve is found. 5. When the engine is carried in vehicle, using to turn the adjusting screw will make the job easy.
司
公
销 营
Shop Manual - April 2014
6-9
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.4 Compression force - Test ● Service standard Location
—
Service Item
Limits
Correction method
2.5MPa {25.5kgf/cm2}
Check
390 kPa { ≤ 4kgf/cm2 }
Check
Standard value
Every cylinder (200 3.0MPa {30.6kgf/cm2} Compression rpm/h) Inter-cylinder presforce — sure difference
Symbol
In Ma t rk er n et a in ti o g n De al pt .
● Special tool Tool name and shape
Part number
Pressure gauge connector
Application
5-85317-001-0 (JKM- Checking the compres1015) sion force
1. Reduction of compression force can be an indication for engine overhaul.
2. Check the compression force regularly and pay attention to its variation from time to time. Understanding the variation of compression force is helpful for troubleshooting. In addition, in a new vehicle or when new parts are installed for replacement, the pressure may be higher due to running-in of the piston ring, valve seat, etc. The pressure will become normal as the parts wear.
司
公
销 营
Pressure gauge connector
ZX335-1004010
Fig. 6-9
3. Before testing, make sure that the engine oil, start motor and battery are in normal condition. 4. The vehicle is to meet the following conditions. A. Preheat the engine until engine coolant temperature reaches 75~85℃ .
B. Switch off all lamps and auxiliary devices. C. Place the gear lever in a neutral position.
6-10
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
5. Remove the entire fuel injector. 6. Cover the fuel injector mounting opening with a rag. 7. Activate the start motor in order to run the engine. Check the cloth if it is stuck with foreign substances. 8. According to the substances (engine oil and/or coolant) adhering to the cloth, the following factors might be involved.
WARNING ● When coolant and/or engine oil is found attached to the rag, running the engine may cause the hot coolant and engine oil to squirt out through the mounting hole of the fuel injector. This is very dangerous. Never touch or look into the fuel injector mounting hole when the engine is running.
In Ma t rk er n et a in ti o g n De al pt .
A. When engine oil is found, it might be improper sealing caused by piston ring. Check the piston ring.
B. When engine oil and coolant are found, it might be cracking of cylinder. Replace the crankcase. 9. Mount the gasket and to the fuel injector mounting hole and fix them with the injector cap. Install the compression force gauge.
司
公
销 营
10. Start the engine and measure the compression force of each cylinder. Calculate the differential pressure between the cylinders. 11. When the compression force and the differential pressure between cylinders deviate from their limits, inject a small amount of engine oil through the fuel injector mounting hole, and measure the compression force again.
● If the compression force is higher, it is probably due to worn or damaged piston ring or cylinder inner surface. ● If the compression force is still low, it is probably due to stuck valve or improper seating, or improperly mounted gasket of cylinder head.
Shop Manual - April 2014
6-11
Testing and Adjusting
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
6-12
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.5 Fuel Injection Timing - Test and Adjust ● Service standard Location
Service Item
Standard value
Limits
—
Fuel injection timing (BTDC)
8 degrees
7~9 degrees
Correction method Adjust
● Tightening torque (Unit: N·m) Part tightened
Tightening torque
Remark
—
Body, fuel delivery valve
39~44
—
—
Nut, injection tube
28~32
—
In Ma t rk er n et a in ti o g n De al pt .
Symbol
● Common tool (Unit: N·m) Symbol
Tool name and shape
Universal connecting rod with extension
Application
MH061099
Inspection and adjustment of fuel injection timing
司
公
销 营
A
14
Part number
A
ZX335-1004011
NOTICE
● Take care not let dust or foreign materials get into the fuel injection pump when adjusting the injection timing.
Shop Manual - April 2014
6-13
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.5.1 Testing 1. Align the TDC mark on the crankshaft pulley with the pointer. Remove the cap of the inspection hole on the timing gear cover in front of the fuel injection pump.
Aligning point
Check if the pointer on the nut-fixing plate on the gear of fuel injection pump is aligned with the outstanding mark on the gear chamber of fuel injection pump.
In Ma t rk er n et a in ti o g n De al pt .
In case of misalignment, turn the crankshaft pulley one more turn and repeat the above steps in order to obtain proper alignment. Check if the marking lines are aligned with each other.
ZX335-1004007
Fig. 6-10
(The marking lines have been aligned properly when assembling the body of fuel injection pump and fixing the flange at factory)
Now, test the angle of crankshaft at the beginning of fuel injection.
司
公
销 营
2. Turn the crankshaft pulley counterclockwise approximate 30 degrees.
1
ZX335-1004012
Fig. 6-11
6-14
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
3. Remove the injection tube from No.1 plunger. This allows you to observe the fuel when it begins to flow out from No.1 plunger.
ZX335-1004013
In Ma t rk er n et a in ti o g n De al pt .
Fig. 6-12
4. Remove from No.1 plunger the valve body ① , seat ② , spring ③ and spool ④ .
1
5. Reassemble the valve body ① and tighten it to the specific torque. Do no reassemble the spring, seat and spool now. Leave them for later reassembly.
2
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3
4
ZX335-1004014
Fig. 6-13
6. Secure the fuel control lever in the fully open position.
ZX335-1004015
Fig. 6-14
Shop Manual - April 2014
6-15
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
7. Slowly turn the crankshaft pulley clockwise while operating the hand pump to feed the fuel constantly. Stop operating the pump immediately when no fuel is seen coming out of No.1 fuel delivery valve. The crankshaft angle is now the engine’s fuel injection beginning angle.
ZX335-1004016
In Ma t rk er n et a in ti o g n De al pt .
Fig. 6-15
8. Observe and make sure that the mark (of fuel injection beginning angle) on crankshaft pulley is in line with the timing pointer. The timing mark is the engine’s fuel injection beginning angle. Discharge the remaining fuel from the body of delivery valve. Make sure that no fuel is delivered from the delivery pump. Note: Engines of the same type may have a fuel injection pump that is different in injection timing. To obtain an engine of required specification, please contact machine supplier or local ISUZU engine service station. These specifications are provided by ISUZU or engine manufacturer.
6-16
TD
C
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销 营
Damping pulley
ZX335-1004017
Fig. 6-16
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
9. Remove the body of fuel delivery valve from No.1 plunger. 10. Install the internal parts (valve seat, spring and spool) on the body.
Body
11. Reassemble the fuel delivery valve AS on No.1 plunger and tighten it to the specific torque.
Seat Spring
12. Install the injection tube to No.1 cylinder and tighten it to the specific torque.
Spool ZX335-1004018
NOTICE
In Ma t rk er n et a in ti o g n De al pt .
Fig. 6-17
● Do not tighten the fuel injection pump body more than specified. The pump body is aluminum and it can be deformed by over-tightening, resulting in unfavorable impact on the operation of control rack.
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Shop Manual - April 2014
6-17
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.5.2 Adjusting 1.
Align the timing pointer with the specific mark on the crankshaft pulley.
2. Perform step 3 through step 6 described in the testing procedure. 3.
Loosen the four (4) nuts on the fuel injection pump. Loosen the nuts. (Also loosen the nuts on the back.)
In Ma t rk er n et a in ti o g n De al pt .
4. Injection timing turns the fuel injection pump in advance along the drive shaft of fuel injection pump in order to make it face outward (getting away from the cylinder block).
ZX335-1004019
Fig. 6-18
Injection timing turns the fuel injection pump in retard along the drive shaft of fuel injection pump in order to make it face inward (approaching the cylinder block). Ref: 1 mm difference between the two marking lines approximates 2º of crankshaft angle.
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5. Keep operating the hand pump to transfer the fuel while slowly turning the fuel injection pump. Stop turning the injection pump when no oil is seen coming out of the fuel delivery valve body of No.1 cylinder. Adjustment of fuel injection pump position is now finished. 6. Tighten the four (4) nuts of fuel injection pump.
7. Remove again the fuel delivery valve body and assemble the spool, spring and seat. Tighten the valve assembly to the specific torque.
Pressure gauge connector
ZX335-1004010
Fig. 6-19
8. Install the injection tube of No.1 cylinder and tighten it to the specific torque.
6-18
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.6 A/C Compressor Belt Tension - Test and Adjust 6.6.1 Testing
Compressor belt pulley
Press the intermediate point of the belt between the drive pulley and the compressor belt pulley with a finger force of about 58.8 N(6 kgf), and check the deflection (A) of the belt, which shall be 5~8 mm (0.20 in~0.31 in).
A
In Ma t rk er n et a in ti o g n De al pt .
Drive belt pulley
ZX335-1004021
Fig. 6-20
6.6.2 Adjusting
● If the belt deflection is abnormal, adjust it according to the following procedure. 1. Loosen the bolts (1) and (2).
4
1
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销 营
2. Move the compressor (3) and the bracket (4) together to adjust belt tension.
3. After positioning the compressor (3), tighten the bolts (1) and (2).
2
4. Recheck belt tension after adjustment. Note:
3
ZXT335-1004022
Fig. 6-21
● Check each belt for damage. Check the V-groove and the V-belt for wear. In addition, it is especially important to keep the V-belt free from friction with bottom of the V-groove. ● Contact local Sany dealer and replace the belt in case of the following conditions.
● The fan belt has been stretched and little margin is left for adjustment. ● Cuts or cracks are found in the belt. ● Abnormal sliding or noise. ● When a new belt is mounted, readjust the belt tension after one hour operation. Shop Manual - April 2014
6-19
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.7 Swing Bearing Clearance - Test ● Tool used for testing swing bearing clearance Symbol
Part Number
Part Name
H
60033930
Dial gauge
● The following steps are to be followed when testing the clearance of swing bearing.
H
ZX335-1004023
WARNING
In Ma t rk er n et a in ti o g n De al pt .
Fig. 6-22
● Park your machine on a level ground. Lower your work equipment to the ground.
● Do not put your hands or feet under the undercarriage during testing. 1. Fix the dial gauge (H) to the track frame and make the pointer point the lower end of the outer race.
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2. Place the work equipment to the maximum reach position. Raise the bucket to a height that the bucket tips and the swing frame bottom are on the same level.
At the moment, the front of upper structure lowers while the rear rises. 3. Reset the dial gauge (H) to zero.
4. Set the arm almost perpendicular to the ground and lower the boom until the front track shoe tilts.
ZX335-1004024
Fig. 6-23
At the moment, the front of upper structure rises while the rear lowers.
150～200mm
5. Read the dial gauge (H). The value indicated by the dial gauge (H) is the clearance of the bearing. 6. Restore the machine to the condition of step 2. Check the dial gauge (H) to see if it reads zero. Repeat step 3 through step 5 if the dial gauge (H) reads a value other than zero. 6-20
ZX335-1004025
Fig. 6-24
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.8 Track Tensioner - Test and Adjust 6.8.1 Testing 1. Move your machine forward at a distance that is equal to the length of track on the ground. Keep running the engine at low idle. Park your machine slowly.
3
2 a
2. Place a straight edge on top of the track grousers between the idler (1) and the front carrier roller (2).
In Ma t rk er n et a in ti o g n De al pt .
A straight edge of angle steel is recommended for this purpose as angle steel bends little. In addition, an L-shaped beam has good performance against bending.
1
3. Measure the maximum clearance (a) between the upper surface of track and the bottom of straight edge.
ZX335-1004026
Fig. 6-25
Max clearance (a): 10~30 mm(0.4~1.2 in)
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Shop Manual - April 2014
6-21
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.8.2 Adjusting If the track tension is incorrect, adjustment is to be made in the following way. 1. Decreasing the tension A. Loosen the valve (1) to discharge grease. Tighten the valve after discharging. 1
WARNING 2
In Ma t rk er n et a in ti o g n De al pt .
● Never loosen the valve over one turn. If the valve is loosened too much, the grease under high pressure may cause the valve to shoot.
ZXT335-1004027
B. Recheck the track tension as per the above method after adjustment. 2. Increasing the tension
A. Add grease through the grease fitting (2) with a grease gun.
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B. Recheck the track tension as per the above method after adjustment. ● Add grease until the gap (b) between the idler guide and the track frame end becomes zero. If the tension is till low, it indicates that the pins and bushings are seriously worn. Replace the pins and bushings, or remove one track shoe.
b ZX335-1004028
Fig. 6-26
6-22
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.9 Oil in Hydraulic Circuits - Test and Adjust Tools used for testing and adjusting hydraulic pressure in work equipment, swing and travel circuits ID —
Part Number
Part Name
60038932
Hydraulic Tester
B210770000084
Adaptor
In Ma t rk er n et a in ti o g n De al pt .
● The hydraulic pressure in work equipment, swing and travel (hydraulic pump output pressure) circuits can be viewed on the monitor.
6.9.1 Testing
1. Preparatory work before measuring
Lower the work equipment to the ground and stop the engine. After the engine is stopped, operate the control levers for several times in order to release the remaining pressure in hydraulic circuits. Open the butterfly nut on the breather valve. Press the relief button to release pressure in the hydraulic tank.
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A. Remove the plug (1) and plug (2) for testing the hydraulic pressure. Plug (1): For oil circuit of back hydraulic pump
Plug (2): For oil circuit of front hydraulic pump
1
B. Install the priming adaptor and connect it to the hydraulic tester. Use an oil pressure gauge with a capacity of 40 MPa {408 kg/cm2}. C. Start the engine and keep it running until the hydraulic pressure rises to a point within the operational range.
ZXT335-1004029
Fig. 6-27
Shop Manual - April 2014
6-23
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
2. Testing the unloading pressure A. Start the engine. B. Test the hydraulic pressure when the engine is running at high idle and all control levers are in neutral position. The hydraulic pressure indicated is the pressure when the unloading valve unloads. 3. Testing the relief pressure of work equipment A. Start the engine and move the cylinder to be measured to its stroke end. B. Test the hydraulic pressure when the engine is running at high idle and the cylinder is in relief condition.
In Ma t rk er n et a in ti o g n De al pt .
The hydraulic pressure indicated is the pressure when the main relief valve is in relief condition. 4. Testing the swing relief pressure
A. Start the engine. Reach out the work equipment as far as possible. Lower the work equipment on the ground in order to restrict swinging. B. Test the hydraulic pressure when the engine is running at high idle and the swing circuit is in relief condition. The hydraulic pressure indicated is the pressure when the swing motor relief valve is in relief condition. 司
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The relief pressure of swing motor is lower than the main relief pressure. 5. Testing the relief pressure of travel circuit
A. Start the engine and lock the travel mechanism.
Place the pin ① between the sprocket and the track frame in order to block the travel mechanism. B. Test the hydraulic pressure when the engine is running at high idle and the travel circuit is in relief condition.
The hydraulic pressure indicated is the pressure when the main relief valve is in relief condition. When the travel circuit is in relief condition, the pressure indicated is always the pressure at high relief.
6-24
1
ZXT335-1004031
Fig. 6-28
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.9.2 Adjusting The unloading valve and safety valve for the boom are not adjustable. 1. Adjusting the main relief pressure (at the high pressure setting side) If the high relief pressure in work equipment and travel circuits is abnormal, adjust the high pressure setting side of the main relief valve (3) according to the following procedure.
In Ma t rk er n et a in ti o g n De al pt .
3
A. Disconnect the pilot hose.
ZXT335-1004900
Fig. 6-29
B. Loosen the locknut (4). Turn the adjusting screw (5) to adjust the pressure. The pressure increases as the retainer is turned right.
The pressure decreases as the retainer is turned left.
Each turn of the retainer approximates: 12.5 MPa {128 kg/cm2}
4
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Locknut:
53.5±4.9 Nm{5.5±0.5 kgm}
5
C. Check the pressure again after adjustment. Test the pressure according to the procedure described above.
Connect the pilot hose before testing the pressure.
ZX335-1004033
Fig. 6-30
Adjustment of the high pressure setting side will affect the low pressure setting side. The low pressure setting side is, therefore, to be adjusted too.
Shop Manual - April 2014
6-25
Testing and Adjusting
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
司
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销 营
6-26
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
2. Adjusting the swing relief pressure If the swing relief pressure is abnormal, adjust the swing motor relief valve (6) according to the following procedure. 6 6
77
In Ma t rk er n et a in ti o g n De al pt .
8 8 ZXT335-1004034
Fig. 6-31
A. Loosen the locknut (7). Turn the adjusting screw (8) to adjust the pressure. Pressure increases as the retainer is turned right. The pressure decreases as the retainer is turned left.
7
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销 营
Each turn of the retainer approximates: 6.71 MPa { 68.4 kg/cm2} Locknut:
78-103 Nm{8.0-10.5 kgm}
B. Check the pressure again after adjustment. Test the pressure according to the procedure described above.
8 ZX335-1004035
Fig. 6-32
Shop Manual - April 2014
6-27
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.10 Control Oil Circuit Pressure - Test and Adjust 6.10.1 Testing Tools used for testing and adjusting the pressure in control oil circuit. ID —
Part Number
Part Name
21008760
Hydraulic Tester
B210770000084
Adaptor
In Ma t rk er n et a in ti o g n De al pt .
Lower the work equipment to the ground and stop the engine. After the engine is stopped, operate the control levers for several times in order to release the remaining pressure in hydraulic circuits. Open the butterfly nut on the breather valve. Press the relief button to release pressure in the hydraulic tank. 1. Remove the hydraulic pressure testing plug (1). 2. Install the priming adaptor and connect it to the hydraulic tester.
● Use an oil pressure gauge with a capacity of 6 MPa {61 kg/cm2}
司
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3. Start the engine and keep it running until the hydraulic pressure rises to the operational range. 4. Test the oil pressure with the engine running at high idle and all control levers in neutral position.
1
2
ZXT215-1004007
Fig. 6-33
6.10.2 Adjusting
1. If the oil pressure measured is lower than 3.5 MPa {36 kgf/cm²}, loosen the locknut (2) and screw in the stud (3). Observe pressure change on the gauge at the same time. Tighten the nut (2) when desired pressure is reached.
3
2
2. Remove all measuring tools after testing. Make sure that the ZX215-1004031
Fig. 6-34 6-28
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.11 Solenoid Valve Output Pressure - Test Tools used for testing the output pressure of solenoid valve ID —
Part Number
Part Name
21008760
Hydraulic Tester
B210770000084
Adaptor
● Make sure that the initial pressure of control oil circuit is normal before testing the output pressure of solenoid valve.
In Ma t rk er n et a in ti o g n De al pt .
Lower the work equipment to the ground and stop the engine. After the engine is stopped, operate the control levers for several times in order to release the remaining pressure in hydraulic circuits. Open the butterfly nut on the breather valve. Press the relief button to release pressure in the hydraulic tank. 1. Disconnect the hose of solenoid valve in order to test the pressure at the outlet.
6
No. 1 2 3 4 5 6
Solenoid valve to be tested
High travel speed valve
5
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4 3 2 1
Backup proportional valve Backup proportional valve Bucket confluence valve Backup
Pilot pressure valve
W365613091
Fig. 6-35
2. Install a tee to location (A) on each solenoid valve and connect the hose. 3. Mount the adaptor onto the tee and connect it to the hydraulic tester. ● Use a hydraulic tester with a capacity of 6 MPa {61 kg/cm2} .
4. Start the engine and keep it running until the hydraulic oil temperature rises to the operational range. 5. Run the engine at full speed. Operate the control levers to open or close each solenoid valve, and measure the pressure. ● The function of each solenoid valve can be checked through the monitor's monitoring function. (This is a special function of the monitor.) 6. Remove all measuring tools after measurement. Make sure that the machine returns to its normal condition. Shop Manual - April 2014
6-29
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
Pilot locking solenoid valve Functioning state Hydraulic lockout control
Function Lock
OFF
Free
ON
Travel speed shift solenoid valve Functioning State
Function
When the 2nd level overheat setting is on Fuel control dial reads lower than 1500 rpm.
In Ma t rk er n et a in ti o g n De al pt .
When travel speed switch is in Lo position Travel signal OFF
When travel speed switch is in Hi position
Travel signal ON
If pressure of both front and back pump is 24.5 MPa {250 kg/cm2} If pressure of both front and back pump is 15.3 MPa {150 kg/cm2}
Other states
司
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6-30
OFF
Shop Manual - April 2014
ON
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.12 Pilot Valve Output Pressure - Test ● Tools used for testing the output pressure of pilot valve ID —
Part Number
Part Name
21008760
Hydraulic Tester
B210770000084
Adaptor
In Ma t rk er n et a in ti o g n De al pt .
● Make sure that the initial pressure of control oil circuit is normal before testing the output pressure of pilot valve. 1. Remove the pilot oil pressure switch or plug. No. 1 2 3 4 5 6
Oil circuit
No.
Oil circuit
Left travel
7
Boom DOWN
Right travel
8
Left swing
Arm IN
9
Bucket DIG
Right swing
10
Arm OUT
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销 营
1
2
3
4
5
6
7
8
9
10
Bucket DUMP Boom UP
ZXT335-1004902
2. Install the adaptor and connect it to the hydraulic tester.
● Use a hydraulic tester with a capacity of 6 MPa{61 kg/cm2}.
3. Start the engine and keep it running until the hydraulic oil temperature rises to the operational range. 4. Measure the output pressure with the engine running at high idle and all control levers of the tested circuit in neutral position. ● When the measured output pressure reads the following values, the pilot valve is normal. 5. Remove all the tools after testing. Make sure that the machine returns to its normal condition.
Control lever
Hydraulic pressure
Neutral position
0{0} Close to the average initial pressure of oil control circuit
Full stroke
(See Table of Standard Values)
Shop Manual - April 2014
6-31
Testing and Adjusting
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
司
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6-32
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.13 Work Equipment and Swing Pilot Valves - Adjust ● If the play of work equipment or swing control lever is too big, adjustment can be made through the following steps.
2 3
1. Remove the work equipment and swing pilot valve assembly.
1
2. Remove the bellows (1). 4
In Ma t rk er n et a in ti o g n De al pt .
3. Loosen the locknut (2). Screw on the disc (3) until it contacts with the four heads of plunger (4). ● Do not move the plunger.
ZX215-1004032
4. When the disc (3) is fixed, tighten the locknut (2) to the specified torque. Locknut: 98~127 Nm {10~13 kgm}
5. Restore the bellows (1).
6. Restore the work equipment and swing pilot valve assembly.
司
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销 营
Shop Manual - April 2014
6-33
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.14 Hydraulic Drift of Work Equipment - Test ● If hydraulic drift occurs to the work equipment (cylinder), check it according to the following procedure. It is to determine whether the failure is caused by cylinder seal or control valve. 1. Check the boom and bucket cylinders.
In Ma t rk er n et a in ti o g n De al pt .
A. Park your machine in an attitude as shown in the illustration on the right, and stop the engine. ● Load the bucket fully with soil or apply rated load to the bucket.
B. Operate the control levers in order to keep the boom in the UP position and the bucket in the DIG position. ● If the lowering speed increases, it is failure of cylinder seal. ● If nothing changes, it is failure of control valve.
ZX215-1004033
司
公
销 营
● Operate the control levers with engine start switch in the ON position.
● If the pressure in accumulator drops, recharge the accumulator after running the engine for about 10 seconds. 2. Check the arm cylinder.
A. Park your machine in an attitude as shown in the illustration on the right. The distance between the arm cylinder and the digging stroke end is 100 mm. Stop the engine.
B. Operate the control levers in order to place the arm in the DIG position. ● If the lowering speed increases, it is the failure of cylinder seal. ● If nothing changes, it is the failure of control valve. ● Operate the control levers with engine start switch in the ON position. 6-34
Shop Manual - April 2014
ZX215-1004034
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
● If the pressure in accumulator drops, recharge the accumulator after running the engine for about 10 seconds. [Ref.] If the hydraulic drift is caused by failure of the cylinder seal, the reason for increase of lowering speed during the above operation is described below: A. If the machine is set in the above position (where the holding pressure is applied to the head end), the oil leaks from the head end to the rod end. The pressure in the rod end is increased as a result. B. As the pressure in the rod end decreases, the pressure in the head end increases to keep a balance. This process is repeated until balance is reached at a certain level depending on the amount of leakage.
In Ma t rk er n et a in ti o g n De al pt .
C. When the pressure is balanced, the lowering speed decreases. If the control levers are operated according to the above procedure, the oil circuit in the rod end opens to the drain circuit (while the head end is closed by a check valve), and the oil flows to the drain circuit from the rod end. As a result, the lowering speed increases. 3. Check the pilot valve.
Test the hydraulic drift respectively while the accumulator is pressurized and the hydraulic lockout control in the LOCK/FREE position. ● Operate the control levers with engine start switch in the ON position.
● If the pressure in accumulator drops, recharge the accumulator after running the engine for about 10 seconds. 司
公
销 营
● If there is a difference in hydraulic drift between the LOCK position and the FREE position, it is the failure (internal fault) of the pilot valve.
Shop Manual - April 2014
6-35
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.15 Remaining Pressure in Hydraulic Lines - Relieve Before disconnecting the lines between the hydraulic cylinders or between the hydraulic motor and the control valve, perform the following steps in order to release the remaining pressure in the hydraulic lines. Even if there is no pressure remaining in the swing motor line and the travel motor line, they will be influenced by the internal pressure of hydraulic tank. The breather valve must therefore be opened to release pressure prior to operation. 1. Stop the engine, loosen the butterfly nut on the breather valve, and press the release button to release the pressure in hydraulic tank.
In Ma t rk er n et a in ti o g n De al pt .
2. Turn the engine start switch to the ON position and operate the control levers for several times. ● The pilot lock valve must be energized. Operate the control levers with the engine start switch in the ON position. ● Operate the control levers 2 or 3 times to release the pressure in the accumulator. 3. Start the engine and keep the engine running at low idle for about 10 seconds in order to increase the pressure in accumulator. And then stop the engine. 4. Repeat the above step 2 through step 3 several times. 司
公
销 营
6-36
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.16 Oil Leakage Amount - Test 1. Testing the oil leakage amount of boom cylinder A. Start the engine and keep the engine running until the hydraulic oil temperature reaches the operational range. And then fully extend the boom cylinder.
1
In Ma t rk er n et a in ti o g n De al pt .
To release the pressure remaining in the lines see “Remaining Pressure in Hydraulic Lines - Relieve” on page 6-36. B. Disconnect the hose (1) on the cylinder rod end and plug the hose opening.
Take care not to disconnect the hose on the cylinder head end.
C. Start the engine and apply relief pressure to the head end of the cylinder while the engine is running at high idle.
D. Hold this state for 30 seconds and then test the amount of oil leakage for one minute.
ZXT335-1004039
Fig. 6-36
司
公
销 营
E. Make sure that the machine returns to its normal condition after testing.
2. Testing the oil leakage amount of arm cylinder
A. Start the engine and keep the engine running until the hydraulic oil temperature reaches the operational range. And then fully extend the arm cylinder.
To release the pressure remaining in the lines, See: Chapter 4 Testing and Adjusting, “Remaining Pressure in Hydraulic Lines - Relieve” on page 6-36. B. Disconnect the hose (2) on the cylinder rod end and plug the hose opening.
2
ZXT335-1004040
Fig. 6-37
Take care not to disconnect the hose on the cylinder head end.
Shop Manual - April 2014
6-37
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
C. Start the engine and apply relief pressure to the head end of the cylinder while the engine is running at high idle. D. Hold this state for 30 seconds. Test the amount of oil leakage for one minute. E. Make sure that the machine returns to its normal condition after testing. 3. Testing the oil leakage amount of bucket cylinder
In Ma t rk er n et a in ti o g n De al pt .
A. Start the engine and keep the engine running until the hydraulic oil temperature reaches the operational range. And then fully extend the bucket cylinder.
3
To release the pressure remaining in the circuits see “Remaining Pressure in Hydraulic Lines - Relieve” on page 6-36. B. Disconnect the hose (3) on the cylinder rod end and plug the hose opening.
ZXT335-1004041
司
公
销 营
Fig. 6-38
Take care not to disconnect the hose on the cylinder head end. C. Start the engine and apply relief pressure to the head end of the cylinder while the engine is running at high idle.
D. Hold this state for 30 seconds and then test the amount of oil leakage for one minute. E. Make sure that the machine returns to its normal condition after testing.
6-38
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
4. Testing the oil leakage amount of swing motor A. Fully extend the work equipment. Lower the bucket on the ground and raise the machine slightly. Stop the engine. 5
B. Disconnect the drain hoses (4) and (5). Blind the hose ends with caps. 4
C. Start the engine and apply swing relief pressure while the engine is running at high idle. Measure the amount of oil leakage under this condition.
ZXT335-1004042
Fig. 6-39
In Ma t rk er n et a in ti o g n De al pt .
● Hold the state described in step 3) for 30 seconds. Measure the amount of oil leakage for one minute.
● After the first measurement, swing the upper structure 180º and measure the leakage again in the same way.
D. Make sure that the machine returns to its normal condition after testing.
司
公
销 营
5. Testing the oil leakage amount of the travel motor A. Remove the cover of the travel motor. B. Start the engine and lock the travel.
Insert the pin ① between the sprocket and the track frame in order to prevent traveling.
1
ZXT335-1004031
Fig. 6-40
Shop Manual - April 2014
6-39
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
C. Disconnect the drain hose (6) of the travel motor. Blind the hose end with a cap.
6
6
D. Start the engine and apply swing relief pressure while the engine is running at high idle. Measure the amount of oil leakage under this condition.
WARNING ● During testing, misoperation of the control levers can cause serious accidents. Make sure that all signals are correct.
ZXT335-1004043
In Ma t rk er n et a in ti o g n De al pt .
Fig. 6-41
● Hold the condition described in step 4) for 30 seconds. Test the amount of oil leakage for one minute.
● Rotate the motor slightly. Swap the positions of the oil distributor and the cylinder and of the cylinder and piston. Repeat the testing several times.
司
公
销 营
E. Make sure that the machine returns to its normal condition after testing.
6-40
Shop Manual - April 2014
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
6.17 Air in Each Component - Purge Purging Steps Item to Be Purged Job Description
1 2 3 Hydraulic Engine Oil CylinPump Starting der
4 Swing Motor
5 6 Travel Operation Motor Starting
● Changing the hydraulic oil ● Cleaning the filter element
○
○
○
(Note)
(Note)
○ ○
○
○
○
○ ○
○
In Ma t rk er n et a in ti o g n De al pt .
● Replacing the return filter element ● Repairing/replacing the hydraulic pump ● Disassembling the suction hose
○
● Repairing/replacing the control valve
○
○
○
● Replacing the oil cylinder ● Disassembling the cylinder piping
○
○
○
● Replacing the swing motor
○
● Disassembling the swing motor ● Replacing the travel motor
● Disassembling the travel motor
Note:
○
○
○
○ ○
司
公
销 营
Purge air from the swing motor and travel motor only when the oil in the motor cases is drained. 1. Purging air from hydraulic pump
1
A. Loosen the plug (1) and make sure that oil leaks through the plug.
B. If you are sure of the leak, tighten the plug (1). Plug: 7.8~9.8 N·m{0.8~1.0 kgf·m}
● Engine starting precaution:
When engine is started after bleeding the air as described above, run the engine at low idle for 10 minutes.
ZXT335-1004500
Fig. 6-42
Shop Manual - April 2014
6-41
Testing and Adjusting
SY365(B)H-9 Crawler Hydraulic Excavator
2. Bleeding air from hydraulic cylinder A. Start the engine and keep the engine running at low idle. B. Raise and lower the boom 4-5 times with the engine running at low idle. ● Do not apply relief pressure and stop the piston at about 100 mm to stroke end. C. Repeat step 2) with the engine running at high idle. D. Apply relief pressure when the piston comes to stroke end with the engine running at low idle. E. Purge air from arm cylinder and bucket cylinder. Repeat step 2) through step 4).
In Ma t rk er n et a in ti o g n De al pt .
● When a new cylinder is used for replacement, it is recommended to purge air from new cylinder before it is installed to work equipment. Especially the boom cylinder, It must be purged prior to installation because its piston is unable to reach the boom-down side stroke end after installation. ● For an excavator whose hydraulic oil has been changed or which has been in storage for a long period of time, slowly operate the boom, arm and bucket cylinders in full stroke at low engine speed under zero load in order to purge the air. Immediate pressurization and loaded operation after change of oil should be avoided. 3. Bleeding air from swing motor
A. Start the engine and run it at low idle.
B. Bleed air from swing motor by slowly turning the upper structure. 司
公
销 营
4. Bleeding air from travel motor
C. Start the engine and run the engine at low idle.
D. Loosen the bleeder plug (1) and make sure that oil oozes through the plug. E. If you are sure of the leak, tighten the plug (1). Bleeder plug: 27.5 - 35.3 Nm {2.8 - 3.6 kgm}
6-42
Shop Manual - April 2014
Testing and Adjusting
BLMaInt e r AkNe rn a tKi t i ng o PAD nal eGp tE.
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
Shop Manual - April 2014
6-43
Testing and Adjusting
BLM In t aAr e kNe rn a tKi t i nP o gA n al DG ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
6-44
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Troubleshooting 7 Troubleshooting
7.1 Checks before Troubleshooting ............................................................................... 7-5 7.2 Failure Symptoms and Troubleshooting Codes ....................................................... 7-6 7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-9 7.3.1 Connector location layout ............................................................................ 7-13 7.3.2 Diagram of system electrical elements ........................................................ 7-18 7.3.3 Diagram of electrical control system ........................................................... 7-20 7.3.4 SWP connectors .......................................................................................... 7-22 7.3.5 A/AMP connectors ....................................................................................... 7-23 7.3.6 DT connectors.............................................................................................. 7-24 7.4 Troubleshooting with an Event Code ..................................................................... 7-25 7.5 Troubleshooting Electrical System (E-Mode)......................................................... 7-49 7.6 Troubleshooting Hydraulic and Mechanical Systems (H-mode) ............................ 7-81 司
公
销 营
Shop Manual - April 2014
7-1
Troubleshooting
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
7-2
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7 TROUBLESHOOTING WARNING ● Stop the machine on a level ground, and check that lock pins, blocks, and parking brake are effective. ● When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. ● If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting.
In Ma t rk er n et a in ti o g n De al pt .
● Be extremely careful not to touch any hot parts or to get caught in any rotating parts. ● When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. ● When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure fi rst. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the fault, to carry out repairs swiftly, and to prevent reoccurrence of the fault. 司
公
销 营
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 some idea of possible causes of the fault that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any fault occurs: ● Parts that have no connection with the fault or other unnecessary parts will be disassembled. ● It will become impossible to find the cause of the fault.
It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fi xed procedure. 2. Points to ask user or operator: A. Have any other problems occurred apart from the problem that has been reported? B. Was there anything strange about the machine before the fault occurred? C. Did the fault occur suddenly, or were there problems with the machine condition before this? D. Under what conditions did the fault occur? E. Had any repairs been carried out before the fault? When were these repairs carried out? Shop Manual - April 2014
7-3
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
F. Has the same kind of fault occurred before? 3. Check before troubleshooting A. Check the oil level. B. Check for any external leakage of oil from the piping or hydraulic equipment. C. Check the travel of the control levers. D. Check the stroke of the control valve spool. E. Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming fault
In Ma t rk er n et a in ti o g n De al pt .
Confirm the extent of the fault yourself, and judge whether to handle it as a real fault or as a problem with the method of operation, etc. When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting
Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of fault, then use the troubleshooting flowchart to locate the position of the fault exactly. ● The basic procedure for troubleshooting is as follows. 司
公
销 营
A. Start from the simple points.
B. Start from the most likely points.
C. Investigate other related parts or information. 6. Measures to remove root cause of fault
Even if the fault is repaired, if the root cause of the fault is not repaired, the same fault will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
7-4
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.1 Checks before Troubleshooting Criterion
1. Check fuel level and type of fuel
—
Add fuel
2. Check for impurities in fuel
—
Clean, drain
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
1. Check for looseness, corrosion of battery terminal and wiring
Tighten or replace
2. Check for looseness, corrosion of alternator terminal and wiring
—
3. Check for looseness, corrosion of start motor terminal and wiring
—
Tighten or replace
1. Check for abnormal noise and smell
—
Repair
2. Check for oil leakage
—
Repair
3. Bleeding air
—
Bleed air
20-30V
Replace
司
公
销 营
1. Check battery voltage (with engine stopped)
Electrics, electrical equipment
Remedy
In Ma t rk er n et a in ti o g n De al pt .
Hydraulic, mechanical Electrical equipment equipment
Lubricating oil, coolant
Item
Tighten or replace
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
5. Check for wet wires (esp. wet connectors or terminals)
—
Disconnect connector and dry
—
Replace
6. Check for blown or corroded fuses
7. Check alternator voltage (with engine speed at middle or higher)
8. Check operating sound of battery relay (when start After running for Replace several minutes: switch is turned ON or OFF) 27.5~ 29.5V Replace —
Shop Manual - April 2014
7-5
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.2 Failure Symptoms and Troubleshooting Codes Troubleshooting No.
Code disE mode H mode played Action to be taken concerning Service Code, Failure code and Failure Code
7
Display Failure code in monitor panel AccordDisplay Service Code in electrical system after ing to checking failure history displayed Display Failure Code in mechanical system after code checking failure history Engine-related failure Engine does not start up easily. (It always takes some time to start up the engine) Engine misfires. Color of exhaust gas is too dark.(Incomplete combustion) Engine pickup is poor.
8
Engine runs rough or is unstable.
9
Engine is short of output, or lacks power
2 3
4 5 6
E-1
E-2
H-2
10 Auto Idle fails. Excessive engine oil consumption, or color of ex11 haust gas is blue 12 Premature engine oil contamination 司
公
销 营
E-5
H-5
13 Excessive fuel consumption Engine cooling water is mixed with engine oil, spurts 14 out or decreases 15 Engine oil amount increases. (Water or fuel gets in) 16 Abnormal noises are heard
17 Excessive vibrations are caused
Failure related to work equipment, swing and travel
18 Power supply of machine cannot be cut off. There are abnormal noises from around hydraulic 19 pump 20 All work equipment, travel and swing do not move Speeds of all work equipment, travel and swing are 21 slow When Machine Swings and Travels Simultaneously, 22 Travel Speed Lowers Largely
7-6
(Engine)
In Ma t rk er n et a in ti o g n De al pt .
1
Symptom
Shop Manual - April 2014
E-3
H-4
H-3 H-1 H-13
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
No.
Symptom
Troubleshooting Code disE mode H mode played Work equipment-related failure
23 All the equipment do not work
(Engine)
E-7
24 Cylinder do not work singly
H-9
25 Drift of cylinder is too large
H-10
26 Work equipment time lag is too big Other work equipment moves, when specific 27 work equipment is relieved 28 Boom-up speed or power is low.
H-11 H-12 H-6
In Ma t rk er n et a in ti o g n De al pt .
E-8
29 Arm speed or power is low.
E-9
H-7
30 Bucket speed or power is low.
E-10
H-8
31 Travel speed or power is low.
E-11
H-15
32 Dual Speed Travel Not Functioning
E-14
Travel-related failure
33 Machine tends to swerve while in travel
H-14
34 Machine is difficult to steer, or lacks power
H-16
35 Travel speed cannot be shifted
司
公
销 营
36 Track shoe does not move (only on one side)
H-17
H-18
Swing-related failure
37 Machine does not swing Swing acceleration is poor, or swing speed is 38 slow Upper structure overruns remarkably when 39 stopping swinging 40 Large shock is made when stopping swinging
H-22
41 Large sound is made when stopping swinging
H-23
42 Hydraulic drift of swing is large
H-24
Shop Manual - April 2014
H-19
H-20
H-21
7-7
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Troubleshooting No.
Symptom
Code disE mode played Monitor panel-related failure E-12
43 Monitor display is blank. 44 Monitor displays nothing. 45
H mode
(Engine)
E-13
Engine coolant temperature reading is incorrect.
E-15 E-16
47 Arm-in pilot pressure reading is incorrect.
E-18
48 Arm-out pilot pressure reading is incorrect.
E-19
49 Boom-up pilot pressure reading is incorrect. Boom-down pilot pressure reading is incor50 rect. Bucket-close pilot pressure reading is incor51 rect. Bucket-open pilot pressure reading is incor52 rect. 53 Swing pilot pressure reading is incorrect.
E-20
In Ma t rk er n et a in ti o g n De al pt .
46 Fuel level reading is incorrect.
E-21 E-22 E-23
E-24
54 Left travel pilot pressure reading is incorrect. Right travel pilot pressure reading is incor55 rect. Other failure
E-25
56 Preheat function fails.
E-6
57 Wiper does not work.
E-17
司
公
销 营
7-8
Shop Manual - April 2014
E-26
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3 Connector Location and Electrical Circuit Diagram Type
Number of pins
Component
Stereogram
CN-101M
A
2
Platform lamp
E-5
CN-102M
S
1
Fuel level sensor
F-6
CN-104M
A
2
Boom lamp (L)
E-7
CN-105M
A
2
Boom lamp (R)
E-7
T-117
Terminal
1
High-temp switch
K-7
T-101
Terminal
1
Battery relay coil (+)
M-2
In Ma t rk er n et a in ti o g n De al pt .
Connector No.
T-102
Terminal
1
Battery relay coil (-)
M-2
T-103
Terminal
1
Battery relay contact (output)
M-2
T-104
Terminal
1
Battery relay contact (input)
M-2
T-105
Terminal
1
Preheater fuse line 21#
M-2
T-106
Terminal
1
Preheater fuse line 16#
M-2
T-118
Terminal
1
Battery ground
M-2
T-500
Terminal
1
Battery ground
M-2
T-107
Terminal
1
Compressor clutch
K-7
T-109
Terminal
1
Engine oil pressure switch
J-7
T-110
Terminal
1
Preheater resistance wire terminal
J-7
T-111
Terminal
1
Start motor terminal B
K-7
T-112
Terminal
1
Alternator terminal B
K-6
T-135
Terminal
1
Start motor terminal S
K-7
T-202
Terminal
1
Chassis ground
W-6
K5
R
5
Horn relay
X-6
K2
R
5
Head lamp relay
X-6
K6
R
5
Work lamp relay
X-6
K4
R
5
Pilot valve relay
X-6
KB
—
5
Battery relay
M-2
K7
R
5
Start relay
X-6
KH
—
5
Preheater relay
Y-6
K3
R
5
Lockout relay
X-6
K9
R
5
Shutdown delay relay
X-6
CN-201F
A
2
Joint connector
W-6
CN-302F
A
3
Intermediate connector
R-6
F-501
Terminal
1
Intermediate connector
R-6
F-502
Terminal
1
Intermediate connector
R-6
司
公
销 营
Shop Manual - April 2014
7-9
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Type
Number of pins
Component
Stereogram
F-503
Terminal
1
Intermediate connector
R-6
F-504
Terminal
1
Intermediate connector
R-6
F-505
Terminal
1
Intermediate connector
R-6
F-506
Terminal
1
Intermediate connector
R-6
F-507
Terminal
1
Intermediate connector
R-6
F-508
Terminal
1
Intermediate connector
R-6
F-509
Terminal
1
Intermediate connector
R-6
CN-502F
D
12
Intermediate connector
R-5
In Ma t rk er n et a in ti o g n De al pt .
Connector No.
7-10
CN-1-110
D
6
Intermediate connector
AD-6
CN-1-112F
3
3
Intermediate connector
W-6
CN-1-111M
S
8
Intermediate connector
W-6
CN-142M
A
35
Monitor
P-5
CN-182P
S
6
Intermediate connector
I-7
CN-155M
S
6
Intermediate connector
J-7
CN-503F
A
2
Intermediate connector
W-6
CN-504F
A
2
Intermediate connector
X-6
CN-505F
A
2
Intermediate connector
X-6
CN-507F
A
2
Intermediate connector
X-6
CN-106M
A
2
Hyd oil temp sensor
I-7
CN-502F
D
8
Intermediate connector
W-6
CN-181M
L
6
Preheater controller
X-6
CN-506F
S
16
Intermediate connector
W-6
CN-180M
S
6
Parking relay
Y-6
CN-140M
DF
3
Front principal pressure sensor
I-7
CN-141M
DF
3
Rear principal pressure sensor
I-7
CN-129M
DF
3
Arm-in pilot sensor
I-6
CN-122M
DF
3
Arm-out pilot sensor
I-6
CN-126M
DF
3
Boom-up pilot sensor
I-6
CN-125M
DF
3
Boom-down pilot sensor
I-6
CN-124M
DF
3
Bucket-dig pilot sensor
I-6
CN-128M
DF
3
Bucket-dump pilot sensor
I-6
CN-123M
DF
3
Swing pilot sensor
I-6
CN-120M
DF
3
Left travel pilot sensor
I-6
CN-121M
DF
3
Right travel pilot sensor
I-6
CN-307M
H
8
Head lamp switch
R-5
司
公
销 营
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Type
Number of pins
Component
Stereogram
CN-303M
H
8
Work lamp switch
R-6
CN-305M
H
8
Washer switch
R-6
CN-304M
H
8
Wiper switch
R-6
CN-104M
A
2
Horn switch
R-6
CN-003F
S
12
Air conditioner
W-4
CN-150F
AMP
2
Front pump solenoid valve
I-7
CN-151F
AMP
2
Rear pump solenoid valve
I-7
CN-135F
AMP
2
Boom priority 2 solenoid valve
J-6
In Ma t rk er n et a in ti o g n De al pt .
Connector No.
CN-134F
AMP
2
Bucket confluence solenoid valve
J-6
CN-132F
AMP
2
Boom priority 1 solenoid valve
J-6
CN-136F
AMP
2
Pilot solenoid valve
J-6
CN-131F
AMP
2
High/low travel speed valve
J-6
CN-133F
AMP
2
Swing priority valve
J-6
CN-211M
AMP
2
Washer motor
K-5
F-300
Terminal
1
Coolant temp sensor
K-7
F-101
W
1
Right horn
I-6
F-100
W
1
Left horn
I-6
CN-140M
AMP
35
Controller
W-6
CN-141M
AMP
35
Controller
W-6
CN-800F
S
2
Alternator terminal L/R
K-7
F-103
S
3
Safety relay
X-6
CN-7-707
AMP
2
Cigar lighter
P-4
CN-150M
D
8
Intermediate connector
AE-3
CN-215F
HL
7
Radio
W-6
PF021
_
_
Fuse box
X-4
CN-1-001
AMP
2
Left speaker
AD-7
CN-1-002
AMP
2
Right speaker
AE-6
CN-1-003
AMP
2
Right head lamp
AB-5
CN-1-004
AMP
2
Left head lamp
AB-5
CN-1-005
AMP
2
Cab lamp
AE-7
司
公
销 营
Shop Manual - April 2014
7-11
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Description
S
SWP type, Yazaki
A/AMP
AMP, Japan
D
DT type, made in Japan
H
Hebi
HL
Hulane
L
Ling Xing
DF
Delphi, U.S.
W
AMP, Japan
Terminal
Round
In Ma t rk er n et a in ti o g n De al pt .
Connector No.
司
公
销 营
7-12
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3.1 Connector location layout
CN-105M
CN-104M
CN-102M
8
6
5
In Ma t rk er n et a in ti o g n De al pt .
7
司
CN-101M
公
销 营
Z
4
3
2
1 ZX305-1005001
A
B
C
D
E
F
Fig. 7-1 Shop Manual - April 2014
7-13
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
CN-111F
CN-113M
CN-155M T-111
CN-113F CN-115M
T-135
CN-116M T-110
CN-182P CN-120M
T-109
CN-121M
T-112
CN-122M CN-123M
CN-800F
In Ma t rk er n et a in ti o g n De al pt .
CN-124M
T-107
CN-125M
T-117
CN-126M
F-300
CN-128M
CN-129M
司
公
销 营
CN-211M
CN-131F
CN-132F
CN-133F
CN-134F
T-105 T-106
T-101
CN-135F
T-102
CN-136F
KB
F-100
T-104
F-101
T-103 T-118
Z
T-500
ZX305-1105041
Fig. 7-2 7-14
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
9
CN-303M
CN-304M
CN-305M CN-307M CN-502F
CN-302M CN-104M F-506 F-507
8
F-508 F-509
7
In Ma t rk er n et a in ti o g n De al pt .
F-501 F-502
F-503
F-504
6
F-505
司
公
销 营
5
4
3
CN-142M
CN-7-707
2
1 ZX305-1105042
N
O
P
Q
R
S
T
Fig. 7-3 Shop Manual - April 2014
7-15
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
CN-1-111M
CN-506F
CN-502F
T-202
F-103 K5
CN-1-112F
K6 K2
CN-503F
K4 CN-504M
K3 K7
CN-505F K9 CN-181M
In Ma t rk er n et a in ti o g n De al pt .
CN-507M
CN-615M
CN-180M KH
司
公
销 营
CN-616M
PF021
CN-215F CN-003F CN-201F
ZX305-1105043 T
U
V
W
X
Fig. 7-4 7-16
Shop Manual - April 2014
Y
Z
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
9
CN-303M
CN-304M
CN-305M CN-307M CN-502F
CN-302M CN-104M F-506 F-507
8
F-508 F-509 F-501
7
In Ma t rk er n et a in ti o g n De al pt .
F-502 F-503
F-504
6
5
4
3
2
F-505
CN-142M
司
公
销 营
CN-7-707
1 ZX305-1105042
N
O
P
Q
R
S
T
Fig. 7-5 Shop Manual - April 2014
7-17
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3.2 Diagram of system electrical elements
CN-7-707F (A-2)
29 1 22 2 3
CN-7-705M
9
1 2 3 4 5 6 7 8 9 10 11 12
CAN+ CAN-
24V 24V GND GND
00A 4 5 6 7 8 00# 9 60a 10 61a 11 12
CAN+ CAN-
1 29 2 22 3 4
22
Cigar lighter
CN-7-113M (D-12)
1
14 23
2
PF021 20
F1 20A F2 10A
13
F3 5A
20
24 F4 15A 25 F5 5A
00A
5 6 7 8 00# 9 10 60a 11 61a 12
21
20b F6 10A
21
26 F7 5A 38 F8 20A
21
20
10A 27 F9 5A 28 F10 29 F1120A
100
00#
CN-506F (S-16)
28 37 66 14 60 22
7 8 9 10 11 12 13 90 14
21 20 21
70 F125A 20A 90 F13 F145A
29 22 00#
64 1 63 2 65 3
21
21
1 64 2 63 3 65
7 8 9 10 11 12 13 14
28 37 66 14 22 90
21 20
10A F15
20
66 20b 38
8 CN-204F (D-12)
24 25 37 14 60 36 35H 33 35L
CN-203M (D-12) 1 2 3 4 5 6 7 8 9 10 11
69 62 61 22 13
1 2 3 4 5 6 50A 7 8 00A 9 70 10 72 11
6
CN-7-112F (D-3) CAN+
To controller circuit CN-112M
2
1 2
CAN-
1 2 57 3 00A 4 00# 5 6 7 8
S
1 2
60a 61a
CN-7-706M (S-2)
35L 35H 37 36 33 72 69 61 25 14
69 62 61 22 13
50A
57 00A
00A 70 72
00# 21 26 0# 24 23 70
1 2 3 57 4 00A 5 00# 6 7 8
司
Start relay
Pilot switch
4
Fuel control dial
公
60a 61a
6 14 5 60
14 6 60 5
CN-506M (D-8)
57 T-107
Compressor clutch
27
F-507 F-506
1 2 3
销 营
14 F-509 69 F-508
Preheat indicator
5
60 14 50A 1 506 2 00A 3 CN-501F (A-3)
CN-502M (D-12)
1
3
Sunlight sensor
Charging indicator
In Ma t rk er n et a in ti o g n De al pt .
7
24 25 37 14 60 36 35H 33 35L
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
Servce lamp
Lockout relay
Refuel
105
2
3 4 5
1
2
3 4 5
1
1
CN-205M (A-2)
1
105
0
11a
2
3 4 5
2
3 4 5
0
11b
11a
610
F-103
11b 60
3
Low-temp switch
Safety relay
0
F-104
21
F-105
12
2 2 CN-505F
F-105
66
T-101
TERMINAL
Start switch
BR ACC R1
B
R2
C
HEAT OFF ON
START
22 62 13
61 11
1 2
1 2
2
CN-504M
2 T-102 T-104 T-120
T-101 15
Start protection relay
1
2 3 45
1
2 3 45
11
0 11C
0
21
1
2
3 4 5
1
2
3 4 5
KB
T-116
T-135 T-102 21 12
14 60 21
B A P1P2
0
-
B
62 1
2
64 6365 3 45
1
0 2
3 45
24
T-500 T-501
Chassis ground
+ -
+
E
Start Chassis motor ground
C
E
E
Parking relay Chassis ground
Alternator
D
Fig. 7-6 7-18
22 646563
Battery relay
1 A
20
Shop Manual - April 2014
Parking motor
33 25 CN-503F (H-8)
Work lamp switch
37 CN-507F (H-8)
Washer switch
25
36 35L 35H
72
70
CN-505F (H-8)
CN-508F (H-8)
Wiper switch
Head lamp switch
ZX305-1105035
E
F
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
● This circuit diagram has been compiled by extracting the wiper system and the switch control systems from the general electrical circuit diagram. Preheat controller
Work lamp relay
Horn relay K5
CN-181M (D-6)
1 14
2 66
3
4
61
1
5 6
31
2
3 4 5
1
2
3 4 5
1 33
0 23 32
Preheater relay
K2
K6 1
Head lamp relay
1
KH
3 4 5
1
2 3 4 5 34 0 24
1 72
2
CN-124F (S-6) 50A 1
0 69
3
4 5
1
2 3 0 70
4 5
1 68
2
71
3
4 5
2 3 14 16
4 5 17
2
507 2
2
MT- 3
3
00A 5
5
MT+
6
Horn switch
6
1 2 3 5 6
Throttle motor AC-2000
31
23
In Ma t rk er n et a in ti o g n De al pt .
T-107
T-105
T-106
21
16
0
1
1
25
2
2
36 35H
61
3
3
4
4
5
5
35L
25 MT+ MT507 50A 00A
7 Wiper
M
6
CN-112M (A-2)
57 66 21
0
26 0#
司
公
销 营
24
CN-506F (S-16)
23 70
1
1
37 2
2
8
Preheater
CN-1-110M (D-6)
35L 35H 37 36 14 33 72 69
9
Washer motor
0
M
37
6 6
61a 60a 20b
0
38
71
0
71
R+ R-
L+ L-
0# 71 0
26
CN-150M (S-8)
1 2 3 4 5
1 2 3 4 5
6 7 8
6 7 8
1
1
2
2
1
1 2
2
Head lamp (R) 0 77
Head lamp (L) 0 77
F-104 (W-1)
32 34
CN-506M (D-16)
6
6
16
16
32
4
Horn
1
1
F-103 (W-1)
34
1
1
CN-101M (A-2)
1
20b
R+
L+ 0# 20b RL-
5
1 2 3 4 5 6 7
2
2
1
CN-104M (A-2) 1
2
2
Revolving frame work lamp
0
1
3
34
Left boom work lamp
0 34
CN-105M (A-2) 1
1
0
2
2
34
Right boom work lamp
2
CN-107M To radio control panel Radio speaker (R)
1
57
0 1
61a
4
60a
5 6
57 2
CN-109M
0#
Radio speaker (L)
0
7
38
26
8
38
1
1
2
2
0
Cab lamp
26
CN-207F
1
To A/C control panel
Fig. 7-7 G
ZX225-1105036
H
I
J Shop Manual - April 2014
K
L 7-19
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3.3 Diagram of electrical control system CN-502F (D-16)
CN-152M (AMP-2) 511 0
1 2
50
240Ω
00
9
4
4
13
13
CN-616M (AMP-81)
7
6
00# 42 509
108B 510 511 108A 508 200 204 207
50 00
202
200
502
201 202 203 204 208
00 00 50 CANCAN+ 11C 201
In Ma t rk er n et a in ti o g n De al pt .
8
1 2 5 11 13 15 19 30 31 34 38 48 L. travel pilot pressure 49 Bkt-dump pilot pressure 50 Boom-down pilot pressure 51 Arm-out pilot pressure 52 Rear pump main pressure53 54 55 56 58 60 65 R. travel pilot pressure 67 Swing pilot pressure 68 Bkt-dig pilot pressure 69 Boom-up pilot pressure 70 Arm-in pilot pressure 71 Front pump main pressure72 73 74 75 77 78 80
207
208 205
206
206
205 602
203 501
603
00
604
50 50
607 608 702 703
CAN+ CAN-
501 502 508 509 510 511 108A
CN-615M (AMP-40)
607
82 83 84 88 89 98 99 100 101 105 113 114 115 119 120 121
5
4
3
108B 27
610
611 702
0
司
公
703
销 营
608
42
604 602 603
00# 00# 42 42
TERMINAL B BRACCR1 R2 C HEAT OFF
27
ON START
22
42
13
2
T-101
T-102 T-104 T-103
13
0
1
2 3 45
1
2 3 45
20
21
KB
Battery relay
T-500
1
T-107
- +- +
A B C
A B
CN-112M (D-3)
GND
Battery
To monitor circuit
CN-115M (D-3)
120 Ω
ZX335-1105037
A
B
C
D
Fig. 7-8 7-20
Shop Manual - April 2014
E
F
G
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
● This circuit diagram has been compiled by extracting the pressure collecting system and the solenoid valve control systems from the general electrical circuit diagram.
50 00 200 50 00 201 50 00 202 50 00 203 50 00 204
50
50 00 208
00 200
50 00 207
B
B
C
C
B
R. travel pilot pressure sensor
B
C C CN-122M (DF-3) A A B
B
C
C
Arm-out pilot pressure sensor
CN-129M (DF-3) A A
B
B
C
C
Arm-in pilot pressure sensor
CN-128M (DF-3) A A
B
B
C
C
Bucket-dump pilot pressure sensor
CN-123M (DF-3) A A
B
B
C
C
50 00 206
50 00 205
207 206
50 00 501
205 501 502
50 00 502
602 603 604 607 608
Boom-down pilot pressure sensor
B C
CN-126M (DF-3) A A
B
B
C
C
Boom-up pilot pressure sensor
CN-124M (DF-3) A A
B
Bucket-dig pilot pressure sensor
B
C C CN-115M (DF-3) A A B
B
C
C
Front pump pressure sensor
CN-116M (DF-3) A A
B
B
C
C
8
Swing pilot pressure sensor
CN-125M (DF-3) A A
B C
9
L. travel pilot pressure sensor
CN-121M (DF-3) A A
In Ma t rk er n et a in ti o g n De al pt .
201 202 203 204 208
CN-120M (DF-3) A A
7
Rear pump pressure sensor
CN-132F (AMP-2)
602 0
603 0
702 703 508 510
1 2
1
1
Boom priority-1 -prptnl valve
2
2
1
1
Boom priority-2 -prptnl valve
2
2
1
1
2
2
High speed travel valve
司
公
销 营
CN-133F (AMP-2)
608 0
108B 27
1
2
2
Swing priority prptnl valve
CN-111F (AMP-2)
702 0
0
1
1
1
2
2
Front pump prptnl valve
CN-113F (AMP-2)
42
703 0
1
1
2
2
508
T-109
509
CN-101M
510
511 42
CN-113M (AMP-2) 1
2
CN-125F (S-2)
1
1
108A
2
2
108B
6
Bkt confluence -prptnl valve
CN-131F (AMP-2)
607 0
511 108A
2
CN-134F (AMP-2)
604 0
509
1
CN-135F (AMP-2)
5
Rear pump prptnl valve Engine oil prsur switch Fuel level
T-116
Coolant temp sensor
4
Hyd oil temp sensor Engine speed sensor
3
Pilot valve relay
Pilot switch
1
2
3
4
5
1
2
3
4
5
CN-205F (A-2) CN-136F (AMP-2)
1 2
2
1 2
Pilot valve
1 ZX225-1105038
H
I
J
K
L
M
Fig. 7-9 Shop Manual - April 2014
7-21
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3.4 SWP connectors Male (plug)
Female (socket)
7123-7414-40
(1 pin)
In Ma t rk er n et a in ti o g n De al pt .
7222-7414-40
7123-1424-40
(2 pins)
7222-7464-40
7123-7464-40
(6 pins)
7222-7484-40
7123-7484-40
(8 pins)
7222-1424-40
司
公
销 营
7222-7564-40
7123-7564-40
(16 pins) W365-130707
Fig. 7-10 7-22
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3.5 A/AMP connectors
Male (plug)
Female (socket)
Part No. ：282080-1 (2 pins)
In Ma t rk er n et a in ti o g n De al pt .
Part No. ：282104-1
282105-1
282087-1
(3 pins)
司
公
销 营
174354-2
174352-2
1473252-1
1473255-1
1473244-1
1473247-1
(2 pins)
(40 pins)
(81 pins) W365-130709
Fig. 7-11 Shop Manual - April 2014
7-23
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.3.6 DT connectors Housing (plug)
Housing (socket) B
A
B
A
DT06-2S
DT04-2P
A
A
B
In Ma t rk er n et a in ti o g n De al pt .
B
C
C DT06-3S
DT04-3P (3 pins)
1
6
2
5
3
4
6
1
5
2
4
3
司
公
销 营
DT04-6P (6 pins) 8 5
DT06-6S
8
5
1
4
1 DT04-8P (8 pins) 4
DT06-8S
12
7
7
12
1
6
6
1
DT04-12P
DT06-12S
(12 pins) W365-130710
Fig. 7-12
7-24
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.4 Troubleshooting with an Event Code
In Ma t rk er n et a in ti o g n De al pt .
Information contained in troubleshooting table ............................................................. 7-26 E015 Power voltage abnormal ..................................................................................... 7-27 E212 Irregular throttle motor current or defective motor connection ............................ 7-28 E240 Hydraulic oil temperature abnormal .................................................................... 7-29 E320 Front pump output pressure abnormal ................................................................ 7-30 E321 Rear pump output pressure abnormal ................................................................ 7-31 E322 Bucket-dig pilot pressure abnormal..................................................................... 7-32 E323 Bucket-dump pilot pressure abnormal ................................................................ 7-33 E324 Arm-in pilot pressure abnormal ........................................................................... 7-34 E325 Arm-out pilot pressure abnormal ......................................................................... 7-35 E326 Boom-up pilot pressure abnormal ....................................................................... 7-36 E327 Boom-down pilot pressure abnormal .................................................................. 7-37 E328 Left travel pilot pressure abnormal ...................................................................... 7-38 E329 Right travel pilot pressure abnormal ................................................................... 7-39 E330 Swing pilot pressure abnormal ............................................................................ 7-40 E332 Motor built-in potentiometer irregular .................................................................. 7-41 E434 Front pump proportional solenoid current abnormal (A) ..................................... 7-42 E435 Rear pump proportional solenoid current abnormal (A) ...................................... 7-43 E436 Front pump proportional solenoid current abnormal (B) ..................................... 7-44 E437 Rear pump proportional solenoid current abnormal (B) ...................................... 7-45 E543 Engine speed abnormal ...................................................................................... 7-46 E244 Fuel control dial setting voltage abnormal .......................................................... 7-47 E145 CAN bus abnormal .............................................................................................. 7-48 司
公
销 营
Shop Manual - April 2014
7-25
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Information contained in troubleshooting table Failure code
Service Code
Code displayed
——
Failure information Controller reaction Machine reaction
Failure sympTitle of failure shown in failure history tom
Failure is described on the monitor display. When failure is detected, the controller has taken action to protect the affected system or equipment. Symptom that is shown on the machine due to action of controller.
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Cause
Possible causes and standard values
1 2
3
• Standard value under normal condition can be used to judge possible causes
4
• Reference for passing the above "Good" or "No Good" judgement Possible causes of trouble (Given numbers are ref- <Symptom of Wiring Harness Failure> erence numbers, which do not in- • Open circuit dicate priority) Faulty contact with connector or open circuit in wiring harness 司
公
销 营
5
• Faulty grounding
An ungrounded wiring is grounded.
• Short circuit
A wiring has mistaken contact with a 24 V electric circuit.
Related circuit diagram
This is part of the circuit diagram which shows the portion where the failure occurred. ● Connector No.: A connector number Indicates a connector. ● Arrow: An arrow roughly indicates the installing location.
7-26
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E015 Power voltage abnormal Failure code
Failure symptom
E015
Power voltage abnormal
Voltage of power supply is higher than 36V during machine operation.
Controller reaction
Driving of motor and solenoid valve is cut off automatically by the system.
Machine symptom
Engine fails to accelerate and machine moves slowly.
Cause
Standard values and troubleshooting references ★ Turn the start switch to the OFF position and leave it in the position for troublePower fail- shooting. ure Volt Under 25 V Check battery voltage. ★ Turn the start switch to the OFF position before proceeding. Turn the start Alternator switch to the START position for trouble shooting. abnormal Measure between alternator terminal B and ground. Volt Around 28 V
1
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Failure description
2
3 4
司
公
销 营
Start switch B
TERMINAL
BR ACC R1 R2 C
HEAT OFF ON
START
13
Charging indicator
G
14
-
+
-
+ Battery relay
0
B R
S
13 0
Delay relay
11b
E
L
B
E Alternator
Safety relay C
R
60
0
M Start motor
S E
0
0 ZX225-1105002
Fig. 7-13 Shop Manual - April 2014
7-27
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E212 Irregular throttle motor current or defective motor connection g Failure code
Failure symptom
E212
Throttle motor loading circuit is abnormal and the engine acceleration fails.
Failure description
Motor feedback voltage is lower than 0.25V or higher than 4.75V
Controller reaction
The controller stops the motor driving system when this failure is detected.
Symptom on machine
Engine acceleration fails and the machine acts slowly. . Standard values and troubleshooting references
Failure of throttle 1 motor coil
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
Between Ĺ and ļ of CN-124M
Resistance
12.2ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. 2 Open circuit of harKeep it in the OFF position while troubleshooting is performed. Unplug the controller and measure the resistance ness Resistance 12.2ȍ between the pins 32 and 33. Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
3
Short circuit of harUnplug the connector CN-124M and measure the ness (grounded) resistance between motor Ĺ ( ļ ) and the hous- Resistance Above 2Mȍ ing. 司
公
销 营
No troubleshooting can be done for failure occurs in the inner of controller. (Except for the above reasons, the controller must be replaced in case of failure.)
Internal failure of 4 controller 5
Controller
Throttle motor
CN-124M
50A#
Sensor
25
507#
Throttle feedback volt
7
MT-
33
GND
16
00A
MT+
32
MT+
MT-
1
1
2
2
3
3
4
4
5
5
6
6
Green White Red
M
Yellow Blue
Chassis harness
Operator station
ZX225-1105001
Fig. 7-14 7-28
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E240 Hydraulic oil temperature abnormal 0 yd au c o te pe atu e ab o a Failure code
Hydraulic oil temperature is abnormal. Only alarm output is effective.
Failure symptom
E240
Controller detects a temperature resistance of hydraulic oil that is lower than 10 ohms or higher than 120 ohms and it lasts more than 3s. Only alarm output is effective. The alarm resets automatically when conditions Controller reaction become normal. Symptom on machine —— Failure description
Cause
Standard values and troubleshooting references Ɣ Turn the start switch to the OFF position and then keep it in the ON position to perform troubleshooting.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
2
3
4
Failure of sensor
Open circuit of harness Short circuit of harness (grounded)
Failure of 24V power supply
Between CN-113M ķ and ground
Voltage
0.2-4.75V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-113M ķ and pin 21 of controller Resistance
Under 1 :
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Resistance Above 1M :
Between CN-113M ķ and ground 司
公
销 营
Ɣ Turn engine start switch to OFF position. Keep it at ON position to perform troubleshooting. Between CN-113M ĸ and ground
Voltage
About 24V
5
CN-115F
0#
1
1
240 ohms
Controller
2
2
CN-113M
Hyd oil temp sensor
511
21
1
1
2
2
Hyd oil temp sensor Signal
24V PWR
24V PWR
Operator station
Chassis harness
ZX225-1105016
Fig. 7-15
Shop Manual - April 2014
7-29
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E320 Front pump output pressure abnormal Failure code
Front pump output pressure is abnormal. Only alarm output is effective.
Failure symptom
E320 Failure description Controller reaction
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Symptom on machine
——
Cause Failure of 5V power supply
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the ON position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
Standard values and troubleshooting references
2
Between CN-151M A and B
Voltage
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of Between CN-151M C and pin 29 of controller signal line Between CN-115M B and ground
3
4
About 5V
Short circuit of signal line (grounded)
Failure of sensor
Under 1ȍ
Resistance
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. 司
Between CN-151M C and ground 公
销 营
Resistance
Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-151M C and ground
Voltage
0.5±0.2V
5
Controller
Front pump signal collecting port GND
5V PWR
Front pump press. sensor
CN-151M
29
501# 00#
23
12
50#
Operator station
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105003
Fig. 7-16
7-30
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E321 Rear pump output pressure abnormal p p p p Failure code
Reading of rear pump output pressure is abnormal. Only alarm output is effective. .
Failure symptom
E321 Failure description Controller reaction
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Symptom on machine
——
Cause
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position Failure of 5V while troubleshooting is performed. power supply Between CN-116M A and B Voltage About 5V
Possible causes and standard values
1
2
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of Between CN-116M C and pin 19 of controller signal line Between CN-116M B and ground
Under 1ȍ
Resistance
Under 1ȍ
3
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-116M C and ground Resistance Above 2Mȍ
4
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position Failure of senwhile troubleshooting is performed. sor Between CN-116M C and ground Voltage 0.5±0.2V
司
公
销 营
5
Controller
CN-116M
Rear pump signal collecting port
19
GND
20
5V PWR
12
502#
C
Signal
B
GND
A
5V
00#
Operator station
50#
Rear pump press. sensor
Chassis harness
ZX225-1105004
Fig. 7-17 Shop Manual - April 2014
7-31
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E322 Bucket-dig pilot pressure abnormal Failure code E322
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
The bucket-dig motion is slow.
Cause
Standard values and troubleshooting references
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of 5V troubleshooting is performed. power supply Between CN-124M A and B Voltage About 5V
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Bucket-dig pilot pressure is abnormal. Only alarm output is effective. .
Failure symptom
2
Open circuit of signal line
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-124M C and pin 10 of controller Between CN-124M B and ground
3
Under 1 :
Resistance
Under 1 :
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-124M C and ground Resistance Above 2M :
4
司
公
销 营
Failure of sensor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-124M C and ground
Voltage
0.5±0.2V
5
Controller
CN-124M
205#
Bucket-dig pilot press. 10 signal collecting port GND 5V PWR
00#
11
50#
12
Operator station
Bucket-dig pilot pressure sensor
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105005
Fig. 7-18
7-32
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E323 Bucket-dump pilot pressure abnormal Failure code
Reading of bucket-dump pilot pressure is abnormal. Only alarm output is effective.
Failure symptom
E323 Failure description
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on.
Controller reaction
Only alarm output is effective.
Symptom on machine
Bucket-dump motion is slow.
Cause
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of 5V troubleshooting is performed. power supply Between CN-128M A and B Voltage About 5V
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Standard values and troubleshooting references
2
Open circuit of signal line
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-128M C and pin 33 of controller Between CN-128M B and ground
Resistance
Under 1ȍ Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. . of signal line (grounded) Between CN-128M C and ground Resistance Above 2Mȍ 司
公
销 营
3
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of sen4 troubleshooting is performed. sor Between CN-128M C and ground Voltage 0.5±0.2V 5
Controller
Bucket-dump pilot press. signal collecting port
GND 5V PWR
CN-128M
204#
33
C
Signal
00#
11 12
Operator station
Bucket-dump pilot pressure sensor
B
GND
A
5V
50#
Chassis harness
ZX225-1105006
Fig. 7-19 Shop Manual - April 2014
7-33
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E324 Arm-in pilot pressure abnormal Failure code
Failure symptom
E324
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
Arm-in motion is slow.
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Cause
1
Possible causes and standard values
Reading of Arm-in pilot pressure is abnormal. Only alarm output is effective. .
Failure of 5V power supply
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-129M A and B
2
Open circuit of signal line
Voltage
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-129M C and controller pin 35 Between CN-129M B and ground
Resistance
司
公
销 营
3
Under 1ȍ
Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-129M C and ground Resistance Above 2Mȍ
4
Failure of sensor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-129M C and ground
Voltage
0.5±0.2V
5
Arm-in pilot pressure signal collecting port
Arm-in pilot press. sensor
CN-129M
Controller
203#
35
00#
GND
11
5V PWR
12
50#
Operator station
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105007
Fig. 7-20 7-34
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E325 Arm-out pilot pressure abnormal
Failure code
Reading of Arm-out pilot pressure is abnormal. Only alarm output is effective. .
Failure symptom
E325
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
Arm-out motion is slow.
Cause
Standard values and troubleshooting references Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Ɣ
Possible causes and standard values
1
Failure of 5V power supply
Between CN-122M A and B
Ɣ
2
Open circuit of signal line
Voltage
About 5V
Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Between CN-122M C and pin 22 of controller Between CN-122M B and ground
Under 1 :
Resistance
Under 1 :
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-122M C and ground Resistance Above 2M : 司
公
销 营
3
Ɣ
4
Failure of sensor
Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-122M C and ground
Voltage
0.5±0.2V
5
Controller
Arm-out pilot press. sensor
CN-122M
Arm-out pilot pressure 22 signal collecting port GND
11
5V PWR
12
202# 00# 50#
C
Signal
B
GND
A
5V
Operator station
Chassis harness
ZX225-1105008
Fig. 7-21 Shop Manual - April 2014
7-35
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E326 Boom-up pilot pressure abnormal Failure code
Failure symptom
E326
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
Boom-up motion is slow.
Cause
Standard values and troubleshooting references
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of 5V troubleshooting is performed. power supply Between CN-126M A and B Voltage About 5V
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Reading of boom-up pilot pressure is abnormal. Only alarm output is effective. .
2
Open circuit of signal line
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-126M C and controller pin 8. Between CN-126M B and ground
Resistance
Under 1ȍ
Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-126M C and ground Resistance Above 2Mȍ 司
公
销 营
3
4
Failure of sensor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-126M C and ground
Voltage
0.5±0.2V
5
Boom-up pilot press. sensor
Controller
Boom-up pilot pressure signal collecting port
GND 5V PWR
206#
8
00#
11
50#
12
Operator station
CN-126M C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105009
Fig. 7-22 7-36
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E327 Boom-down pilot pressure abnormal
Failure code
Reading of boom-down pilot pressure is abnormal. Only alarm output is effective. .
Failure symptom
E327
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
Boom-down motion is slow.
Cause
Standard values and troubleshooting references Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
Failure of 5V power supply
Between CN-125M A and B
2
Open circuit of signal line
Voltage
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-125M C and controller pin 9 Between CN-125M B and ground
Resistance
Under 1ȍ Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-125M C and ground Resistance Above 2Mȍ 司
公
销 营
3
4
Failure of sensor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-125M C and ground
Voltage
0.5±0.2V
5
Controller
Boom-down pilot pressure signal collecting port
GND 5V PWR
Boom-down pilot press. sensor
CN-125M
9
207# 00#
11 12
Operator station
50#
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105010
Fig. 7-23 Shop Manual - April 2014
7-37
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E328 Left travel pilot pressure abnormal Failure code E328
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
Left travel speed is low. Travel deviates.
Cause
Standard values and troubleshooting references
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of 5V troubleshooting is performed. power supply Between CN-120M A and B Voltage About 5V
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Reading of left travel pilot pressure is abnormal. Only alarm output is effective. .
Failure symptom
2
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of Between CN-120M C and pin 34 of controller signal line Between CN-120M B and ground
Resistance
Under 1ȍ
Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-120M C and ground Resistance Above 2Mȍ 司
公
销 营
3
Failure of sen4 sor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-120M C and ground
Voltage
0.5±0.2V
5
Controller
CN-120M
Left travel pilot press. signal collecting port GND 5V PWR
200#
34
00#
11
50#
12
Operator station
Left travel pilot pressure sensor
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105011
Fig. 7-24 7-38
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E329 Right travel pilot pressure abnormal Failure code E329
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on. Only alarm output is effective.
Failure description Controller reaction Symptom on machine
Right travel speed is low. Travel deviates.
Cause
Standard values and troubleshooting references
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of 5V troubleshooting is performed. power supply Between CN-121M A and B Voltage About 5V
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Reading of right travel pilot pressure is abnormal. Only alarm output is effective. .
Failure symptom
2
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of Between CN-121M C and pin 30 of controller signal line Between CN-121M B and ground
3
Resistance
Under 1ȍ Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-121M C and ground Resistance Above 2Mȍ 司
公
销 营
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of sen4 troubleshooting is performed. sor Between CN-121M C and ground Voltage 0.5±0.2V 5
Controller
CN-121M
Right travel pilot press. 30 signal collecting port
201# 00#
GND 5V PWR
11
12
Operator station
50#
Right travel pilot pressure sensor
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105012
Fig. 7-25
Shop Manual - April 2014
7-39
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E330 Swing pilot pressure abnormal Failure code
Reading of swing pilot pressure is abnormal. Only alarm output is effective. .
Failure symptom
E330 Failure description
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec when the power is on.
Controller reaction
Only alarm output is effective.
Symptom on machine
Swinging motion is slow.
Cause
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Failure of 5V troubleshooting is performed. power supply Between CN-123M A and B Voltage About 5V
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Standard values and troubleshooting references
2
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of Between CN-123M C and pin 18 of controller signal line Between CN-123M B and ground
Resistance
Under 1ȍ
Under 1ȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line (grounded) Between CN-123M C and ground Resistance Above 2Mȍ 司
公
3
销 营
Failure of sen4 sor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-123M C and ground
Voltage
0.5±0.2V
5
Controller
CN-123M
Swing pilot pressure signal collecting port
208#
18
00#
GND
11
5V PWR
12
50#
Operator station
Swing pilot pressure sensor
C
Signal
B
GND
A
5V
Chassis harness
ZX225-1105013
Fig. 7-26 7-40
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E332 Motor built-in potentiometer irregular
Failure code
The potentiometer built in the motor is irregular. It returns to auto deceleration when time point is detected.
Failure symptom
E332
Controller reaction
When machine power is on, throttle position feedback has a voltage other than 0.25-4.75V lasting more 50 msec. Returns to auto deceleration.
Symptom on machine
The throttle fails to increase engine speed.
Failure description
Standard values and troubleshooting references
Failure of 5V power source
Ɣ Turn the start switch to the OFF position and then keep it in the ON position to perform troubleshooting.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Causes 1
2
3
Between CN-155M ķ and Ļ
Volt
About 5V
Ɣ Turn the start switch to the OFF position before troubleshooting. Kee the Open circuit switch in the OFF position to perform troubleshooting. of signal Between CN-155M ĸ and the controller port pin 7 Under 1ȍ line Resistance Between CN-155M Ļ and ground Under 1ȍ
Short cuit of Ɣ Turn the start switch to the OFF position before troubleshooting. Kee the switch in the OFF position to perform troubleshooting. signal line (grounded) Between CN-155M ĸ and ground Resistance Above 2Mȍ 司
公
销 营
Controller CN-142M Throttle position feedback
CN-502
CN-113
7
GND
16
Sensor 5V
25
507#
00A# 50A#
6
6
4
4
3
3
507#
00A# 50A#
7
7
4
4
6
6
Operator station
CN-155M
507#
00A# 50A#
2
2
5
5
1
1
507#
00A# 50A#
Throttle position Throttle position GND
5V
Chassis harness ZX225-1105045
Fig. 7-27
Shop Manual - April 2014
7-41
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E434 Front pump proportional solenoid current abnormal (A) Failure code
Front pump proportional solenoid current is abnormal. The system operates slowly.
Failure symptom
E434
Abnormality occurs in loaded circuit of proportional solenoid. Current which is above 1.3A lasts for 3 second. Differential current occurs in drive protection loop. Stop the solenoid when failure is detected. Power supply must be restored.
Failure description Controller reaction
Symptom on machine System operates slowly.
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
1
Open circuit of harness
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-111F ķ and pin 28 of controller Between CN-111F ĸ and ground
Short circuit 2 of harness (grounded)
Under 1ȍ
Resistance
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-111F ķ and wire 0#
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Failure of proKeep it in the OFF position while troubleshooting is performed. 3 portional valve Unplug the connector CN-111F, and measure the coil Resistance 17.5ȍ resistance between solenoid valve's ķ and ĸ 司
公
销 营
4
No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of troller this failure.)
5
Controller
CN-150F
Front pump SV signal output port GND
702#
28
0#
3
Operator station
Front pump SV
1
Signal
2
GND
Chassis harness
ZX225-1105014
Fig. 7-28
7-42
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E435 Rear pump proportional solenoid current abnormal (A)
Failure code
Rear pump proportional solenoid current is abnormal. The system operates slowly.
Failure symptom
E435
Abnormality occurs in loaded circuit of proportional solenoid. Current which is above 1.3A lasts for 3 second. Differential current occurs in drive protection loop. Stop the solenoid when failure is detected. Power supply must be restored.
Failure description Controller reaction
Symptom on machine System operates slowly.
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
1
Open circuit of harness
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-113F ķ and pin 17 of controller Between CN-113F ĸ and ground
2
Short circuit of harness (grounded)
Under 1ȍ
Resistance
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-113F ķ and wire 0#
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Failure of proKeep it in the OFF position while troubleshooting is performed. 3 portional valve Unplug the connector CN-113F, and measure the coil Resistance 17.5ȍ resistance between solenoid valve's ķ and ĸ . 司
公
销 营
4
No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of troller this failure.)
5
Controller
CN-151F
Rear pump SV signal output port GND
17
3
Operator station
703#
0#
Rear pump SV
1
Signal
2
GND
Chassis harness
ZX225-1105015
Fig. 7-29 Shop Manual - April 2014
7-43
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E436 Front pump proportional solenoid current abnormal (B) Failure code
Front pump proportional solenoid current is abnormal. The system operates slowly.
Failure symptom
E436
Abnormality occurs in loaded circuit of proportional solenoid. Current which is under 0.2 A lasts for 3 seconds and PWM output is greater than 10V. Stop the solenoid when failure is detected. Power supply must be restored.
Failure description Controller reaction
Symptom on machine System operates slowly.
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
1
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of Between CN-150F ķ and pin 28 of controller harness Between CN-150F ĸ and ground
2
Short circuit of harness (grounded)
Resistance
Under 1ȍ
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-150F ķ and wire 0#
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Failure of pro3 portional valve Unplug the connector CN-150F, and measure coil the resistance between solenoid valve's ķ and Resistance 17.5ȍ ĸ. 司
公
销 营
4
No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of troller this failure.)
5
Controller
CN-150F
Front pump SV signal output port GND
702#
28
0#
3
Operator station
Front pump SV
1
Signal
2
GND
Chassis harness
ZX225-1105014
Fig. 7-30
7-44
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E437 Rear pump proportional solenoid current abnormal (B)
Failure code
Rear pump proportional solenoid current is abnormal. The system operates slowly.
Failure symptom
E437
Abnormality occurs in loaded circuit of proportional solenoid. Current which is under 0.2 A lasts for 3 seconds and PWM output is greater than 10V. Stop the solenoid when failure is detected. Power supply must be restored.
Failure description Controller reaction
Symptom on machine System operates slowly.
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
1
Open circuit of harness
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-151F ķ and pin 17of controller Between CN-151F ĸ and ground
2
Short circuit of harness (grounded)
Resistance
Under 1ȍ Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-151F ķ and wire 0#
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Failure of pro3 portional valve Unplug the connector CN-151F, and measure coil the resistance between solenoid valve's ķ and Resistance 17.5ȍ ĸ 司
公
销 营
4
No troubleshooting can be done for failure occurs in the inner of controller. Failure of con(Except for the above reasons, the controller must be replaced in case of troller this failure.)
5
Controller
CN-151F
Rear pump SV signal output port GND
17
3
Operator station
703#
0#
Rear pump SV
1
Signal
2
GND
Chassis harness
ZX225-1105015
Fig. 7-31
Shop Manual - April 2014
7-45
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E543 Engine speed abnormal Failure code
Failure symptom
E543
Engine speed is abnormal. Only alarm output is effective.
Failure description
CPU detects out that engine speed is too low (below 100 rpm). Only alarm output is effective. The alarm resets automatically when conditions Controller reaction become normal. Symptom on machine ——
Cause Normal condition
Code 43 will be displayed on the monitor when the engine start switch is turned from the OFF position to the ON position.
In Ma t rk er n et a in ti o g n De al pt . 1
Possible causes and standard values
Standard values and troubleshooting references
2
Open circuit of harness
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-125M ķ and pin 16 of controller Between CN-125M ĸ and pin 6 of controller
3
Short circuit of harness (grounded)
Under 1ȍ
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-125M ķ and ground 司
公
销 营
4
Resistance
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Failure of sensor Unplug the connector CN-125M, and measure the resistance between ķ and ĸ of the speed Resistance 2.3 r 0.2k : sensor.
5
Controller
CN-125M
Engine speed collection
16
GND
6
108A
108B
Operator station
Engine speed sensor
1
Signal
2
GND
Chassis harness
ZX225-1105017
Fig. 7-32
7-46
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E244 Fuel control dial setting voltage abnormal Failure code E544
Fuel control dial setting voltage is abnormal and engine returns auto deceleration.
Failure symptom
Failure description
When power is on, voltage of fuel control dial other than 0.25-4.75V lasts for over 200 msec.
Controller reaction
Throttle is moved to idle position.
Symptom on machine
Engine returns auto deceleration.
Causes 1
Possible causes and standard values
Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the ON position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
5V power failure
Standard values and troubleshooting references
2
3
CN-501F Ľ and Ŀ
Volt
About 5V
Open circuit Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of signal line CN-501F ľ and controller pin19 Resistance Under 1ȍ Short cir- Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the cuit of OFF position while troubleshooting is performed. signal line CN-501F ľ and ground Resistance Above 2Mȍ (grounded) 司
公
销 营
4
5
Short circuit Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the ON position while troubleshooting is performed. of signal line (contact with CN-501F ľ and ground Volt Under 5V power supply) Dial failure
Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Unplug connector CN-501F and measure fuel conResistance trol dial Ľ and Ŀ .
CN-7-113M
CN-209F
Sensor 5V
25
3
3
3
3
GND
16
4
4
9
9
Fuel control dial setting voltage
19
5
5
2
2
5K±15%ȍ
CN-501F
50# 506# 0#
7
7
9
9
8
8
Yellow Red Blue
Fuel control dial
Operator station
ZX225-1105018
Fig. 7-33 Shop Manual - April 2014
7-47
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E145 CAN bus abnormal Failure code
Failure symptom
E145
Abnormality of CAN bus activates alarm.
Failure description
Time-out of CAN bus communication lasts for over 3s.
Controller reaction
Only alarm output is effective.
Symptom on machine
----
1
Standard values and troubleshooting references
CAN resistance failure
Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Causes
Between CN-7-709 A and B
Resistance
60ȍ
Between CN-185 A and B
Resistance
60ȍ
Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
2
Open circuit Unplug controller connector and measure pin of Harness 12 and CN-7-112 A. Unplug controller connector and measure pin 11 and CN-7-112 B.
Under 1ȍ
Resistance
Under 1ȍ
ControlNo troubleshooting can be done for failure occurs in the inner of controller. (Except ler internal for the above reasons, the controller must be replaced in case of this failure.) failure 司
公
销 营
CN-185M A B
Controller
CANH
12
CANL
11
F11 15A
F13 10A
CN-7-709M A
120 ohms
CN-7-112F A B
CN222F 4
7 CN-221M
CN-7-113M 1
2 9
120 ohms
B
CANH
CANL 42
35 12
5 43 24 0 11 0 31
Monitor
3
21 PWR
Operator station
PWR
Chassis harness ZX335-1005040
Fi 30 Fig. 77-34 7-48
20
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.5 Troubleshooting Electrical System (E-Mode)
In Ma t rk er n et a in ti o g n De al pt .
E-1 Engine does not crank .......................................................................................... 7-51 E-2 Engine runs rough or is unstable .......................................................................... 7-54 E-3 Power supply of machine cannot be cut off .......................................................... 7-55 E-4 Throttle motor not working .................................................................................... 7-56 E-5 Auto idle not functioning ........................................................................................ 7-57 E-6 Preheat function fails ............................................................................................ 7-59 E-7 All components not working .................................................................................. 7-60 E-8 Boom-up speed or power is low............................................................................ 7-61 E-9 Arm speed or power is low .................................................................................... 7-62 E-10 Bucket speed or power is low ............................................................................. 7-63 E-11 Travel speed or power is low............................................................................... 7-65 E-12 Blank monitor display .......................................................................................... 7-66 E-13 Monitor displays nothing ..................................................................................... 7-67 E-14 Dual speed travel not functioning........................................................................ 7-68 E-15 Incorrect engine coolant reading......................................................................... 7-69 E-16 Incorrect fuel level reading .................................................................................. 7-70 E-17 Wiper does not work ........................................................................................... 7-71 E-18 Incorrect arm-in pilot pressure reading ............................................................... 7-72 E-19 Incorrect arm-out pilot pressure reading ............................................................. 7-73 E-20 Incorrect boom-up pilot pressure reading ........................................................... 7-74 E-21 Incorrect boom-down pilot pressure reading....................................................... 7-75 E-22 Incorrect bucket-dig pilot pressure reading ......................................................... 7-76 E-23 Incorrect bucket-dump pilot pressure reading..................................................... 7-77 E-24 Incorrect swing pilot pressure reading ............................................................... 7-78 E-25 Left travel pilot pressure reading incorrect .......................................................... 7-79 E-26 Right travel pilot pressure reading incorrect ....................................................... 7-80 司
公
销 营
Shop Manual - April 2014
7-49
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Fuse box connection table ● This table gives all power supply units and rated currents of fuse box power supplies. ● If power supply is normal, check the fuse box and fuses when you perform troubleshooting of the electrical system. Information contained in troubleshooting table Failure information Related information
Symptom on machine Failure occurred and troubleshooting information Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Cause
Possible causes and standard values
● Standard value under normal condition can be used to judge possible causes ● Reference for passing the above "Good" or "No Good" judgement
Possible causes of trouble (Given numbers are refer- <Symptom of Wiring Harness Failure> ence numbers, which do not ● Open circuit indicate priority) Faulty contact with connector or open circuit in wiring harness 司
公
销 营
1
● Faulty grounding
An ungrounded wiring is grounded.
● Short circuit
A wiring has mistaken contact with a 24 V electric circuit.
7-50
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-1 Engine does not crank Trouble
Engine cannot be started.
Related information
Cause Low battery capacity
Battery voltage
Voltage
≥ 24V
Internal fail- ★ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. 2 ure of engine OFF position: between wire 22# and wire 11# Resistance ≥ 1M Ω start switch ★ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Failure of pilot Lockout control in unlocked position: between 3 ≤1 Ω switch 105 # and 27# wire Resistance Lockout control in locked position: between wire ≥1M Ω 105 # and wire 27# ★ Turn engine start switch to OFF position. Keep the engine running during troubleshooting. (When all power supplies, grounding, signal and engine inputs are normal except engine output, it is the failure of start motor) 4 Failure of Engine starting motor Start switch Voltage start motor Power supply: Terminal B and ground 20—30V Start Between start motor input terminal S and ground 20—30V ★ Turn engine start switch to OFF position before proceeding. Turn it to the ON position to perform troubleshooting. Open circuit ≤1 Ω Wire 21# and start motor terminal B 5 of harness Wire 12# and start motor terminal S Resistance ≤1 Ω
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
Standard values and troubleshooting references ★ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
司
公
销 营
Start relay terminal L and safety relay terminal S
Shop Manual - April 2014
≤1
Ω
7-51
Troubleshooting
Cause
Standard values and troubleshooting references
Failure of fuse Battery terminal "+" (wire 20#) and control dial F1 wire 22#
Short circuit 7 of harness (grounded)
≤1
Ω
★ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Start relay terminal S and ground ≥1M Start motor input terminal S and ground
Resistance
≥1M
Ω Ω
★ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while Internal failure 8 troubleshooting is performed. of alternator Alternator terminal R and ground Voltage ≤ 1.5V 9 Start relay
10
★ Turn engine start switch to OFF position. Move it to ON position when performing troubleshooting. Between relay coils ≥ 300 Ω Resistance Between start relay terminal B and line 11# ≤1 Ω ★ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Check parking relay — Resistance Measure resistance of motor coil. Approx 63 Ω
Failure of parking unit
司
公
销 营
7-52
Resistance
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
6
SY365(B)H-9 Crawler Hydraulic Excavator
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
21
16 F13-160A 14
TERMINAL B BR ACC R1 R2 C HEAT OFF ON START S0 22 62 61 11
Start switch
897044-4180
61 66
1 3
4
2
6
0
1
4
3
17 GR-1 GLOW PLUG
Preheat relay
68 69 HL2
5
Low-temp switch
2
PReheat indicator
13
3
6 5
1
2
64 65
A
63
P2
E3
k7
P1
B E
0
Parking relay
HLR
Charging indicator
Parking motor
G
22
In Ma t rk er n et a in ti o g n De al pt .
14
14
P600G
F1-20A
F2-10A
B1
B2
Safety relay
+
-
+
11
k1
Battery relay
0
L
B
E
11a
11b
R
S
12 60
E
620
k3
Lockout relay
27
BAT-1 Battery
司
公
销 营
F7-10A
0
k3 Start relay
0
k11
606
60
Engine
M1
B
C
-
R
E2
21
20
R0
Preheater
Preheat controller
S
0
B
M E
Start motor
0
0
105
SQ1 Pilot switch
D-1 15 15a
22
D-10
0
K4 Pilot valve relay
0
VA7
Pilot solenoid valve
0
k-8 Shutdown relay
ZX225-1105020
Fig. 7-35
Shop Manual - April 2014
7-53
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-2 Engine runs rough or is unstable
Failure information
Engine Runs Rough or Is Unstable
Related information
Engine speed can be read on the monitor.
Standard values and troubleshooting references
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Open circuit of 1 harness Unplug the connector controller, and measure Resistance 2.3±0.2 Kȍ the resistance between pin 16 and pin 7. 2
Internal failure in sensor
Between CN-125M A and B
Resistance
2.3±0.2 Kȍ
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. of harness (grounded) Between CN-125M A and ground Resistance Above 1Mȍ
3
4
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
Internal failure No troubleshooting can be done due to internal failure. (Failure lies in the controller if the reasons above are ruled out) of controller 司
公
销 营
5
Controller
HCU_J1
RPM sensor input signal
GND
CN-125M （S-2）
RPM sensor
16
A
Signal
7
B
GND
Operator station
Chassis harness
ZX225-1105021
Fig. 7-36
7-54
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-3 Power supply of machine cannot be cut off Failure information
Engine cannot be stopped. Engine stalls when start switch it turned to OFF position. There is no time delay for power cutout.
Cause
Standard values and troubleshooting references
Failure of battery When the engine start switch is operated, if the operation of battery relay conrelay tact is heard, the battery is normal. Turn the start switch OFFĺONĺOFF.
1
Breakdown of surge diode
2
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between battery relay wire 20# and wire 21#
Resistance Above 1Mȍ
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
3
21
16
F13-160A 14
TERMINAL B BR ACC R1 R2 C HEAT OFF ON START S0 22 62 61 11
Start switch
897044-4180
61 66
司
公
销 营
1
3
4
2
6
0
1
4
3
17
GR-1 GLOW PLUG
Preheat relay
68 69 HL2
5
Low-temp switch
2
PReheat indicator
13
3
6 5
1
2
64 65
A
63
P2
E3
k7
P1
B
E
0
Parking relay
HLR
Charging indicator
Parking motor
G
22
F2-10A
B2
Safety relay B
C
-
+
-
+
11
k1 Battery relay
0
R
L
B
E
E2
21
20
B1
14
14
P600G
F1-20A
11a
11b
R
S
k3
Lockout relay
27
BAT-1 Battery
F7-10A
0
k3 Start relay
0
S
0
B
M E
Start motor
0
k11 606
60
Engine
M1
12 60
E
620
R0
Preheater
Preheat controller
0
105
SQ1 Pilot switch
D-1 15 15a
22
D-10
0
K4 Pilot valve relay
0
VA7 Pilot solenoid valve
0
k-8 Shutdown relay
ZX225-1105020
Fig. 7-37 Shop Manual - April 2014
7-55
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-4 Throttle motor not working Failure information Related information
Standard values and troubleshooting references
Preheat Ɣ Turn he start switch to the ON position and keep it in the ON position while troubleshooting is performed. 1 fuse failure. The monitor shows failure code 41. Coolant temperature and oil level are normal. Ɣ Turn he start switch to the ON position and keep it in the ON position while troubleSensor shooting is performed. 2 power Measure the voltage between motor plug, 50# wire abnormal Volt 5.0V and ground.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Causes
Engine speed does not increase or decrease. Turn the fuel control dial but engine speed does not change.
Unplug the connector of the harness between throttle motor and chassis.
3
Throttle motor failure
Measure the resistance between the blue and red wires. Measure the resistance between the yellow and green wires. 司
7-56
Resistance
5kȍ ± 10%
Throttle Ɣ Turn he start switch to the ON position and keep it in the ON position while troubleshooting is performed. motor failure The monitor shows failure codes 41, 12, 13, 14 and 32. 公
4
8~15ȍ
销 营
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-5 Auto idle not functioning Failure information Related information
Cause
1
Auto idle speed do not work Engine speed do not decrease wen the mode is auto idle speed and grip keeps still in NEUTRAL position
Standard values and troubleshooting references Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
Error of boomLevers in NEUTRAL, pressure signal transmitted up signal
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Lever in operation, pressure signal transmitted
Pressure
2
0-39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
Error of boomLevers in NEUTRAL, pressure signal transmitted down signal Lever in operation, pressure signal transmitted
3
0 KG
Pressure
0 KG 0-39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
Error of arm-in Levers in NEUTRAL, pressure signal transmitted signal Lever in operation, pressure signal transmitted
Pressure
0 KG 0-39 KG
司
公
销 营
4
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
Error of arm-out Levers in NEUTRAL, pressure signal transmitted signal Lever in operation, pressure signal transmitted
5
Pressure
0 KG 0-39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
Error of bucketLevers in NEUTRAL, pressure signal transmitted dig signal Lever in operation, pressure signal transmitted
Shop Manual - April 2014
Pressure
0 KG 0-39 KG
7-57
Troubleshooting
Cause
SY365(B)H-9 Crawler Hydraulic Excavator
Standard values and troubleshooting references Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
6
Error of Bucketdump signal
Levers in NEUTRAL, pressure signal transmitted
Pressure 0-39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. 7
Error of swing signal
Levers in NEUTRAL, pressure signal transmitted Lever in operation, pressure signal transmitted
0 KG Pressure 0-39 KG
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Lever in operation, pressure signal transmitted
0 KG
Ɣ urn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
8
Error of travel signal
Levers in NEUTRAL, pressure signal transmitted Lever in operation, pressure signal transmitted
0 KG
Pressure
0-39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. 司
9
Error of attachment signal
公
Levers in NEUTRAL, pressure signal transmitted 销 营
Lever in operation, pressure signal transmitted
10
7-58
0 KG
Pressure
0-39 KG
Failure of con- No troubleshooting can be done for it is internal failure. (If it is not caused troller by one of the factors listed above, it should be the failure of controller.)
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-6 Preheat function fails
Failure information
Engine does not preheat.
Related information
Cause
Standard values and troubleshooting references
2
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between wire 21# and preheat relay wire 16#
Resistance Under 1ȍ
When the preheat function is activated, if operation of the preheat relay contact is heard, the relay is normal. The start switch is to be switched HEATĺOFFĺHEAT.
Failure of preheat relay
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Failure of pre1 heat fuse
3
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep of harness it in the OFF position while troubleshooting is performed. (grounded) Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Between preheat controller pin 3# and start switch wire 61#
Failure of preBetween preheat controller pin 4# and preheat relay heat controlwire 68# ler Between preheat controller pin 1# and preheat relay wire 14#
Under 1ȍ
司
公
销 营
4
Between preheat controller pin 2# and low temp switch wire 66#
TERMINAL B BR ACC R1 R2 C HEAT OFF ON START
S0 Start switch 22 62 13
21n4-10430
61 11
21
16
F13-160A 14
61
66
Low temp SW
0
13
1
3
2
1
4
3
4
2
5
Under 1ȍ Under 1ȍ
GR-1 GLOW PLUG
P600G Preheater R0
20
Preheat indicator
Preheat controller
-
+
BAT-1
14 11
17
Preheat relay
68 6 69 HL2
Under 1ȍ
Resistance
F2-10A
-
21
+
Battery
k1 Batt. relay
F1-20A
0
20
Control switch harness
Cab harness
Chassis harness ZX225-1005039
Fig. 7-38
Shop Manual - April 2014
7-59
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-7 All components not working
Failure information
The machine is motionless while operated after starting.
Related information Cause
Standard values and troubleshooting references
Possible causes and standard values
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Failure of lockout switch
Item
Lockout control lever
Resistance
LOCK
Between wire 105# and wire 27#
Under 1ȍ
In Ma t rk er n et a in ti o g n De al pt .
1
2
3
Short circuit of wire (grounded) Failure of coil inside lockout solenoid valve
Between 105# and ground
Resistance
Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-136F 1 and 2
Resistance
About 34ȍ
司
公
销 营
0
Pilot switch
Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
4
105
FREE
CN-201F
CN-205F (D-12)
1
4
2
10
1
2
3
4
5
1
2
3
4
5
105 27
CN-302M CN-136F (D-12) (AMP-2) 606 1 606 1
0
8
0
2
27 +24V Cab harness
Chassis harness
ZX225-1005040
Fig. 7-39
7-60
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-8 Boom-up speed or power is low
Failure information
Boom-up speed or power is low. Pilot pressure of the boom in operation can be checked on the monitor.
Related information
1
Standard values and troubleshooting references
Failure of sensor
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Levers in NEUTRAL, boom-up pressure signal Lever in operation, boom-up pressure signal
2
Short circuit of harness (grounded)
Open circuit of 3 harness
4
Failure of controller
GND
5V PWR
0-39 KG
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between harness ( from controller pin 8 to CN126M A) and ground
Resistance
Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between controller pin 11 and CN-126M B
Resistance Under 1ȍ
No troubleshooting can be done due to internal failure. (Failure lies in the controller if the reasons above are ruled out) 司
公
销 营
Boom-up pilot press. sensor
Controller
Boom-up pilot pressure signal collecting port
0 KG
Pressure
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
8
206# 00#
11
12
50#
CN-126M C
Signal
B
GND
A
5V
Operator station
Chassis harness
ZX225-1105009
Fig. 7-40
Shop Manual - April 2014
7-61
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-9 Arm speed or power is low Failure information
Arm speed or power is low during operation. Pilot pressure of the arm in operation can be checked on the monitor.
Related information
1
Failure of sensor
Standard values and troubleshooting references Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. Levers in NEUTRAL, arm-in and arm-out pressure signals
0 KG
Pressure
Levers in operation, arm-in and dump pressure signal
0-39 KG
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
2
3
Short circuit of harness Between harness (from controller pin 35 to CN129M A) and ground (grounded) Between harness (from controller pin 22 to CN122M A) and ground
Resistance
Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Open circuit of harness Between controller pin 11 and CN-129M B Resistance Under 1ȍ Between controller pin 11 and CN-122M B 司
公
销 营
4
Failure of controller
No troubleshooting can be done due to internal failure. (Failure lies in the controller if the reasons above are ruled out) CN-122M （DF-3）
Arm out press. sensor
A
Signal
B
GND
C
5V
Controller
Arm out press. sensor
Arm in press. sensor
22
CN-129M （DF-3）
Arm in press. sensor
35
A
Signal
Sensor GND
11
B
GND
Sensor 5V
12
C
5V
Operator Station
Chassis harness
ZX225-1105022
Fig. 7-41 7-62
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-10 Bucket speed or power is low Failure information Related information
Cause
Bucket speed or power is low during operation. Pilot pressure of the bucket can be checked on the monitor.
Standard values and troubleshooting references Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.
Failure of sen- Levers in NEUTRAL, bucket-dig/dump pressure sor signals Levers in operation, bucket-dig/dump pressure signals
0 KG Pressure
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
2
3
Short circuit of harness (grounded)
Open circuit of harness
0-39 KG
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Between harness (from controller pin 10 to CN124M A) and ground Between harness (from controller pin 33 to CN128M A) and ground
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. 司
公
销 营
Between controller pin 11 and CN-124M B Between controller pin 11 and CN-128M B
Resistance Under 1ȍ
4
Defective buck- Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. et conÀuence solenoid valve Between CN-134F 1 and 2 Resistance About 34ȍ
5
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the troller controller if the reasons above are ruled out)
Shop Manual - April 2014
7-63
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
CN-128M （DF-3）
Bucket dump press. sensor
A
Signal
B
GND
C
5V
Controller
Bucket dump press. sensor
33
CN-124M （DF-3）
Bucket dig press. sensor
10
A
Signal
Sensor GND
11
B
GND
Sensor 5V
12
C
5V
Bucket confluence signal
27
In Ma t rk er n et a in ti o g n De al pt .
Bucket dig press. sensor
CN-134F （AMP-2）
Bucket confluence Proportional valve
1
Signal
2
GND
司
公
销 营
Chassis harness
Operator Station
ZX225-1105023
Fig. 7-42
7-64
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-11 Travel speed or power is low Failure information Related information
Cause
Travel speed or power is low during operation. Pilot pressure of travel operation can be checked on the monitor. Standard values and troubleshooting references
Possible causes and standard values
Ɣ Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting. 1
Failure of sen- Levers in NEUTRAL, left and right travel pressure sor signals
In Ma t rk er n et a in ti o g n De al pt .
Levers in operation, left and right travel pressure signals
0 KG Pressure
2
Short circuit of harness (grounded)
0-39 KG
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between harness (from controller pin 34 to CN120M A) and ground Between harness (from controller pin 30 to CN121M A) and ground
Resistance
Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Open circuit of 3 harness Between controller pin 11 and CN-120M B Resistance Under 1ȍ Between controller pin 11 and CN-121M B 司
公
销 营
4
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the troller controller if the reasons above are ruled out) CN-121M （DF-3）
R. travel press. sensor
A
Signal
B
GND
C
5V
Controller
HCU_J2
R. travel press. sensor
30
CN-120M （DF-3）
L. travel press. sensor
34
A
Signal
Sensor grounding wire
11
B
GND
Sensor 5V
12
C
5V
L. travel press. sensor
HCU_J1 Operator station
Chassis harness
Fig. 7-39
ZX225-1105024
Fig. 7-43 Shop Manual - April 2014
7-65
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-12 Blank monitor display Failure information
Monitor display is blank after the machine is powered on.
Related information Standard values and troubleshooting references
1 Failure of fuse
Ɣ Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Between wire 42# and ground
About 24V
Voltage
Between wire 43# and ground
About 24V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
2
Open circuit of harness
Between CN-7-113M pin 1 and CN-222F pin 4 Between CN-7-113M pin 2 and CN-222F pin 7
Under 1ȍ
Resistance
Under 1ȍ
Between CN-7-113M pin 9# and ground
3
4
Short circuit of harness (grounded)
Failure of monitor
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between harness (from CN-7-113M pin 1 to CN222F pin 4 and ground 司
公
销 营
Between harness (from CN-7-113M pin 2 to CN222F pin 7 and ground
Above 1Mȍ
Resistance
Above 1Mȍ
No troubleshooting can be done for it is internal failure. (If it is not caused by one of the factors listed above, it should be the failure of monitor.)
CN-7-709M
CN-185M A
A
120 ohms
Controller
Under 1ȍ
120 ohms
B
B
HCU-J2
CN-7-112F
12
A
CANL
11
B
F11 15A
F13 10A
4
7
CN-222F
CN-221M
CN-7-113M 1
2
9
CANH CANL
42
43
35 12
5
24
Monitor
CANH
0
11 0 31
21
PWR Operator station
20
PWR
Chassis harness
ZX335-1005050
Fig. 7-44 7-66
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-13 Monitor displays nothing Display of monitor is illuminated but no information is shown on the screen after machine is powered on.
Failure information Related information Cause Failure of resistance
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-1-185M A and B
Resistance
2
120 ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of harness Between CN-7-112F pin A and controller pin 12
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
Standard values and troubleshooting references
Between CN-7-112F pin B and controller pin 11
Resistance
Under 1ȍ Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
3
Short circuit Between harness (from CN-7-112F pin A to conof harness troller pin 12) and ground (grounded) Between harness (from CN-7-112F pin B to controller pin 11 and ground
Above 1Mȍ
Resistance
Above 1Mȍ
司
公
4
Failure of monitor or controller
销 营
No troubleshooting can be done for it is internal failure. (If it is not one of the failures stated above, it should be the failure of monitor or controller.)
CN-7-709M
CN-185M A
A
120 ohms
Controller
HCU-J2
120 ohms
B
B
CN-7-112F
12
A
CANL
11
B
F11 15A
F13 10A
4
7
CN-222F
CN-221M
CN-7-113M 1
2
9
CANH CANL
42
43
35 12
5
24
Monitor
CANH
0
11 0 31
21
PWR Operator station
20
PWR
Chassis harness
ZX335-1005050
Fig. 7-45 Shop Manual - April 2014
7-67
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-14 Dual speed travel not functioning Failure information
Only low speed travel is functioning during operation.
Related information
Press the Hi/Lo button on the monitor to change travel speed.
Possible causes and standard values
Cause
Failure of dual Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. speed travel solenoid valve Between CN-131F A and B Resistance About 34ȍ Open circuit of harness
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
1
Standard values and troubleshooting references
2
Between CN-131F pin A and controller pin 7
Between CN-131F pin B and controller pin 3
3
Resistance
Under 1ȍ
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Short circuit Keep it in the OFF position while troubleshooting is performed. of harness Between harness (from CN-131F pin A to con(grounded) Resistance Above 1Mȍ troller pin 7) and ground
4
司
公
销 营
Controller
CN-131F （AMP-2）
High speed travel solenoid valve
GND
High speed travel solenoid valve
7
A
Signal
3
B
GND
Operator Station
Chassis harness
ZX225-1105025
Fig. 7-46
7-68
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-15 Incorrect engine coolant reading Engine coolant temperature sensor cannot correctly reÀect current coolant temperature. Coolant temperature can be checked on the monitor.
Failure information Related information
Cause
Standard values and troubleshooting references
Possible causes and standard values
Standard values for engine coolant temperature sensor 50ć
130ȍ
80ć
48.5±4.2ȍ
100ć
26.7±2.5ȍ
In Ma t rk er n et a in ti o g n De al pt .
1
Failure of coolant temperature sensor
110ć
2
3
4
Open circuit of lead
Short circuit of lead (grounded) Lead short to 24V circuit
20ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between wire 510# and controller pin 32
Resistance
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between wire 510# and ground
Resistance Above 1Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the ON position while troubleshooting is performed. 司
公
销 营
Wire 510# to ground
Voltage
Under 1V
Controller
Coolant temperature sensor
510
32
Operator Station
Chassis harness
ZX335-1005053
Fig. 7-47
Shop Manual - April 2014
7-69
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-16 Incorrect fuel level reading Failure information
Engine fuel level sensor cannot correctly reÀect current fuel level.
Related information
Fuel level can be checked on the monitor.
Cause
Standard values and troubleshooting references
Possible causes and standard values
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. 1
Fuel level sensor error
Pin
Resistance
FULL (Upper limit)
Approx. 10 ȍ
EMPTY (Lower limit)
85-95ȍ
In Ma t rk er n et a in ti o g n De al pt .
Between wire 509# and ground
Fuel level
Open circuit of 2 lead
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between wire 509# and controller pin 17
Resistance
Under 1ȍ
3
Short circuit of Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. lead (grounded) Between wire 509# and ground Resistance Above 1Mȍ
4
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Lead short to 24V Wire 509# grounded Voltage Under 1V 司
公
销 营
Controller
Fuel level sensor
17
Operator Station
509
Chassis harness
ZX335-1005054
Fig. 7-48
7-70
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-17 Wiper does not work Failure information
Wiper does not work.
Related information
Cause
Internal Fail- Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. ure of wiper motor Between wiper wire 25# and ground Resistance ˚ 10ȍ
1
Possible causes and standard values
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
2
Between CN-403F 1 and CN-1-110 2 Open circuit of Between wiper switch wire 35L# and lead CN-1-110M 5
Resistance
Between wiper switch wire 35L# and CN-1-110M 4
Under 1ȍ Under 1ȍ Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Short circuit of Keep it in the OFF position while troubleshooting is performed. 3 lead (groundHarness from CN-403F 1 to CN-1-110M ed) Resistance Above 1Mȍ 2 short to ground 司
公
销 营
4
Wiper switch
CN-401F （D-12）
2
F5 5A
25
CN-403M （D-12）
1
CN-204M （D-12）
6
6
7
2
6
7
36
CN-203F （D-12）
35L
35H
12
CN-1-110M （D-6） 2
2
3
3
4
4
5
5
25 36
35L
M
35H
21
PWR
Operator station
ZX225-1005049
Fig. 7-49
Shop Manual - April 2014
7-71
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-18 Incorrect arm-in pilot pressure reading Failure information
Reading of arm-in pilot pressure is incorrect.
Related information
Possible causes and standard values
Cause
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Failure of 5V power supply
1
Between CN-129M ķ and Ĺ
Open circuit of signal line
Voltage
Approx. 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
2
Standard values and troubleshooting references
3
4
Short circuit of signal line
Failure of sensor
Between CN-129M ĸ and controller pin 35
Resistance
Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-129M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-129M ĸ and ground
5
Voltage
0.5V- 4.5V
司
公
销 营
Controller
CN-129M （DF-3）
Arm in pressure sensor
Arm in pressure sensor
35
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator Station
Chassis harness
ZX225-1105026
Fig. 7-50
7-72
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-19 Incorrect arm-out pilot pressure reading
Failure information
Reading of arm-out pilot pressure is incorrect.
Related information
Possible causes and standard values
Cause 1
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Failure of 5V power supply
Between CN-122M ķ and Ĺ
Open circuit of signal line
Voltage
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
2
Standard values and troubleshooting references
3
4
Short circuit of signal line
Failure of sensor
Between CN-122M ĸ and controller pin 22
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-122M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
5
Between CN-122M ĸ and ground
Voltage
0.5V- 4.5V
司
公
销 营
Controller
CN-122M （DF-3）
Arm out pressure sensor
Arm out pressure sensor
22
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator Station
Chassis harness
ZX225-1105027
Fig. 7-51
Shop Manual - April 2014
7-73
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-20 Incorrect boom-up pilot pressure reading Failure information
Incorrect Boom-up Pilot Pressure Reading
Related information Cause
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
1
Possible causes and standard values
Standard values and troubleshooting references
Between CN-126M ķ and Ĺ
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of signal line
In Ma t rk er n et a in ti o g n De al pt .
2
Voltage
3
4
Between CN-126M ĸ and controller pin 8
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Short circuit of signal line
Between CN-126M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position Failure of senwhile troubleshooting is performed. sor Between CN-126M ĸ and ground Voltage 0.5V- 4.5V 司
公
销 营
5
Controller
CN-126M （DF-3）
Boom up pressure sensor
Boom up pressure sensor
8
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator Station
Chassis harness
ZX225-1105028
Fig. 7-52
7-74
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-21 Incorrect boom-down pilot pressure reading Failure information
Boom-down pilot pressure reading is incorrect.
Related information
Cause
Possible causes and standard values
1
Standard values and troubleshooting references Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
Between CN-125M ķ and Ĺ
Voltage
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Open circuit of signal line
In Ma t rk er n et a in ti o g n De al pt . 2
3
4
About 5V
Between CN-125M ĸ and controller pin 9
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
Short circuit of signal line
Between CN-125M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of sensor
Between CN-125M ĸ and ground 司
公
销 营
Voltage
0.5V- 4.5V
5
Controller
CN-125M （DF-3）
Boom down pressure sensor
Boom down pressure sensor
9
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator Station
Chassis harness ZX225-1105029
Fig. 7-53
Shop Manual - April 2014
7-75
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-22 Incorrect bucket-dig pilot pressure reading Failure information
Bucket-dig pilot pressure reading is incorrect.
Related information
Possible causes and standard values
Cause
1
Standard values and troubleshooting references Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
Between CN-124M ķ and Ĺ
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Open circuit of signal line
Voltage
2
3
4
Short circuit of signal line
Failure of sensor
Between CN-124M ĸ and controller pin 10
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-124M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to OFF position. Then, keep it at OFF position to perform troubleshooting. Between CN-124M ĸ and ground
Voltage
0.5V- 4.5V
司
公
销 营
5
Controller
CN-124M （DF-3）
Bucket dig pressure sensor
Bucket dig pressure sensor
10
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator Station
Chassis harness
ZX225-1105030
Fig. 7-54
7-76
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-23 Incorrect bucket-dump pilot pressure reading Failure information
Bucket-dump pilot pressure reading is incorrect.
Related information
1
Standard values and troubleshooting references Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
Between CN-128M ķ and Ĺ 2
Open circuit of signal line
Voltage
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
3
4
Short circuit of signal line
Failure of sensor
Between CN-128M ĸ and controller pin 33
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-128M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-128M ĸ and ground
Voltage
司
0.5V- 4.5V
公
销 营
5
Controller
CN-128M （DF-3）
Bucket dump pressure sensor
Bucket dump pressure sensor
33
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Chassis harness
Operator Station
ZX225-1105031
Fig. 7-55
Shop Manual - April 2014
7-77
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-24 Incorrect swing pilot pressure reading
Failure information
Swing pilot pressure reading is incorrect.
Related information
Cause
Possible causes and standard values
1
Standard values and troubleshooting references Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
Voltage
About 5V
In Ma t rk er n et a in ti o g n De al pt .
Between CN-123M ķ and Ĺ 2
3
4
Open circuit of signal line Short circuit of signal line
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-123M ĸ and controller pin 18
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-123M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position Failure of senwhile troubleshooting is performed. sor Between CN-123M ĸ and ground Voltage 0.5V- 4.5V 司
公
销 营
5
Controller
CN-123M （DF-3）
Swing pilot press. sensor
Swing pilot press. sensor
18
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator station
Chassis harness
ZX225-1105032
Fig. 7-56
7-78
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-25 Left travel pilot pressure reading incorrect
Failure information
Left Travel Pilot Pressure Reading is incorrect.
Related information
Cause
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
1
Possible causes and standard values
Standard values and troubleshooting references
Between CN-120M ķ and Ĺ
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
Open circuit of signal line
Voltage
2
3
4
Short circuit of signal line
Failure of sensor
Between CN-120M ĸ and controller pin 34
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-120M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-120M ĸ and ground
Voltage
司
公
销 营
0.5V- 4.5V
5
Controller
CN-120M （DF-3）
Left travel pilot pressure sensor
Left travel pilot pressure sensor
34
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator Station
Chassis harness
ZX225-1105033
Fig. 7-57
Shop Manual - April 2014
7-79
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
E-26 Right travel pilot pressure reading incorrect Failure information
Right travel pilot pressure reading is incorrect.
Related information
Cause
Possible causes and standard values
1
Standard values and troubleshooting references Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed.
Failure of 5V power supply
Between CN-121M ķ and Ĺ Open circuit of signal line
About 5V
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed.
In Ma t rk er n et a in ti o g n De al pt .
2
Voltage
3
4
Short circuit of signal line
Failure of sensor
Between CN-121M ĸ and controller pin 30
Resistance Under 1ȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in the OFF position while troubleshooting is performed. Between CN-121M ĸ and ground
Resistance Above 2Mȍ
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn the start switch to the ON position and keep it in the ON position while troubleshooting is performed. Between CN-121M ĸ and ground
Voltage
司
0.5V- 4.5V
公
销 营
5
Controller
CN-121M （DF-3）
R. travel pilot press. sensor
R. travel pilot press. sensor
30
2
Signal
Sensor GND
11
3
GND
Sensor 5V
12
1
5V
Operator station
Chassis harness
ZX225-1105034
Fig. 7-58
7-80
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
7.6 Troubleshooting Hydraulic and Mechanical Systems (H-mode)
In Ma t rk er n et a in ti o g n De al pt .
A schematic of hydraulic and mechanical systems ...................................................... 7-82 Information contained in troubleshooting table ............................................................. 7-84 H-1 Work equipment speed slow, or swing and travel speeds slow ............................. 7-85 H-2 Engine speed drops sharply or engine stalls ......................................................... 7-86 H-3 Work equipment, swing, and travel systems do not work ...................................... 7-87 H-4 Abnormal noise in hydraulic pump ......................................................................... 7-88 H-5 Auto deceleration not functioning........................................................................... 7-88 H-6 Boom speed slow .................................................................................................. 7-89 H-7 Arm speed slow ..................................................................................................... 7-90 H-8 Bucket speed slow ................................................................................................. 7-91 H-9 Work equipment cylinders no response in separate operation ............................. 7-92 H-10 Work equipment drifts excessively ...................................................................... 7-93 H-11 Work equipment moves sluggishly ..................................................................... 7-96 H-12 Other work equipment moves while single oil circuit is relieved .......................... 7-96 H-13 Travel speed drops considerably while swinging and travelling .......................... 7-97 H-14 Machine deviates during travel ............................................................................ 7-98 H-15 Travel speed low .................................................................................................. 7-99 H-16 Machine not steered easily or steering power low ............................................. 7-100 H-17 Travel speed cannot be shifted .......................................................................... 7-101 H-18 Travel system fails (only at one side)................................................................. 7-102 H-19 Swing operation fails.......................................................................................... 7-103 H-20 Swing acceleration poor or swing speed low ..................................................... 7-105 H-21 Upper structure overrunning remarkably .......................................................... 7-107 H-22 Large shock produced upon swing stoppage .................................................... 7-108 H-23 High noise produced upon swing stoppage ....................................................... 7-109 H-24 Swing drift excessive ..........................................................................................7-110 司
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Shop Manual - April 2014
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Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
A schematic of hydraulic and mechanical systems This diagram is a simpli¿cation of the diagram of the whole hydraulic system and can be referred to in troubleshooting the hydraulic and mechanical systems.
DIG
DUMP
DOWN
UP
BWD
Boom Bucket
FWD
L. travel R. travel BWD
RIGHT
LEFT
OUT
Swing
R. pilot valve
In Ma t rk er n et a in ti o g n De al pt .
IN
Arm
Travel pilot valve
FWD
L. pilot valve
Pilot valve
16
Boom priority
1
2
3
4
5
6
7
8
9
10 11 12
15
Bucket conflu.
14
Swing priority
Accumulator
13
Travel speed change
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19
17
1 2 3
20
18
Regulator
Regulator Servo
Servo
P1
P2
M
FRONT
REAR
ZX225-1105039
Fig. 7-59 7-82
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
6D Safety valve Suction valve 6X 6 6 Safety & suction valve
Bucket Cylinder
1
11
S&S
Bucket valve
1
2
Arm 2 valve
S&S
Bucket confluence valve
15 regenerS&S Arm S&S ation valve
2
14
12
Arm cylinder
S&S
Standby valve
S&S
Standby actuating element
9
Boom Cylinder
S&S
S&S
9
Boom 2
10
L. travel valve
Su
3
6
Su
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Left travel motor
8
13
Sa
R. travel valve
Sa
Su
Balance valve
Servo
Sa
7
Straight travel vavle
Su
4
Swing valve
Swing motor
Servo
Su
Sa
5
Anti-swing valve
Brake release valve
13
Balance valve
Boom valve
Sa
9
Su
In Ma t rk er n et a in ti o g n De al pt .
Boom retainer valve
10
Standby valve confluence
Anti-swing valve
Arm retainer valve
1
Right travel motor
1 2 3
ZX225-1105040
Fig. 7-60
Shop Manual - April 2014
7-83
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Information contained in troubleshooting table ● The following information is contained in the troubleshooting table and related electric circuit diagrams. Fully understand these information before carrying out troubleshooting. Failure information
Trouble which occurs on the machine
Related information
Information related to detected trouble or troubleshooting
7-84
Standard values and troubleshooting references
1
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
2
3 Possible causes of ● < Description > trouble (Given num● Standard value in normal state, which is used to judge possible 4 bers are reference causes that might be OK or N/G. numbers, which do not indicate priority) ● A reference value is used to determine OK or N/G. 司
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5
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-1 Work equipment speed slow, or swing and travel speeds slow
Failure information Related information
Cause
● Work equipment speed is slow or the travel and swing speeds are slow. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Standard values and troubleshooting references
Defective adjustment or malfunction of main relief valve
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. 1
Control levers Arm IN
Main relief pressure 33~34.3 MPa
{337~350 kg/cm2}
If normal pressure cannot be restored after adjustment, it is possible the failure of main relief valve or internal defect. Check the valve directly.
2
Malfunction of pilot relief valve
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Control levers Pilot control pressure 司
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All levers in NEUTRAL
3.9~4.1 MPa
{40~42 kg/cm2}
3
Malfunction of regulator
The regulator possibly fails. Check the servo mechanism of the regulator.
4
Malfunction of main pump
If the trouble is caused by other factors, it might be the main pump that has performance deterioration, malfunction or internal defect.
Shop Manual - April 2014
7-85
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-2 Engine speed drops sharply or engine stalls Failure information
● Engine speed drops sharply or engine stalls.
Related information
● Information concerned
1 2 3
Failure of injection pump Malfunction of regulator Clogging of oil filter element Carbon buildup at fuel injection nozzle Clogging of air cleaner Abnormal wear of engine
Standard values and troubleshooting references Injection pump may be defective. Check it directly. Regulator may have malfunction. Check its servo mechanism. Oil filter element may be clogged. Check the element directly.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
4 5 6
Carbon built up at fuel injection nozzle. Check it directly. Air cleaner may be clogged. Check it directly.
Engine may be worn abnormally. Check it directly.
7 Failure of oil pump Oil pump may be defective. Check it directly. 司
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7-86
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-3 Work equipment, swing, and travel systems do not work Failure information Related information
Cause
Malfunction of pilot relief solenoid valve
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Pilot lockout control lever Pilot relief pressure LOCKED
0 {0}
Possible causes and standard values
In Ma t rk er n et a in ti o g n De al pt .
1
● Whole work equipment, swing, and travel systems do not work. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
FREE
3.9~4.1 MPa
{40~42 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Failure of relief valve Control lever Pilot relief pressure 2 (pilot pump) 3.9~4.1 MPa All levers in NEUTRAL {40~42 kg/cm2} The main pump may have malfunction or internal defect. Check it by following method. 司
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3
Failure of hydraulic pump
4 Failure of coupling
● Remove the oil pressure measurement plug and start the engine. If oil flows out of the opening, the piston pump is in good condition. Internal failure of the coupling can stop rotation of the pump shaft. Check the coupling. ● Loosen the oil delivery line of the pilot pump. If no oil is seen, it is probably the failure of coupling.
Shop Manual - April 2014
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Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-4 Abnormal noise in hydraulic pump Failure information
● Abnormal noise is produced from the hydraulic pump
Related information
Standard values and troubleshooting references
1
Low level of hydraulic oil
Make a visual check.
2
Inferior hydraulic oil
Hydraulic oil probably contains air. Make a visual check.
Clogging of It is probably the clogging of the vent on top of the hydraulic tank that 3 vent on top of causes negative pressure in the hydraulic tank. Press the release button hydraulic tank of the breather valve to eliminate air. Check again if the noise disappears. Clogging of It is probably the clogging of hydraulic tank strainer that causes negative 4 hydraulic tank pressure in the oil suction line. Make a visual check. strainer
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
―
5
Failure of main pump
The main pump may have internal defect. Check the main pump. 司
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H-5 Auto deceleration not functioning Failure information
Related information
Possible causes and standard values
Cause
7-88
1
Sensor failure
● Auto-deceleration is not functioning. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Standard values and troubleshooting references
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Control levers Pilot valve output pressure NEUTRAL
0 {0}
Operation
3.5~4.1MPa {36~42 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Failure of Control levers Pilot valve output pressure 2 NEUTRAL 0 {0} pilot valve 3.5~4.1MPa Operation {36~42 kg/cm2} Controller 3 Controller may be defective. Check it directly. failure
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-6 Boom speed slow Failure information
● The boom moves slowly.
Related information
● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Cause
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Boom control lever Pilot valve output pressure NEUTRAL
0 {0}
Boom UP Boom DOWN
≥ 3.5MPa {36 kg/cm2}
Possible causes and standard values
In Ma t rk er n et a in ti o g n De al pt .
Malfunction of right 1 pilot valve (boom circuit)
Standard values and troubleshooting references
2 3
Malfunction of boom Spool of boom control valve may have malfunction. Check it directly. control valve (spool) ● Stop the engine before troubleshooting. Perform troubleshooting Press sensor failure while the engine is running at high idle. Check the sensor by replacing it with a new one. Malfunction of boom Retaining valve of boom control valve may have malfunction. Check control valve (retainthe valve directly. ing valve) Malfunction or defective seal of boom The relief valve and makeup valve in boom control valve may have control valve malfunction or defective seal. Check the valves directly. (Relief valve and makeup valve) ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Charge the bucket with a load of approximate 1260 kg. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylFailure of boom inder from the main valve. Measure the displacement of piston for 15 cylinder minutes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure see "Hydraulic Drift of Work Equipment - Test" on page 6-34. 司
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4
5
6
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Shop Manual - April 2014
7-89
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-7 Arm speed slow Failure information Related information
Cause
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Arm control lever Pilot valve output pressure NEUTRAL
0 {0}
In Ma t rk er n et a in ti o g n De al pt .
Malfunction of left 1 pilot valve (arm circuit)
● The arm moves slowly. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Possible causes and standard values
Arm IN or Arm OUT
7-90
≥ 3.5MPa
{36 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. 2 Press sensor failure Check the sensor by replacing it with a new one. Malfunction of arm Spool of arm control valve may have malfunction. Check it directly. control valve (spool) Malfunction of arm Regeneration valve of arm control valve may have malfunction. 4 control valve (reCheck it directly. generation valve) Malfunction or defective seal of arm The relief valve or makeup valve inside the arm control valve may have 5 control valve (Relief malfunction or defective seal. Check the valves directly. valve and makeup valve) ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Cut off the oil passage to the high-pressure side of the cylinder. DisconFailure of arm cylin- nect the cylinder from the main valve. Measure the displacement of piston 6 for 15 minutes after the cylinder becomes stable. If the measured value is der greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure see "Hydraulic Drift of Work Equipment - Test" on page 6-34. 3
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Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-8 Bucket speed slow Failure information Related information
Cause
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Bucket control lever Pilot valve output pressure NEUTRAL
0 {0}
In Ma t rk er n et a in ti o g n De al pt .
Malfunction of right 1 pilot valve (bucket circuit)
● The bucket moves slowly. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Possible causes and standard values
Bucket DIG or Bucket DUMP
≥ 3.5MPa
{36 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. 2 Press sensor failure Check the sensor by replacing it with a new one. Malfunction of 3 bucket control valve Spool of bucket control valve may have malfunction. Check it directly. (spool) Malfunction or defective seal of Relief valve and makeup valve in bucket control valve may have mal4 bucket control valve function or defective seal. Check the valves directly. (relief valve and makeup valve) ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Charge the bucket with a load of approximate 1260 kg. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylFailure of bucket inder from the main valve. Measure the displacement of piston for 15 5 cylinder minutes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure see "Hydraulic Drift of Work Equipment - Test" on page 6-34. 司
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Shop Manual - April 2014
7-91
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-9 Work equipment cylinders no response in separate operation
● Boom cylinder gives no response in separate operation. ● Arm cylinder gives no response in separate operation.
Failure information
● Bucket cylinder gives no response in separate operation. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Related information
7-92
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Work equipment control lever Pilot valve output pressure
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
1
Malfunction of pilot valve
NEUTRAL
DIG or DUMP
0 {0}
≥ 3.5MPa
{36 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. 2 Press sensor failure Check the sensor by replacing it with a new one. 司
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3
Malfunction of conSpool of control valve may have malfunction. Check it directly. trol valve (spool)
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-10 Work equipment drifts excessively Failure information (1) Related information
Failure of boom cylinder
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Charge the bucket with a load of approximate 1260 kg. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylinder from the main valve. Measure the displacement of piston for 15 minutes after the cylinder becomes stable. If the measured value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure see "Hydraulic Drift of Work Equipment - Test" on page 6-34. Boom retaining valve or pilot valve may be worn or sluggish. Check the valves.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
● The boom drifts at excessive speed. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
1
Failure of boom retaining valve Malfunction or defective seal of The relief valve and the makeup valve in the boom control valve may 3 boom control valve have a defective seal. Check the seals. (relief valve and makeup valve) 2
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4
Failure of boom valve spool
Spool of boom valve may be worn excessively. Check the spool.
Shop Manual - April 2014
7-93
Troubleshooting
Failure information (2) Related information
1
2
3
4
7-94
● The arm drifts excessively. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Standard values and troubleshooting references
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Cut off the oil passage to the high-pressure side of the cylinder. Disconnect the cylinder from the main valve. Measure the displacement of pisFailure of arm ton for 15 minutes after the cylinder becomes stable. If the measured cylinder value is greater than 10 mm, it is deemed that cylinder has a defective seal. For more information on the measuring procedure see "Hydraulic Drift of Work Equipment - Test" on page 6-34. Relief valve or makeup valve of the arm control valve may be defective. Malfunction or defective seal of Check the valves directly. arm control valve ★ The performance of seal can be judged by replacing it with another (relief valve and relief valve or makeup valve.(Never replace it with the boom-down makeup valve) relief valve or makeup valve as their pressures are set differently.) Failure of arm Arm retaining valve or pilot valve may be worn or sluggish. Check the retaining valve valves. Failure of arm Arm valve (spool) may be worn excessively. Check it directly. valve (spool)
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
SY365(B)H-9 Crawler Hydraulic Excavator
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Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
Failure information (3)
1
Cause
Standard values and troubleshooting references
Failure of bucket cylinder
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Bucket control levers Leakage from bucket cylinder Bucket-dig relief 20 ml/min Seal of relief valve or makeup valve of bucket control valve may be defective. Check it directly.
Defective seal of bucket control valve ★ The performance of seal can be judged by replacing it with anoth2 (relief valve and er relief valve or makeup valve. (Never replace it with the boommakeup valve) down relief valve or makeup valve as their pressures are set differently. ) Defective seal of Seal of bucket control valve spool may be defective. Check it direct3 bucket control valve ly. (spool)
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
● The bucket drifts excessively. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
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Shop Manual - April 2014
7-95
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-11 Work equipment moves sluggishly ● Work equipment moves sluggishly. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Failure information
Cause
Standard values and troubleshooting references
Malfunction of 1 arm regeneration valve
Regeneration valve of arm may have malfunction. Check it directly.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
Relief valve or makeup valve of control valve may have malfunction. Check it directly.
Malfunction of ● For arm and boom, whether a valve has malfunction can be judged control valve 2 (relief valve and by replacing it with another relief valve or makeup valve. makeup valve) (Never replace it with the boom-down relief valve or makeup valve as their pressures are set differently. )
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H-12 Other work equipment moves while single oil circuit is relieved
Failure information
Possible causes and standard values
Related information
7-96
Cause
1
● Other work equipment moves while single oil circuit of certain work equipment is relieved. ● Set the working mode to S to perform troubleshooting.
Standard values and troubleshooting references
Defective seal Seal of control valve may be defective. Check it directly. of control valve
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-13 Travel speed drops considerably while swinging and travelling Failure information
Cause
Standard values and troubleshooting references
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
● Travel speed drops considerably in swinging plus travelling operation. ● If the travel speed is low in only travelling operation, check first according to H-15.
1
Failure of straight travel valve
The straight travel valve gives no response. Check the spool and the logic oil circuit drain port.
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Shop Manual - April 2014
7-97
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-14 Machine deviates during travel Failure information Related information
● Machine deviates during travel. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Cause
2 Possible causes and standard values
Malfunction of travel pilot valve
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure Forward
3.5~3.9 MPa
In Ma t rk er n et a in ti o g n De al pt .
1
Standard values and troubleshooting references
Malfunction of pilot relief valve
Reverse
{ 36~40 kg/cm2}
Difference occurs between 0.4 MPa {4 kg/cm2} left and right output ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Control lever Control circuit source pressure All levers in NEUTRAL
3.5~3.9 MPa
{ 36~40 kg/cm2}
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3
Failure of regulator
4
Sluggishness of proportional solenoid valve
Check the regulator by swapping the front and back regulators. ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel control lever Proportional valve output pressure Operate both control levers ≤ 0.1 MPa
5 6
7
Sluggishness of travel conCheck the valve spool to see whether it works well. trol valve (spool) Internal leakage of central Check it by swapping the lines. swivel joint ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Malfunction of travel motor Travel control lever Leakage of travel motor Travel relief 27.2 ml/min Final drive may have internal defect. Check it directly.
7-98
8
Failure of final drive
9
Failure of travel pilot pressure sensor
● Internal defect of the final drive can be determined through abnormal noise, abnormal heat, and metal powder or debris contained in the oil drained. Travel control levers Pilot valve output pressure The monitor reads: 3.5~3.9MPa Forward or backward
{ 36~40 kgf/cm2} Output difference between the left and the right Check it by swapping.
Shop Manual - April 2014
0.4 MPa {4 kgf/cm2}
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-15 Travel speed low Failure information Related information
Cause
Malfunction of travel pilot valve
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure 3.5~3.9 MPa { 36~40 kg/cm2}
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
● Machine travel speed is low. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
2
Malfunction of pilot relief valve
Forward or reverse
Difference occurs between front ≤ 0.4 MPa output and rear output ≤ {4 kg/cm2} ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Control lever Control circuit source pressure All levers in NEUTRAL 司
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3.5~3.9 MPa { 36~40 kg/cm2}
销 营
3
4 5
6
7
Sensor failure
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel speed Travel control 3.5~3.9 MPa Low Operation { 36~40 kgf/cm2} 3.5~3.9 MPa High Operation { 36~40 kgf/cm2} Check it by replacement.
Malfunction of travel Spool of travel control valve may have malfunction. Check it directly. control valve (spool) Malfunction of The makeup valve in travel control valve may have malfunction. Check it travel control valve directly. (makeup valve) ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Failure of travel moTravel control lever Oil leakage of travel motor tor
Travel relief 27.2 ml/min Final drive may have internal defect. Check it directly. ● Internal defect of the final drive can be determined through abnormal Failure of final drive noise, abnormal heat, and metal powder or debris contained in the oil drained.
Shop Manual - April 2014
7-99
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-16 Machine not steered easily or steering power low ● Machine is not steered well or steering power is low ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Failure information Related information
Cause
7-100
Malfunction of travel pilot valve
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure Both sides in NEUTRAL
0 {0} 3.5~3.9 MPa Either side operated { 36~40 kg/cm2} ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure Failure of travel pilot 3.5~3.9 MPa 2 Both sides operated pressure sensor { 36~40 kgf/cm2} 3.5~3.9 MPa Either side operated { 36~40 kg/cm2}
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
Standard values and troubleshooting references
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3
Malfunction of travel control valve (spool)
Spool of travel control valve may have malfunction. Check it directly.
Malfunction of travel The makeup valve in travel control valve may have malfunction. 4 control valve (makeup Check it directly. valve) Seal of relief valve in travel motor may be defective. Check it diFailure of travel motor rectly. 5 (relief valve) ● The failure of seal can be determined by swapping the front and back motors or the left and right motors. Seal of check valve in travel motor may be defective. Check it diFailure of travel motor rectly. 6 (check valve) ● The failure of seal can be determined by swapping the front and back motors or the left and right motors.
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-17 Travel speed cannot be shifted Failure information
Cause
Standard values and troubleshooting references
Malfunction of travel 1 speed shifting solenoid valve
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Solenoid valve output Travel speed Travel control lever pressure Lo Operated 0 {0}
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
● Travel speed cannot be shifted. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Hi
2
Operated
3.5~3.9 MPa
{ 36~40 kg/cm2}
Failure of travel mo- Speed shifting assembly of travel motor may have malfunction. tor (in speed change) Check it directly.
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Shop Manual - April 2014
7-101
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-18 Travel system fails (only at one side) ● One side of the tracks cannot make a turn. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Failure information Related information
7-102
Standard values and troubleshooting references
Defective seat of 1 travel control valve (makeup valve) Defective seat of 2 travel motor (relief valve) Defective seat of 3 travel motor valve (makeup valve)
Seat of makeup valve in travel control valve may have malfunction. Check it directly. Seat of relief valve in travel control valve may have malfunction.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
Check it directly.
Seat of check valve in travel motor valve may have malfunction. Check it directly.
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Speed of travel mo4 Travel control lever Leakage from travel motor tor drops. Travel relief 27.2 ml/min Final drive may have internal defect. Check it directly. 司
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● Internal defect of final drive can be determined with abnormal noise, overheat, and metal powder or debris contained in the oil drained. ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Travel control lever Pilot valve output pressure The monitor read: 3.5~3.9 MPa Failure of pilot presForward or backward 6 sure sensor { 36~40 kgf/cm2} Output difference between the left 0.4 MPa {4 kgf/cm2} and the right Check it by swapping. 5 Failure of final drive
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-19 Swing operation fails Failure information (1) Related information
Cause
Standard values and troubleshooting references
Malfunction of swing motor (park- Parking brake of swing motor may have malfunction. Check it directly. ing brake) ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
1
● Upper structure fails to swing in either direction. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
2
Swing control lever Swing relief pressure Improper adjustment or malfunc25.5~28.5 MPa Swing relief tion of swing motor {260~291 kg/cm2} (relief valve) If oil pressure does not become normal after adjustment, swing motor relief valve may have malfunction or internal defect. Check the relief valve directly. ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Failure of swing Swing control lever Leakage from swing motor motor 司
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3
Swing relief ≥ 10 ml/min Swing mechanism may have internal defect. Check it directly.
4
Failure of swing mechanism
● Internal defect of swing mechanism can be determined with abnormal noise, overheat, and metal powder or debris contained in the oil drained.
Shop Manual - April 2014
7-103
Troubleshooting
Trouble (2)
Cause
● Upper structure only fails to swing in one direction. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle.
1
Malfunction of pilot valve
Malfunction of 2 swing control valve (spool) Defective seal 3 of swing motor (makeup valve)
Left control lever
Pilot valve output pressure
NEUTRAL
0 {0}
Swing
≥ 3.5MPa { ≥ 36 kg/cm2}
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
SY365(B)H-9 Crawler Hydraulic Excavator
Spool of swing control valve may have malfunction. Check it directly. Seal of makeup valve in swing motor may have defect. Check it directly. ● Failure of the seal can be determined by swapping the right and left makeup valves and check for any changes.
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7-104
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-20 Swing acceleration poor or swing speed low Failure information (1) Related information
Standard values and troubleshooting references
Malfunction of 1 swing motor (park- Parking brake of swing motor may have malfunction. Check it directly. ing brake) ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Swing control lever Swing relief valve Improper adjust-
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
● Swing acceleration is poor, or swing speed is low. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
ment or malfunc25.5~28.5 MPa Swing relief tion of swing motor {260~291 kg/cm2} (relief valve) If oil pressure does not become normal after adjustment, swing motor relief valve may have malfunction or internal defect. Check the relief valve directly. ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Failure of swing 3 Swing control lever Leakage from swing motor motor 2
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Swing relief
4
≤ 10 ml/min
Clogging of brake Disassemble, clean and check. control lines
Shop Manual - April 2014
7-105
Troubleshooting
Failure information (2) Related information
7-106
1
Malfunction of pilot valve
● Swing acceleration is only poor on one side, or swing speed is low. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Swing control lever Pilot valve output pressure NEUTRAL Left swing
0 {0} ≥ 3.5MPa { ≥ 36 kg/cm2}
Right swing Malfunction of swing motor Pressure compensation valve of swing motor may have malfunction. 2 (pressure com- Check it directly. pensation valve) Seal of makeup valve in swing motor may have defect. Check it directly. Defective seal 3 of swing motor ● Swap the left and right makeup valves and observe the result to de(makeup valve) termine whether the seal fails. ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. One-side leakSwing control lever Pilot valve output pressure age of swing pilot 4 pressure sensor NEUTRAL 0 {0} (shuttle valve) Left swing 3.5~3.9MPa {36~40 kg/cm2} Right swing
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
SY365(B)H-9 Crawler Hydraulic Excavator
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Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-21 Upper structure overrunning remarkably
Failure information (1) Related information
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Swing control lever Swing relief pressure
Improper adjustment or malfunc25.5~28.5 MPa 1 Swing relief tion of swing motor {260~291 kg/cm2} (relief valve) If oil pressure does not become normal after adjustment, swing motor relief valve may have malfunction or internal defect. Check the relief valve directly. ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Failure of swing 2 Control lever Leakage from swing motor motor
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
● Upper structure overruns remarkably when it stops swinging in both directions. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Swing relief 司
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Failure information (2) Related information
Possible causes and standard values
Cause
1
Malfunction of pilot valve
≤ 10 ml/min
● Swing acceleration is only poor on one side, or swing speed is low. ● Set the working mode at gear (10) of power mode (S) to perform troubleshooting.
Standard values and troubleshooting references
● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle. Swing control lever Pilot valve output pressure NEUTRAL Left swing
0 {0}
≥ 3.5MPa { ≥ 36 kg/cm2}
Right swing Malfunction of swing 2 Spool of swing control valve may have malfunction. Check it directly. control valve (spool) Seal of makeup valve in swing motor may be defective. Check it diDefective seal of rectly. 3 swing motor (make● Swap the left and right makeup valves and observe the result to up valve) determine whether the seal fails.
Shop Manual - April 2014
7-107
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-22 Large shock produced upon swing stoppage ● Large shock is produced when upper structure stops swinging. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Failure information Related information
Standard values and troubleshooting references ● Stop the engine before troubleshooting. Perform troubleshooting while the engine is running at high idle.
1
Malfunction of swing pilot valve
Swing control lever
Pilot valve output pressure
NEUTRAL
0 {0}
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
Left swing
≥ 3.5MPa { ≥ 36 kg/cm2} Right swing Reverse prevention valve of swing motor may have malfunction. Malfunction of swing Check it directly. 2 reverse prevention ● Replace the valve with a new on to determine whether the valve valve fails. 3
Malfunction of swing Swing relief valve may be worn or sluggish. relief valve 司
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7-108
Shop Manual - April 2014
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-23 High noise produced upon swing stoppage
Failure information Related information
Malfunction of 1 back pressure valve Malfunction of 2 swing motor (relief valve)
Standard values and troubleshooting references Back pressure valve may have malfunction. Check it directly.
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Cause
● High noise is produced when upper structure stops swinging. ● Set working mode to S and fuel control dial at position 10 to carry out troubleshooting.
Relief valve of swing motor may have malfunction. Check it directly.
Seal of makeup valve in swing motor may have malfunction. Check it diMalfunction of rectly. 3 swing motor ● Swap the left and right makeup valves and observe the result to deter(makeup valve) mine whether the seal fails. . The swing mechanism is suspected of an internal failure. Check the inside of the machinery itself. Failure of swing 4 ● Internal defect of swing mechanism can be determined with abnormechanism mal noise, overheat, and metal powder or debris contained in the oil drained. 司
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Shop Manual - April 2014
7-109
Troubleshooting
SY365(B)H-9 Crawler Hydraulic Excavator
H-24 Swing drift excessive
Failure information (1)
Cause
Standard values and troubleshooting references
Failure of swing Swing holding brake control lines and holding brake pilot valve may be 1 holding brake defective. Check them directly. control lines
In Ma t rk er n et a in ti o g n De al pt .
Possible causes and standard values
Related information
● Hydraulic drift of swing is large (when swing holding brake is applied). ● When swing lock switch is turned ON or when swing holding brake release switch is in normal position, swing holding brake operates and upper structure is fixed with disc brake.
Malfunction of 2 swing motor (parking brake)
Parking brake of swing motor may have malfunction. Check it directly.
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Failure information (2)
Possible causes and standard values
Related information
7-110
Cause
● Hydraulic drift of swing is large (when swing holding brake is released). ● When swing holding brake release switch is in release position, swing holding brake is released and upper structure is secured by only hydraulic pressure.
Standard values and troubleshooting references
Malfunction or deSwing control valve spool may have malfunction or defective seal. 1 fective seal of swing Check it directly. control valve (spool) 2
Failure of swing moSeal of relief valve in swing motor may be defective. Check it directly. tor (relief valve)
3
Failure of swing mo- Seal of makeup valve in swing motor may be defective. Check it ditor (makeup valve) rectly.
Shop Manual - April 2014
Troubleshooting
BLMaInt e r AkNe rn a tKi t i ng o PAD nal eGp tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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Shop Manual - April 2014
7-111
Troubleshooting
BLM In t aAr e kNe rn a tKi t i nP o gA n al DG ep tE.
SY365(B)H-9 Crawler Hydraulic Excavator
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7-112
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
Disassembly and Assembly 8 Disassembly and Assembly
8.1 How to Read This Manual ....................................................................................... 8-5 8.1.1 Removing and installing an assembly............................................................ 8-5 8.2 Operating Precautions ............................................................................................. 8-6 8.3 Start Motor AS ........................................................................................................ 8-9 8.3.1 Removal ......................................................................................................... 8-9 8.3.2 Installation ...................................................................................................... 8-9 8.4 Fuel Injection Pump AS ........................................................................................ 8-10 8.4.1 Removal ....................................................................................................... 8-10 8.4.2 Installation .................................................................................................... 8-12 8.5 Engine Front Oil Seal ............................................................................................ 8-13 8.5.1 Removal ....................................................................................................... 8-13 8.5.2 Installation .................................................................................................... 8-13 8.6 Engine Rear Oil Seal ............................................................................................ 8-14 8.6.1 Removal ....................................................................................................... 8-14 8.6.2 Installation .................................................................................................... 8-14 8.7 Cylinder Head AS .................................................................................................. 8-15 8.7.1 Removal ....................................................................................................... 8-15 8.7.2 Installation .................................................................................................... 8-19 8.8 Radiator AS ........................................................................................................... 8-20 8.8.1 Removal ....................................................................................................... 8-20 8.8.2 Installation .................................................................................................... 8-23 8.9 Engine and Hydraulic Pump AS ............................................................................ 8-24 8.9.1 Removal ....................................................................................................... 8-24 8.9.2 Installation .................................................................................................... 8-30 8.10 Final Drive AS ..................................................................................................... 8-31 司
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Shop Manual - April 2014
8-1
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
8.10.1 Removal ..................................................................................................... 8-31 8.10.2 Installation .................................................................................................. 8-32 8.11 Final Drive AS ...................................................................................................... 8-33 8.11.1 Disassembly ............................................................................................... 8-33 8.11.2 Assembly .................................................................................................... 8-36 8.12 Swing Motor and Swing Drive AS ....................................................................... 8-42 8.12.1 Removal ..................................................................................................... 8-42 8.12.2 Installation .................................................................................................. 8-43 8.13 Swing Motor and Swing Drive AS ....................................................................... 8-44 8.13.1 Disassembly............................................................................................... 8-44 8.13.2 Assembly.................................................................................................... 8-49 8.14 Idler AS ............................................................................................................... 8-54 8.14.1 Disassembly............................................................................................... 8-54 8.14.2 Assembly.................................................................................................... 8-55 8.15 Sprocket .............................................................................................................. 8-58 8.15.1 Removal ..................................................................................................... 8-58 8.15.2 Installation .................................................................................................. 8-58 8.16 Track AS ............................................................................................................. 8-59 8.16.1 Removal ..................................................................................................... 8-59 8.16.2 Installation .................................................................................................. 8-60 8.17 Swing Bearing AS ............................................................................................... 8-62 8.17.1 Removal ..................................................................................................... 8-62 8.17.2 Installation .................................................................................................. 8-63 8.18 Swing frame AS .................................................................................................. 8-64 8.18.1 Removal ..................................................................................................... 8-64 8.18.2 Installation .................................................................................................. 8-66 8.19 Swivel Joint AS .................................................................................................... 8-67 8.19.1 Removal ..................................................................................................... 8-67 8.19.2 Installation .................................................................................................. 8-69 8.20 Central Swivel Joint AS ....................................................................................... 8-70 8.20.1 Disassembly............................................................................................... 8-70 8.20.2 Assembly.................................................................................................... 8-70 8.21 Hydraulic Tank AS ............................................................................................... 8-71 8.21.1 Removal ..................................................................................................... 8-71 8.21.2 Installation .................................................................................................. 8-73 8.22 Control Valve AS .................................................................................................. 8-74 司
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8-2
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
8.22.1 Removal ..................................................................................................... 8-74 8.22.2 Installation .................................................................................................. 8-79 8.23 Hydraulic Pump AS ............................................................................................. 8-80 8.23.1 Removal ..................................................................................................... 8-80 8.23.2 Installation .................................................................................................. 8-83 8.24 Middle Oil Seal (Hydraulic Pump Input Shaft) ..................................................... 8-84 8.24.1 Removal ..................................................................................................... 8-84 8.24.2 Installation .................................................................................................. 8-84 8.25 Pilot Valve AS (Work Equipment) ....................................................................... 8-85 8.26 Travel Pilot Valve AS ........................................................................................... 8-86 8.27 Hydraulic Cylinder AS ......................................................................................... 8-87 8.27.1 Disassembly............................................................................................... 8-88 8.27.2 Assembly.................................................................................................... 8-92 8.28 Work Equipment AS ............................................................................................ 8-97 8.28.1 Removal ..................................................................................................... 8-97 8.28.2 Installation .................................................................................................. 8-99 8.29 Air Conditioner AS ............................................................................................. 8-100 8.29.1 Removal ................................................................................................... 8-100 8.29.2 Installation ................................................................................................ 8-103 8.30 Counterweight AS ............................................................................................. 8-104 8.30.1 Removal ................................................................................................... 8-104 8.30.2 Installation ................................................................................................ 8-105 8.31 Cab AS .............................................................................................................. 8-106 8.31.1 Removal ................................................................................................... 8-106 8.31.2 Installation ................................................................................................ 8-109 8.32 Cab Window Glass ............................................................................................8-110 8.32.1 Removal ....................................................................................................8-111 8.32.2 Installation .................................................................................................8-114 8.33 Front Window AS ............................................................................................... 8-126 8.33.1 Disassembly............................................................................................. 8-126 8.33.2 Assembly.................................................................................................. 8-129 8.34 Monitor - Remove and Install ............................................................................. 8-135 8.34.1 Removal ................................................................................................... 8-135 8.34.2 Installation ................................................................................................ 8-135 8.35 Controller AS ..................................................................................................... 8-136 8.35.1 Removal ................................................................................................... 8-136 司
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Shop Manual - April 2014
8-3
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
8.35.2 Installation ................................................................................................ 8-136 8.36 Radio ................................................................................................................. 8-137 8.36.1 Structure .................................................................................................. 8-137 8.36.2 Removal and installation .......................................................................... 8-139 8.36.3 Connector model and wiring .................................................................... 8-140 8.37 Battery ............................................................................................................... 8-141 8.37.1 Structure .................................................................................................. 8-141 8.37.2 Removal and installation .......................................................................... 8-142 8.37.3 Replacement ............................................................................................ 8-143 8.38 Start Switch........................................................................................................ 8-144 8.38.1 Structure ................................................................................................. 8-144 8.38.2 Removal ................................................................................................... 8-145 8.38.3 Working principle ..................................................................................... 8-146 8.38.4 Wiring ....................................................................................................... 8-146 8.39 Fuse Box............................................................................................................ 8-147 8.40 Wiper ................................................................................................................. 8-148 8.40.1 Structure .................................................................................................. 8-148 8.40.2 Working principle ..................................................................................... 8-149 8.40.3 Removal ................................................................................................... 8-150 8.40.4 Installation ................................................................................................ 8-150 8.40.5 Angle adjustment of wiper arm................................................................. 8-151 8.41 Relays ................................................................................................................ 8-152 8.41.1 Engine relays ........................................................................................... 8-152 8.41.2 Other relays ............................................................................................. 8-153 8.41.3 Removal and installation .......................................................................... 8-154 8.41.4 Relay connector and wiring...................................................................... 8-154 8.42 Sensors.............................................................................................................. 8-155 8.43 Connector Terminals ......................................................................................... 8-157 8.43.1 Insertion ................................................................................................... 8-157 8.43.2 Removal ................................................................................................... 8-158 司
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8-4
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8 DISASSEMBLY AND ASSEMBLY 8.1 How to Read This Manual 8.1.1 Removing and installing an assembly Special tools ● Special tools for parts removal and installation are listed. ● Necessary characteristics of the tools are noted in the list of special tools. ■ : Special tools that cannot be substituted and must be used.
In Ma t rk er n et a in ti o g n De al pt .
● : Very important tools, which can be substituted with commercially available ones. Removal of parts
● The "Removal" section contains procedure, precautions and the amount of oil or coolant to be discharged. ● The symbols used the in the "Removal" section are described below:
This symbol indicates that safety-related precautions must be observed when doing the job. This symbol is followed by instructions or precautions when performing a procedure. This symbol indicates related rules and precautions that must be obeyed when installing the pats. This symbol indicates the amount of oil or coolant to be discharged. 司
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★
Installation of parts
● Unless specified otherwise, installation of a part is to be performed in a reverse order of removing the part. ● The mark used in the "Installation" section indicates the rules and precautions related to parts installation. ● Symbols used in the "Installation" sections are shown below:
This symbol indicates that safety-related precautions must be observed when doing the job. ★
This symbol is followed by instructions or precautions when performing a procedure. This symbol indicates that specific coating agent must be used. This symbol indicates the lubricant required. This symbol indicates a torque specified. This symbol indicates the amount of oil or coolant to be added.
Shop Manual - April 2014
8-5
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.2 Operating Precautions Observe the following precautions before removing or installing (disassembling or assembling) a component. 1. Precautions to be observed prior to removal operation ● Dispose the engine coolant properly if antifreeze is used in the engine coolant. ● After disconnecting a hose or tube, seal the openings to prevent invasion of dirt or dust. ● Use a suitable container to contain oil drained.
In Ma t rk er n et a in ti o g n De al pt .
● Matching mark must be made at where is necessary before removing a part in order to avoid mistake during reinstallation. ● Do not pull the wire and avoid the wire coming off its contact. To avoid excessive force imposing on the wire, hold the connector when disconnecting a wire. ● Tag the wires and the hoses in order to ensure their connecting positions. By doing so, mistakes can be avoided during reinstallation. ● Count and check the number and thickness of the shims, and keep them in a safe place. ● When raising or lifting a component, be sure to use a proper lifting equipment of ample strength. 司
● When forcing screws are used to remove any components, tighten the screws evenly in turn. 公
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● The surrounding area must be cleaned before removing a component. Cover the component after removal in order to prevent invasion of dirt or dust.
8-6
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Precautions to be observed when disassembling the lines The lines disassembled must be blinded with plugs. A. Thread-connected hoses Inner Diameter (mm)
Code
Description
Light Thread Connection B210780001189
Plug
8
B210780001190
Plug
10
B210780000077
Plug
12
B210780000078
Plug
In Ma t rk er n et a in ti o g n De al pt .
6
15
B210780000883
Plug
20
B210780000079
Plug
22
60056667
Plug
Heavy Thread Connection
12
B210780001142
Plug
16
60002397
Plug
20
B210780000080
25
B210780000081
Plug Plug
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B. Thread-connected adaptors (plug and nut used in combination) Inner Dia.(mm)
Code
Description
Code
Description
Light Thread Connection
6
B210780000903
Cone Plug
23002925
Nut
8
B210780001146
Plug
B210770000011
Nut
10
B210780000088
Plug
B210334000011
Nut
12
B210780000089
Plug
B210334000012
Nut
15
B210780000882
Plug
B210334000004
Nut
20
B210780000090
Plug
B210334000010
Nut
22
B210780000091
Plug
B210780000112
Nut
Heavy Thread Connection 12
B210780001143
Plug
B210780000406
Nut
16
A820205001523
Plug
B210780000405
Nut
20
B210780000902
Plug
B210780000904
Nut
25
B210780001172
Plug
B210334000006
Nut
Shop Manual - April 2014
8-7
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
performed as the following:
2. Precautions to be observed prior to installation
(1) Start the engine and run the engine at low idle. (2) Operate the work equipment control lever in order to cycle the movement of the hydraulic cylinder 4 or 5 times. Hold 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. (4) You can run the engine at normal speed after this operation.
● Tighten all the screws and nuts (sleeve nuts) to specified torques. ● Install the hoses without twisting or interference. ● Replace the gaskets, O-rings, cotter pins and lock plates with new ones. ● Bend the cotter pin or lock plate securely.
● This procedure is to be performed before using your machine for the first time after repair or long storage.
● Before applying the sealant to the gasket, clean the gasket surface of oil and dust. Check the gasket for contamination or damage. Apply the gasket sealant evenly.
3. Precautions to be observed upon completion of the operations
In Ma t rk er n et a in ti o g n De al pt .
● Before applying the adhesive, clean the parts of oil and dust. Apply 2 or 3 drops of adhesive to the threaded portion.
● Clean all parts, and correct any damage, dents, burrs, or rust. ● Apply engine oil to the moving parts.
● Before installing a snap ring, make sure that the snap ring is mounted properly in the circular groove.
● Before connecting the wiring connector, clean the wiring connector of oil, dirt or water. Make sure that the wiring connector is connected securely.
● Before using an eyebolt, check the eyebolt for deformation or deterioration. Screw on the eyebolt as far as possible and align it to the direction of the hook. ● Before tightening the half flanges, tighten it evenly in turn in order to prevent over tightening on one side.
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● Completely discharge the engine coolant, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Check the coolant level again. ● Add hydraulic oil to the specified level after disassembly and reinstallation of a hydraulic unit. Run the engine to circulate the hydraulic oil through the system. Check the oil level again. ● Purge the air from the system after removing and repairing the lines or hydraulic unit and reassembling the parts. ● To purge the air, see related information in “Testing and Adjusting”. ● Add the specified amount of grease (MoS2) to the work equipment related parts.
● After reassembling the hydraulic cylinder, main pump or other hydraulic equipment that has been disassembled and repaired, it is necessary to purge the air from the hydraulic cylinder prior to initial operation of the cylinder. The purging procedure is 8-8
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.3 Start Motor AS 8.3.1 Removal
NOTICE
In Ma t rk er n et a in ti o g n De al pt .
● Before removing the start motor assembly, disconnect the cable from the negative post (-) of the battery. Insulate the cable and negative post (-) with tape. 1. Open the engine hood.
2. Disconnect the Cables (2), (3) and (4).
3. Remove the start motor fixing bolt (1) in order to remove the start motor.
1
2
3
4
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ZXT335-1006001
Fig. 8-1
8.3.2 Installation
● Installation is performed in the reverse procedure of removal.
Shop Manual - April 2014
8-9
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.4 Fuel Injection Pump AS 8.4.1 Removal NOTICE ● Disconnect the negative (-) post of battery.
In Ma t rk er n et a in ti o g n De al pt .
1. Open the engine hood.
ZXT335-1006002
Fig. 8-2
2. Disconnect the air hoses (1) and (2) of the crankcase.
1 2
司
公
销 营
ZXT335-1006003
Fig. 8-3
3. Remove the fuel return line (3), fuel delivery line (4), fuel supply line (5) and lubrication line (7).
3
● After disconnecting the hoses, cork them to prevent fuel leak.
4
5 6
7 ZXT335-1006004
Fig. 8-4 8-10
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. Remove the six (6) fuel delivery lines (8)
8
ZXT335-1006005
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-5
5. Remove the air hose (9).
6. Remove the bolt (10) fixing the electronic shutdown device and the bolt (11) of governor motor. 7. Remove the fuel injection pump mounting nut in order to remove the fuel injection pump assembly.
9
10
11
司
公
销 营
ZXT335-1006006
Fig. 8-6
Shop Manual - April 2014
8-11
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.4.2 Installation ● Installation is performed in the reverse procedure of removal. Torques for: Fuel supply line connector bolt: 28-46 N•m Fuel return line nut: 28-46N•m Fuel delivery line nut: 28-32N•m Engine oil line nut: 16-25N•m ● Install the fuel injection pump as the following: A. Check the fuel injection timing.
In Ma t rk er n et a in ti o g n De al pt .
See “Fuel Injection Timing - Test and Adjust” on page 6-13.
B. Assemble the fuel injection pump assembly and tighten the nuts. Nut: 9.8±2 Nm {10±0.2 kgm}
● Purge the air.
Purge the air from the fuel injection system.
司
公
销 营
8-12
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.5 Engine Front Oil Seal 8.5.1 Removal
3
1. Remove the radiator assembly. See “Radiator AS” on page 8-20.
2
2. Remove the engine fan (1), belt (2) and pulley (3).
1
In Ma t rk er n et a in ti o g n De al pt .
3. R e m o v e t h e b o l t ( 4 ) a n d t h e n t h e
ZX335-1006007
Fig. 8-7
crankshaft belt pulley (5).
4. Remove the front oil seal (6).
5
司
公
销 营
6
4
ZX335-1006008
Fig. 8-8
8.5.2 Installation
● Installation is performed in the reverse procedure of removal.
Shop Manual - April 2014
8-13
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.6 Engine Rear Oil Seal 8.6.1 Removal 2
1. Remove the hydraulic pump assembly. See “Hydraulic Pump AS” on page 8-80. 2. Remove the flywheel (1).
In Ma t rk er n et a in ti o g n De al pt .
3. Remove the rear oil seal (2).
ZX335-10
Fig. 8-9
8.6.2 Installation
● Installation is performed in the reverse procedure of removal.
司
公
销 营
Sealant
● Install the rear oil seal as the following:
A. Apply engine oil to the lip of rear oil seal.
ø2mm
B. Clean the seal surface.
C. Apply sealant along the sealing line continuously and uniformly.
Line
Sealant (Tianshan 1596)
D. Installation is to be performed within three (3) minutes after application of sealant. It is important to keep the applied sealant in proper area.
8-14
ZX335-1006010
Fig. 8-10
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.7 Cylinder Head AS 8.7.1 Removal NOTICE ● Disconnect the cable from the negative post (-) of the battery. 1. Drain coolant from the engine. Coolant: 26 L
In Ma t rk er n et a in ti o g n De al pt .
2. Open the engine hood.
ZXT335-1006011
Fig. 8-11
3. Remove the air intake hose (1).
1
司
公
销 营
ZXT335-1006012
Fig. 8-12
4. Disconnect the lines (2) and (3) between the fuel filter and the fuel injection pump.
4
2
5. Remove the fuel filter bracket (4) and the fuel filter assembly (5).
5
3
ZXT335-1006013
Fig. 8-13 Shop Manual - April 2014
8-15
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Disconnect the six (6) fuel delivery lines (6).
6
ZXT335-1006014
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-14
7. Remove the cover (7) of exhaust muffler connector.
7
8. Disconnect the air intake hose (8).
9. Disconnect the air intake hose (9) and the crankcase breathing hose (10) between turbocharger and intercooler.
8
司
公
9
销 营
10
ZXT335-1006015
Fig. 8-15
8-16
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
10. Disconnect the oil delivery line (11) and the oil return line (12). 11. Remove the turbocharger system assembly.
In Ma t rk er n et a in ti o g n De al pt .
12. Remove the exhaust manifold (13).
司
公
销 营
11
13
12
ZX335-1006016
Fig. 8-16 Shop Manual - April 2014
8-17
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
13. Remove the radiator inlet hose (14) and outlet hose (15).
14
15
ZXT335-1006017
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-17
14. Remove the six (6) nozzle seats (16).
16
司
公
销 营
ZXT335-1006018
Fig. 8-18
8-18
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
15. Remove the rocker arm cover (17). 16. Remove the camshaft assembly (18). 17. Remove the rocker arm assembly (19). 18. Remove the bolts of cylinder head and lift the cylinder head assembly in order to disassemble it.
In Ma t rk er n et a in ti o g n De al pt .
19. Remove the cylinder head gasket (21).
8.7.2 Installation
● Installation is performed in the reverse procedure of removal.
Rocker cover bolt:
7.8-9.8N.m{0.8-1.0kgf.m}
司
公
销 营
Cylinder head bolt:
88N.m{9.0 kgf.m }+90°
Cylinder head bolt threads: engine oil Camshaft flange surface: engine oil
Camshaft journal circumference: engine oil
● Adjusting valve clearance
● See “Valve Clearance - Adjust” on page 6-7. ● Adding coolant
Add engine coolant to the specific level. Start the engine to circulate coolant in order to eliminate all foams. Check the coolant level again.
ZX335-1006019
Fig. 8-19
Shop Manual - April 2014
8-19
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.8 Radiator AS 8.8.1 Removal 1. Open the engine hood 2. Open the pressure cap (1). Drain engine coolant via the drain valve beneath the coolant tank. Coolant: Approx. 26 L
In Ma t rk er n et a in ti o g n De al pt .
1
ZXT335-1006020
Fig. 8-20
3. Disconnect the pipes from the hydraulic oil cooler delivery port (2) and supply port (3). Seal the ports in order to prevent the leakage of hydraulic oil in the hydraulic system.
司
公
销 营
4. Drain hydraulic oil from the cooler and from radiator.
2
Hydraulic oil radiator: Approx. 8 L
3
ZXT335-1006021
Fig. 8-21
5. Remove hose (4) of coolant tank.
4
ZXT335-1006022
Fig. 8-22 8-20
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Remove the inlet and outlet houses (5) and (6) of the water cooler.
6
Hydraulic oil radiator: Approx. 5.6 L
5
ZXT335-1006023
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-23
7. Remove the inlet and outlet air hoses (7) and (8) of the intercooler.
8
7
司
公
销 营
ZXT335-1006024
Fig. 8-24
8. Remove the four bolts (9) of the A/C radiator. Remove the A/C radiator and put it in a suitable place.
9
ZXT335-1006025
Fig. 8-25
Shop Manual - April 2014
8-21
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
9. Remove the radiator fan guard (10).
10
ZXT335-1006026
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-26
10. Remove the four bolts (11) from the bottom of radiator.
司
公
销 营
11
11
ZXT335-1006027
Fig. 8-27
11. Remove the bolts (12) and (13) of both left and right brackets.
12 13
ZXT335-1006028
Fig. 8-28
8-22
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
12. Install eyebolts (14) on both sides of the radiator and lift the radiator assembly. ● Before lifting the radiator assembly, move the radiator assembly in axial direction until the fan is free from the fan guard.
14
ZXT335-1006029
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-29
8.8.2 Installation
● Installation is performed in the reverse procedure of removal.
● Adjust the clearance (a) between the fan and guard so that the clearance is uniform around the fan.
司
公
销 营
● The clearance (a) should read as the following on the left, right, top and bottom points. ● Standard clearance (a) (around the fan): 10 mm ● Fan dia. (b): ø830 mm
● Guard inner dia. (c): ø850 mm
● Refilling engine coolant and hydraulic oil
Refill engine coolant and hydraulic oil to the specific levels. Start the engine to circulate the coolant and oil. Check the coolant level and oil level again. Engine coolant: Approx. 26 L. Hyd oil radiator: Approx. 8 L.
Shop Manual - April 2014
8-23
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.9 Engine and Hydraulic Pump AS 8.9.1 Removal Lower the work equipment to the ground in order to ensure safety. Stop the engine. Disconnect the cable from the battery negative (-) post. Loosen the butterfly nut on the breather valve and press the relief button to release internal pressure.
In Ma t rk er n et a in ti o g n De al pt .
● Mark the lines to avoid mistakes during reinstallation.
1. Remove the hydraulic tank suction filter and block the opening. 2. Discharge engine coolant.
Coolant: About 22.9 L
3. Open the engine hood.
ZXT335-1006030
司
公
销 营
Fig. 8-30
4. Disconnect lines (1), (2) and (3).
2
3
1
ZXT335-1006031
Fig. 8-31
8-24
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. D i s c o n n e c t h o s e s ( 4 ) , ( 6 ) a n d ( 7 ) . Disconnect the cables (5) and (8) of main pump pressure sensors.
6 5
7
4
8
ZXT335-1006032
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-32
6. Remove the hose (9) and the clamps (10).
9
10
司
公
销 营
10
ZXT335-1006033
Fig. 8-33
7. Remove the main pump negative feedback hoses (11) and (12).
12
11
ZXT335-1006034
Fig. 8-34
Shop Manual - April 2014
8-25
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8. Remove the main pump PSV hose (13), clamp (14) and cable (15).
13
15
14
ZXT335-1006035
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-35
9. Disconnect the engine fuel hoses (16) and (17) and the engine oil hoses (18) and (19).
21
20
22
10. Disconnect the engine speed sensor cables (20) and (21) as well as the clamp (22).
16
18
17
19
司
公
销 营
ZXT335-1006036
Fig. 8-36
11. Unscrew the throttle guy connecting bolt (23) and the electronic shutdown device connecting bolt (24).
24
23
ZXT335-1006037
Fig. 8-37
8-26
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
12. Remove the coolant temperature sensor, high temperature switch external cables (25) and (26) as well as the hose clamps (27). 25 26
27 ZXT335-1006038
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-38
13. Disconnect the compressor cables (28) and (29) as well as the hoses (30) and (31).
28
29
31
司
公
销 营
30
ZXT335-1006039
Fig. 8-39
14. Disconnect the external cable (32) of engine oil pressure sensor and the cable (33) of engine oil pressure sensor.
32
34
15. Remove the clamps (34).
16. Remove the starter main cable (35).
36
17. Disconnect the alternator cable (36). 35 33 ZXT335-1006040
Fig. 8-40
Shop Manual - April 2014
8-27
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
18. Remove the hose clamp (37). 37
ZXT335-1006041
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-41
19. Disconnect the hoses (38), (39) and (40) between the engine and the radiator. 20. Disconnect the air intake hose (41).
39
38
司
公
销 营
40
41
ZXT335-1006042
Fig. 8-42
21. Disconnect the hose (42) between the engine and the radiator.
42
ZXT335-1006043
Fig. 8-43
8-28
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
22. Disconnect the radiator fan guard (43).
43
In Ma t rk er n et a in ti o g n De al pt .
ZXT335-1006044
Fig. 8-44
23. Remove the fixing bolt (44) on each of the four (4) mounting plates of the damper. Lift the engine and main pump assembly.
44
Engine and hydraulic pump AS:
44
836 kg
司
公
销 营
ZXT335-1006045
Fig. 8-45
Shop Manual - April 2014
8-29
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.9.2 Installation ● Installation is performed in the reverse procedure of removal. ● Open the radiator tank cap to refill coolant. Add coolant to the coolant tank. Engine coolant:Approx. 26 L ● Refill the hydraulic tank with hydraulic oil. Hydraulic tank: Approx. 380 L
In Ma t rk er n et a in ti o g n De al pt .
● Start the engine to circulate the coolant in order release the foams, and check the coolant level again. ● Start the engine to circulate the hydraulic oil in the hydraulic system, and check the oil level again. ● Purging the air.
See “Air in Each Component - Purge” on page 6-41.
司
公
销 营
8-30
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.10 Final Drive AS 8.10.1 Removal 1. Remove the sprocket. See “Sprocket” on page 8-58.
WARNING ● Lower the work equipment to the ground in order to ensure safety. Stop the engine. Operate the breather valve to release internal pressure.
In Ma t rk er n et a in ti o g n De al pt .
1 ZX335-1006046
Fig. 8-46
2. Remove the motor cover plate (1).
3
3. Disconnect the four hoses (2) of the travel motor and the corresponding hose connectors. 4. Remove the 24 mounting bolts (3) connecting the final drive assembly with the sprocket. And the remove the sprocket.
司
公
销 营
2
5. Remove the bolts (4) connecting the final drive with the track frame. Lift the final drive (5) in order to disassemble it. ● Take care not to damage the surface of mounting seal installed on the hose base.
4
ZXT3355-1006247
Fig. 8-47
● Never use the threaded holes to lift the cover when lifting the final drive.
Number of Bolts Travel motor plus reducer
SY365(B)H-9 18 389 kg
3 2
4
ZX335-1006147
Fig. 8-48
Shop Manual - April 2014
8-31
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.10.2 Installation ● Installation is performed in the reverse procedure of removal.
Mounting bolts (final drive AS): 245~309 Nm {25~31 kgm} ● Refilling hydraulic oil. Add hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again. ● Purging the air.
In Ma t rk er n et a in ti o g n De al pt .
See “Air in Each Component - Purge” on page 6-41.
司
公
销 营
8-32
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.11 Final Drive AS 8.11.1 Disassembly 1. Discharging the oil Open the drain plug to discharge oil from the final drive tank. Final drive tank: About 4.0 L
2. Cover
①
In Ma t rk er n et a in ti o g n De al pt .
Unscrew the mounting bolts. Remove the cover (1) with the help of eyebolts ① .
1
司
公
销 营
ZX335-1006049
Fig. 8-49
3. Spacer
2
Remove the spacer (2).
ZX335-1006050
Fig. 8-50
Shop Manual - April 2014
8-33
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. No. 1 planetary carrier assembly 3
A. Remove No.1 planetary carrier assembly (3).
ZX335-1006051
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-51
B. Disassembling No.1 planetary carrier assembly.
9
7
a. Remove the screw (4). Remove the coverplate (5) from the planetary carrier (6).
b. Remove the thrust washer (7), gear (8), bearing (9), bearing inner race (10) and thrust washer (11).
5
4
10
8
司
公
销 营
11
6
ZX335-1006052
Fig. 8-52
5. No.1 sun gear shaft
12
Remove No.1 sun gear shaft (12).
ZX335-1006053
Fig. 8-53
8-34
Shop Manual - April 2014
SY365(B)H-9 Crawler Hydraulic Excavator
Disassembly and Assembly
6. Thrust washer.
13
14
Remove the thrust washer (13). 7. No.2 sun gear Remove No.2 sun gear (14).
ZX335-1006054
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-54
8. Disassembling No.2 planetary carrier assembly
18
A. Remove the screw (15). Remove the plate (16) and the planetary gear (17) from the carrier (22). B. Remove the bearing inner race (19) and outer race (18). Remove the plate (20).
19
15 16
17
20 21
23
司
公
销 营
C. Remove the screw (21) in order to take down the planetary carrier (22) and shims (23) from the body.
22
ZX335-1006055
Fig. 8-55
9. Boss assembly
②
A. Remove the boss assembly (24) from the travel motor with the help eyebolts ②.
24
ZX335-1006056
Fig. 8-56
Shop Manual - April 2014
8-35
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
B. Disassemble the boss assembly as the following.
27
26
a. Remove the floating seal (25). b. Remove the bearings (26) and (27) from the boss (28). ● Take care not to damage the bearing retainer while disassembling the bearing (26). 25
28 ZX335-1006057
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-57
C. Remove the floating seal (29) from the travel motor (30).
29
司
公
销 营
30
ZX335-1006058
Fig. 8-58
8.11.2 Assembly
26
● Clean all the parts. Make sure that these parts are free from contamination or damage. Apply some engine oil to the sliding surfaces prior to installation.
27
1. Boss assembly
A. Install the bearings (26) and (27) by pressing them onto the boss (28). 25
B. Install the floating seals (25).
28 ZX335-1006057
Fig. 8-59
8-36
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Remove any oil or dust from the O-ring or O-ring contact surfaces. Dry the parts before installing the floating seals. ● After installing the floating seal, make sure that the angle of floating seal is within 1 mm. ● Apply a thin layer of engine oil to the sliding surface after the floating seal has been installed.
ZX335-1006059
Fig. 8-60
In Ma t rk er n et a in ti o g n De al pt .
C. Install the floating seal (29) on the travel motor (30). ● See the above step 2 for the installation procedure.
29
司
公
销 营
30
ZX335-1006058
Fig. 8-61
D. Place the boss assembly (24) on the travel motor with the help of eyebolts ② . Carefully tap the bearing to pressfit it.
②
24
ZX335-1006056
Fig. 8-62
Shop Manual - April 2014
8-37
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
2. Calculation of shim thickness A. Measure the thickness (H) of the raised part of No.2 planetary carrier (22).
22
H
ZX335-1006060
B. Measurement of raised thickness
Fig. 8-63
In Ma t rk er n et a in ti o g n De al pt .
Apply 3000 Kg load to the bearing and measure the value (H) of the raised part of bearing. ● Turn the boss 2-3 times before applying a pushing force.
● Do not use a spray gun to cushion the bearing.
Load 3000Kg
h
● Do not push or strike the retaining valve. C. Shim thickness calculation: C=H-h.
司
公
销 营
ZX335-1006061
Fig. 8-64
D. Place the shims on the body and insert the dowel pin. Press the carrier assembly onto the dowel pin and tighten it with screw (21). Apply locking adhesive to the threads.
Tensiometer
Screw-locking adhesive:
(Kesaixin 1277)
Screw (21): 539±28 Nm {55±2.9 kgm} ● Use a tensiometer to measure the tangential force of boss to motor case rotation.
ZX335-1006062
Fig. 8-65
Tangential force: Max. 294N {30 kg} Maximum tangential force occurs at the beginning of direction change.
8-38
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
3. Assembly of No.2 planetary carrier assembly
18
19
15 16
Assemble the No.2 planetary carrier assembly through to the following steps.
17 20
● Replace the plates (20) and (16) with new ones.
23
21
A. Assemble the bearings (18) and (19) on the gear (17). Assemble the top and bottom plates (16) and (20), and place the gear assembly into the planetary carrier (22).
22
ZX335-1006055
Fig. 8-66
In Ma t rk er n et a in ti o g n De al pt .
B. Lock it with screw (15). Screw (15):
13
14
539±28 Nm {55±2.9 kgm}
● Check the flexibility of gear (17) after assembling the planetary carrier assembly. 4. Thrust washer
Install the thrust washer (13).
司
公
销 营
5. No.2 sun gear
Install No.2 sun gear (14).
ZX335-1006054
Fig. 8-67
6. No.1 sun gear shaft
12
Install No.1 sun gear shaft (12).
ZX335-1006053
Fig. 8-68
Shop Manual - April 2014
8-39
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
7. No.1 planetary carrier assembly A. Install No.1 planetary carrier assembly as the following.
9
7
5
4
10
8
● Replace the thrust washers (7) and (11) with new ones. a. Assemble bearings (9,10) on gear (8). Assemble the top washer (7) and the bottom washer (11). Place the gear assembly in the carrier assembly (6).
11
6 ZX335-1006052
Fig. 8-69
In Ma t rk er n et a in ti o g n De al pt .
b. Secure the coverplate (5) to the planetary carrier (6) with screw (4). B. Install No.1 planetary carrier assembly (3).
3
司
公
销 营
ZX335-1006051
Fig. 8-70
8. Spacer
2
Install the spacer (2).
ZX335-1006050
Fig. 8-71
8-40
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
9. Cover
①
Assemble the cover (1) with the help of eyebolts ① . Use a torque wrench to tighten the bolts. Bolts: 73.4±3.63 Nm {7.5±0.4 kgm}
1 ZX335-1006049
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-72
司
公
销 营
Torque wrench
ZX335-1006063
Fig. 8-73
10. Refilling the oil
Tighten the drain plug and refill engine oil through a filler. Final drive case: About 4.7 L
● After the final drive has been successfully installed to the chassis, check the oil to see if it has reached the specified level.
Shop Manual - April 2014
8-41
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.12 Swing Motor and Swing Drive AS 8.12.1 Removal Release the remaining pressure in the hydraulic return circuit. See “Remaining Pressure in Hydraulic Lines - Relieve” on page 6-36. Lower the work equipment to the ground in order to ensure safety. Stop the engine. Press the release button of the breather valve to release remaining pressure in the hydraulic tank. Place the hydraulic lockout control in the locked position.
4
3
In Ma t rk er n et a in ti o g n De al pt .
6
1. Disconnect the hose (1) through the hose (9).
2
7
(1): Between oil tank and swing motor (port Dr)
5
1
(2): Between central swivel joint and swing motor (port Dr) (3): Between swing motor and main valve (port M) (4): Between swing motor and main valve port Px (port A)
司
公
销 营
ZXT335-1006064
Fig. 8-74
(5): Between swing motor and main valve (port B) (6): Between swing motor and main valve port Px (port SH)
(7): Between swing motor and solenoid valve block (port PG)
9
2. Remove the 14 fixing bolts (8).
3. Lift the swing motor and swing mechanism assembly (9) in order to disassemble it.
8
Slowly lift the swing motor and swing mechanism assembly in order to avoid damaging the hoses and other parts. Swing motor and swing drive AS: 425.5 kg
8-42
ZXT335-1006065
Fig. 8-75
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.12.2 Installation ● Installation is performed in the reverse procedure of removal.
Mounting bolts (swing motor and swing mechanism AS): 490~608 Nm {50~62 kgm} ● Refilling of hydraulic oil
In Ma t rk er n et a in ti o g n De al pt .
Refill hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again. ● Purging of air
See “Air in Each Component - Purge” on page 6-41.
司
公
销 营
Shop Manual - April 2014
8-43
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.13 Swing Motor and Swing Drive AS 8.13.1 Disassembly 1. Draining of oil 2
Open the drain plug to drain the oil from the swing mechanism. 1
Swing drive case: Approx. 10.5 L 2. Swing motor assembly
In Ma t rk er n et a in ti o g n De al pt .
A. Place the swing motor and swing mechanism assembly on a suitable cribbing. Take care not to damage the drive gear or let it contact the ground. B. Unscrew the four(4) bolts (1) in order to remove the swing motor assembly (2).
ZXT335-1006066
Fig. 8-76
Swing motor assembly: 67.5 kg
3. No.1 sun gear
司
公
销 营
2
Remove No.1 sun gear (2).
ZX335-1006067
Fig. 8-77
8-44
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. No.1 planetary carrier assembly
4
3
In Ma t rk er n et a in ti o g n De al pt .
A. Remove No.1 carrier assembly (3) and the plate (4).
ZX335-1006068
Fig. 8-78
B. Disassemble No.1 carrier assembly.
Cut the rivets on the shaft (8) to remove the shaft (8), and remove in turn the gear (6), bearing (9) and plate (7).
6
5
7
8
9
司
公
销 营
ZX335-1006069
Fig. 8-79
5. Gear ring
10
Unscrew the mounting bolts to remove the gear ring (10).
ZX335-1006070
Fig. 8-80 Shop Manual - April 2014
8-45
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. No.2 sun gear
11
In Ma t rk er n et a in ti o g n De al pt .
Remove No.2 sun gear (11).
ZX335-1006071
Fig. 8-81
7. No.2 planetary carrier assembly
12
A. Remove No.2 carrier assembly (12).
司
公
销 营
ZX335-1006072
Fig. 8-82
8-46
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
B. Disassemble No.2 carrier assembly with hands through the following steps. a. Hammer the pin (13) in the shaft (14) in order to push the shaft (14) out of the carrier assembly (19).
19
16
15
18 17
● Hammer out the pin (13) after removing the shaft.
14 13
b. Remove the thrust washer (16) and gear (17). c. Insert the pin (15) to remove the bearing (18) from the shaft. Remove the pin (15).
ZX335-1006073
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-83
8. Snap ring
20
Remove the snap ring (20).
司
公
销 营
ZX335-1006074
Fig. 8-84
9. Disassembling the main shaft
Push
21
22
A. Place the shaft housing assembly on a press and push the shaft assembly (21) out of the shaft housing assembly (22).
ZX335-1006075
Fig. 8-85 Shop Manual - April 2014
8-47
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
B. Disassemble the shaft assembly in the following procedure.
Push
Remove the bearing (23) from the shaft (24).
23
In Ma t rk er n et a in ti o g n De al pt .
24
ZX335-1006076
Fig. 8-86
10. Bearing
26
Remove the bearing (25) and the oil seal (26) from the housing (27).
27
司
公
销 营
25
Fig. 8-87
8-48
Shop Manual - April 2014
ZX335-1006077
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.13.2 Assembly
23
● Clean all the parts and check for any contamination or damage. Apply engine oil to the sliding surfaces of the parts. 1. Bearing Press the bearing (23) into the housing (27).
27
ZX335-1006078
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-88
2. Oil seal
27
Press the oil seal (26) into the housing (27).
26
Oil seal mounting surface: gasket sealant (Loctite 515)
司
公
销 营
ZX335-1006079
Fig. 8-89
3. Housing assembly
24
A. Position the plate (28) on the shaft (24). B. Position the housing assembly (22) on the shaft (24). Press to fit the bearing.
22
28
ZX335-1006080
Fig. 8-90
Shop Manual - April 2014
8-49
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. Bearing
22
25
Press to fit the bearing (25). ● When press-fitting the bearing, press the bearing inner race and outer race simultaneously. Never press only the inner race. ● After assembling the bearing, check if the housing rotates freely.
In Ma t rk er n et a in ti o g n De al pt .
ZX335-1006081
Fig. 8-91
5. No.2 Planetary carrier assembly
Reassemble No.2 carrier assembly through the following steps.
19
A. Assemble the plate (16) in the carrier assembly (19).
16
15
18 17
司
公
销 营
B. Assemble the gear (17) in the carrier assembly (19). Put the bearing (18) on the shaft (14). Slightly tap the pin (15) into the bore after alignment. Use a rubber hammer to tap the pin. Make sure that the pin (15) must not be higher than the bearing (18).
13
ZX335-1006073
Fig. 8-92
C. Push the shaft assembly into the carrier assembly (19). Be careful not to damage the gear and the plate. Align the pin hole of the shaft with that of the carrier assembly, and install the pin (13). Carefully tap the pin with a rubber hammer during installation. ● Installation of the shaft requires rotating the planetary gear. Take care not to damage the thrust washer.
8-50
14
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Assemble in turn the snap ring (20), No.2 carrier assembly and No.2 sun gear (11).
11
No.2 planetary carrier
20
In Ma t rk er n et a in ti o g n De al pt .
ZX335-1006082
Fig. 8-93
7. Installation of gear ring
10
Apply sealant on the mating surface indicated by (C) and tighten it with screws. Never get the sealant onto the gear ring (10). Mating surface: Sealant (Loctite 515)
c
司
公
销 营
ZX335-1006083
Fig. 8-94
8. No.1 planetary carrier assembly
A. No.1 carrier assembly is assembled as the following.
a. Install the plate (7) on the carrier assembly (5).
5
6
7
8
9
b. Install the gear (6) onto the plate after installing the bearing (9) into the gear. c. Press the shaft (8) into the gear (6) and the carrier assembly (5). Rivet one end of the shaft. ● Check if the gear rotates freely.
ZX335-1006069
Fig. 8-95
Shop Manual - April 2014
8-51
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
B. Install No.1 carrier assembly (3) and the plate (4).
4
In Ma t rk er n et a in ti o g n De al pt .
3
ZX335-1006068
Fig. 8-96
9. No.1 sun gear assembly
2
Install No.1 sun gear (2).
司
公
销 营
ZX335-1006067
Fig. 8-97
8-52
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
10. Installation of swing motor assembly Install the swing motor assembly after applying sealant to the mating surfaces of the gear ring and the motor cover. Mating surface: sealant (Loctite 515) Swing motor assembly: 55 kg Mounting bolts (swing motor): 156±5 Nm {16±0.5 kg}
In Ma t rk er n et a in ti o g n De al pt .
● The 14 bolt holes of the swing motor and swing drive assembly are distributed nonuniform. The mating direction of each hole is exclusive, as shown in the illustration on the right. The installation of swing motor requires proper alignment of the bolt holes in order to ensure the installation orientation. 11. Refilling of lubricant
Screw on the drain plug and refill lubricant through the filler to the specified level (the upper mark of oil stick).
司
公
销 营
ZX335-1006084
Fig. 8-98
Swing drive case: About 4 L
Shop Manual - April 2014
8-53
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.14 Idler AS 8.14.1 Disassembly
7
8
1. Remove the dowel pin (1) and the support (2).
6 13
12
10
2. Remove the floating seals (3) from the support (2) and the idler (4).
5
3. Remove the O-ring (11). Remove the idler (4) from the shaft (5) and the support assembly (7).
9
3
1
In Ma t rk er n et a in ti o g n De al pt .
● The idler contains 80 ml oil, which should be drained completely before disassembling. Spread a cloth on the floor to prevent smearing of the floor by the oil.
11
4
2
ZX335-1006085
Fig. 8-99
4. Remove the floating seals (6) on the other side from the idler (4), shaft (5) and support assembly (7).
司
公
4
6
销 营
6
5
7
ZX335-1006086
Fig. 8-100
5. Remove the dowel pin (8) in order to remove the support (7) from the shaft (5).
9，10
6. Remove the bushings (9) and (10) from the idler (4).
5
4
7
8 ZX335-1006087
Fig. 8-101 8-54
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.14.2 Assembly 1. Install the bushings (9) and (10) in the idler (4). 9
10
4
4
ZX335-1006088
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-102
2. Assemble the O-ring. Use the dowel pin (8) to install the support (7) on the shaft (5).
9，10
5
4
司
公
销 营
7
8 ZX335-1006087
Fig. 8-103
3. Install the floating seals (6) on the idler (4), shaft (5) and support (7) assembly. ● Floating seals
Completely remove the grease from the contact surfaces (hatched area in the illustration on the right) of O-ring and floating seal before installing the floating seal. In addition, care must be taken to keep the contact surface of floating seal free from dust.
6
ZX335-1006089
Fig. 8-104
Shop Manual - April 2014
8-55
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● After installation of the floating seals, check that the sealing inclination should be less than 1 mm and the seal protrusion be within a range of 5-7 mm.
a
ZX335-1006090
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-105
4. Install the shaft (5) and support (7) assembly to the idler (4).
7
5
4
司
公
销 营
ZX335-1006091
Fig. 8-106
8-56
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. Install the floating seal (3) to the idler (4) and support (2). 4
● Apply oil to the sliding surface of floating seal. Care must be taken to keep the sliding surface from any contaminants or dust.
3 2
3
● Remove the oil and dust from the contact surfaces of the O-ring and floating seal. ZX335-1006092
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-107
3
司
公
销 营
ZX335-1006093
Fig. 8-108
6. Install the O-ring. Use the dowel pin (1) to install the support (2).
7
8
6
13
7. Refill oil and screw on the plug.
12
10
Oil: About 80 ml (No.18 hyperbola gear oil)
5
Plug: 205.8±49 Nm {21±5 kgm}
9
4
11
3
2
1
ZX335-1006085
Fig. 8-109
Shop Manual - April 2014
8-57
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.15 Sprocket 8.15.1 Removal
1
1. Remove the track assembly. For more information see “Track AS” on page 8-59. 2. Swing the work equipment 90° and lift the chassis with the help of the work equipment. Place a block ① between the track frame and the track shoe.
①
3. Remove the sprocket (1).
In Ma t rk er n et a in ti o g n De al pt .
Sprocket: 98.4 kg
ZX335-1006094
Fig. 8-110
8.15.2 Installation
● Installation is performed in the reverse procedure of removal.
司
公
销 营
Threads (bolt - sprocket):
Thread sealant (Kesaixin 1277).
Bolts (sprocket):
927±103 N·m {94.6±10.5 kgf·m}
8-58
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.16 Track AS Special tools Mark
Part Name
Necessity
Qty
M
Manual/electric hydraulic track removing/installing machine
●
1
8.16.1 Removal
In Ma t rk er n et a in ti o g n De al pt .
1. Choose a place that has enough space to spread the track. Park the machine when the master pin is between the idler and the carrier roller.
2. Lower the work equipment. Loosen the grease fitting (1) and release the track tension.
1
WARNING
司
公
销 营
● The adjustment cylinder is under extremely high pressure. Never loosen the grease fitting by more than one turn. Move the machine back and forth if no grease is seen.
ZXT335-1006095
Fig. 8-111
3. Pull out the master pin (2) with the tool (M).
2
M
ZX335-1006096
Fig. 8-112
Shop Manual - April 2014
8-59
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. Remove the tool (M). Move the machine forward so that the temporary pin ② is in front of the idler. Place the block ① . 5. Remove the temporary pin ② and the dust seal. Move the machine backward to spread the track (3).
②
3
① ZX335-1006097
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-113
8.16.2 Installation
● Installation is performed in the reverse procedure of removal.
Corner
Track shoe nut (Square)
See “Track Tensioner - Test and Adjust” on page 6-21.
R
司
公
● Installation procedure of track shoe bolts and nuts
销 营
Corner
A. Bring the R side of the track shoe nut (1) to the link seat surface. Both seat surfaces should be in close contact when assembling the track shoe. ● If the track shoe bolts are installed from the other side, the corner of nut will interfere with the link seat surface, causing the nut to raise and the bolt to loosen.
R
R
Corner
Seat surface Must be in Close contact.
B. Tighten the bolts of track shoe to the torque below. Track shoe bolts: 1029±60 Nm {105±6 kgm}
ZX335-1006098
Fig. 8-114
8-60
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Use the tool (M) to press the master pin. Make sure that the protrusion of master pin meets the size (a). Master pin protrusion (a): 4.2±2mm
a
ZX335-1006099
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-115
● Before installing the dust seal, apply grease (G2-LI) to its contact surface with the bushing.
司
公
销 营
Shop Manual - April 2014
8-61
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.17 Swing Bearing AS 8.17.1 Removal 1. Remove the swing frame assembly. For more information See “Swing frame AS” on page 8-64. 2. Remove the 36 bolts (1) in order to take off the swing bearing assembly. 3. Lift the swing bearing assembly (2).
1
In Ma t rk er n et a in ti o g n De al pt .
ZXT335-1006100
Fig. 8-116
Swing bearing assembly; 526 kg
2
司
公
销 营
ZXT335-1006101
Fig. 8-117
8-62
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.17.2 Installation ● Installation is performed in the reverse procedure of removal. Threads (bolt - swing bearing): Thread adhesive (Tianshan 1277) Mounting bolts (swing bearing): Step 1:
In Ma t rk er n et a in ti o g n De al pt .
Use a pneumatic spanner to tighten the bolts. Step 2:
Tightened to:
927±103 Nm {94.6±10.5 kgm}
A. When a torque wrench is used to tighten the bolts, tighten first the four corners and then mark them. B. Other bolts will be tightened clockwise or counterclockwise. After one bolt is tightened, tighten the next one on the diagonal position and make a mark.
司
公
销 营
C. Tighten the rest bolts in the same way.
● Let the S mark in the soft zone of the inner race of the inner ring face the right side, as shown in the photo, and install the swing bearing to the track frame.
Inner race soft zone
● Apply grease to the inside of the gear ring of the swing bearing.
All gear teeth must be covered by grease . Swing bearing: Grease(MoS2 G2-LI):15 L
ZXT335-1006102
Fig. 8-118
Shop Manual - April 2014
8-63
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.18 Swing frame AS 8.18.1 Removal Fully extend the arm and the bucket. Lower the work equipment to the ground and engage the hydraulic lockout control. 1. Disassemble the work equipment assembly. See “Work Equipment AS” on page 8-97. 2. Remove the counterweight assembly. See “Counterweight AS” on page 8-104.
1
In Ma t rk er n et a in ti o g n De al pt .
3. Remove the four (4) hoses (1) of boom cylinder. Cork the hoses to stop oil flowing out.
ZXT335-1006103
4. Lift the boom cylinder assembly (2).
Fig. 8-119
5. Remove the plate (3) and the pin (4). Lift
司
公
销 营
2
ZXT335-1006104
Fig. 8-120
8-64
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
the boom cylinder assembly (2) in order to disassemble it. Remove the boom cylinder assembly on the other side in the same way.
4
Boom cylinder AS: 264 kg 6. Remove the plate (5), air intake hose (6)
3
ZXT335-1006105
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-121
and fan guard (7).
Removal of the swing frame requires removing other parts that interfere with the lifting of swing frame. 7. Disconnect the six (6) hoses over the
司
公
销 营
rotary joint assembly on the side of swivel joint.
7
6
5
ZXT335-1006106
Fig. 8-122
(8): Central swivel joint (port A)-
Left travel control valve (port BTL)
(9): Central swivel joint (port C)-
Left travel control valve (port ATL)
(10): Central swivel joint (port F)-
Solenoid valve
(11): Central swivel joint (port G)Swing motor (port T) (12): Central swivel joint (port D)Right travel control valve (port ATR) (13): Central swivel joint (port B)-
8
9
10
11
12
13
ZXT335-1006107
Fig. 8-123
Right travel control valve (port BTR) 8. Remove the bolt (14). 9. Unscrew the 32 swing frame mounting Shop Manual - April 2014
8-65
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
bolts in order to remove the swing frame assembly (15). Lift the swing frame assembly off the machine.
15
● Remove the front and rear mounting bolts of the platform. Use a lever block to adjust the swing frame so that the platform can reach a balance both longitudinally and laterally. Remove the last two bolts finally. Take care not to damage the central swivel joint assembly while removing the swing frame assembly.
In Ma t rk er n et a in ti o g n De al pt .
ZXT335-1006108
Swing frame assembly:
Model
Assembly (kg)
SY365(B)H-9
14,755
Only swing frame (kg) 3,040
司
公
8.18.2 Installation
销 营
● Installation is performed in the reverse procedure of removal.
Clamping screws (air intake hose): 5.4~6.4 Nm {0.55~0.65 kgm}
Mating surface (swing bearing): Flat surface sealant (Tianshan 1596)
Threads (bolt - swing frame): Thread adhesive: (Tianshan 1277) Mounting bolts (swing frame):
Step 1: Tighten the bolts with a pneumatic spanner. Step 2: tighten them again.
490~608 Nm {50~62 kgm}
● Refilling of hydraulic oil Refill through the filler opening the hydraulic oil to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again. ● Purging the air Purge the air from the travel motor. See “Air in Each Component - Purge” on page 6-41.
8-66
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.19 Swivel Joint AS 8.19.1 Removal Release remaining pressure in the hydraulic return circuit. See “Remaining Pressure in Hydraulic Lines - Relieve” on page 6-36. ● Tag each line so as to ensure correct reinstallation. 1. Disconnect the hoses (1) through (8) on the central swivel joint of the travel motor.
1
In Ma t rk er n et a in ti o g n De al pt .
(1): Central swivel joint (port T) -
2
Left travel motor (port T)
(2): Central swivel joint (port T) -
Right travel motor (port T)
ZXT335-1006109
Fig. 8-124
(3): Central swivel joint (port B) -
Left travel motor (port PA)
(4): Central swivel joint (port D) -
3
司
公
销 营
Right travel motor (port PB)
(5): Central swivel joint (port A) -
8
4
5
Left travel motor (port PB)
(6): Central swivel joint (port C) -
6
7
Right travel motor (port PA)
(7): Central swivel joint (port E)-
Left travel motor (port X)
ZXT335-1006110
Fig. 8-125
(8): Central swivel joint (port E) -
Right travel motor (port X)
Shop Manual - April 2014
8-67
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
2. Disconnect the hoses (7) through (12) between: (9): Central swivel joint (port T) -
14
Swing motor (port Dr)
13
(10): Central swivel joint (port E) Solenoid valve (port PT)
12
11
(11): Central swivel joint (port C) Left travel control valve (port BTL)
9 10
(12): Central swivel joint (port A) -
In Ma t rk er n et a in ti o g n De al pt .
Right travel control valve (port ATL)
(13): Central swivel joint (port D) -
ZXT365-1308111
Fig. 8-126
Left travel control valve (port BTR)
(14) Central swivel joint (port B) -
Right travel control valve (port ATR)
3. Remove the two(2) pin rolls (16) in order to remove the plate (15).
司
公
销 营
4. Remove the four bolts (a) in order to remove the plate (b).
16
b
15
a
16
ZXT335-1006112
Fig. 8-127
5. Remove the four mounting bolts (17).
17
ZXT335-1006113
Fig. 8-128 8-68
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Remove the swivel joint assembly (18). Central swivel joint: 45 kg 18
ZXT335-1006114
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-129
8.19.2 Installation
● Installation is performed in the reverse procedure of removal. Install the central swivel joint facing the direction indicated in the illustration.
B D
司
公
销 营
(In the illustration, the machine is viewed from the above.)
Central swivel joint
Sprocket
● Refilling of oil (hydraulic tank)
Refill through the filler opening the hydraulic oil to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again. ● Purging the air
Purge the air from the travel motor. See “Air in Each Component - Purge” on page 6-41.
A C
ZX335-1006115
Fig. 8-130
Shop Manual - April 2014
8-69
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.20 Central Swivel Joint AS 8.20.1 Disassembly 1
1. Remove the fixing bolt (1).
2
2. Remove the cover (2).
3 4 5
3. Remove the rotor (12) from the housing (6). ● Take care not to damage the sliding surface of the seal of the rotor (12). 4. Remove the O-ring (3), oil seal (8) and retainer (7) from the housing (6).
In Ma t rk er n et a in ti o g n De al pt .
6
5. Remove the rotary seal (9) and O-ring (10) from the housing (6).
7 8 9
6. Remove the oil seal (11) from the rotor (12).
10
11
8.20.2 Assembly
1. Install the oil seal (11) on the rotor (12).
司
公
销 营
12
● Let the lip face the dust ring of housing.
2. Install the O-ring (10), rotary seal (9) in the housing (6). 3. Fix the rotor (12) on a work bench. Install the housing (6) on the rotor (12).
The clearance between the housing (6) and the rotor (12) approximates 0.1 mm, so the rotor must be inserted slowly in the axial direction. Take care not to damage the rotary seal and the O-ring.
13
ZX335-1006116
Fig. 8-131
Dust ring
4. Use a rubber hammer to tap the housing (6) in order to match the rotor (12) properly.
Lip
5. Install the O-ring (3) and retainer (7) on the rotor (12). Housing
6. Install the cover (2) and tighten the bolts (1). Fixing bolts: 49 Nm {5 kgm}
8-70
ZX335-1006117
Fig. 8-132
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.21 Hydraulic Tank AS 8.21.1 Removal 1. Drain oil from the hydraulic tank.
1
Hydraulic oil: About 260 L 2. Open the engine hood.
2
3. Remove the engine hood (1), beam (2) and control valve cover (3).
In Ma t rk er n et a in ti o g n De al pt .
3
ZXT335-1006118
Fig. 8-133
4. Remove the covering (4) and the main pump partition (5). 5. Remove the engine partition (6) and the bracket (7) at the hydraulic tank side.
4
6
司
公
销 营
5
7
ZXT335-1006119
Fig. 8-134
6. Remove the two(2) oil return tubes (8) and (9) of the hydraulic tank.
8
9
ZXT335-1006120
Fig. 8-135 Shop Manual - April 2014
8-71
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
7. Remove the six hoses. (10): Oil return (T-block, pilot) (11): Oil return D2 (main valve)
14
15
16
(12) & (13): Oil return (leak of main pump) (14): Oil return (solenoid valve)
13
(15): Oil return D1/D3 (main valve) (16): Oil return (swing motor)
12
● Tag the hoses for identification.
11
10
● Use socket nuts to protect the hose connectors and cone seals against damage.
ZXT335-1006121
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-136
8. Disconnect the oil suction tube (17) from the bottom of hydraulic tank and the oil suction hose (18) connected with the oil suction tube of the main pump. 9. Remove the six (6) mounting bolts (19) from the bottom of hydraulic tank. Lift the hydraulic tank assembly.
17
19
司
公
销 营
10. Move the hydraulic tank assembly away in order to disassemble it. Hydraulic tank AS: 234 kg
8-72
18
ZXT335-1006122
Fig. 8-137
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.21.2 Installation ● Installation is performed in the reverse procedure of removal.
Drain plug (hydraulic tank): 58.8~78.5 Nm {6.0~8.0 kgm}
Screw
● After tightening the hose clamping screw, check that the screw should be in the range indicated in the illustration.
Upper side
In Ma t rk er n et a in ti o g n De al pt .
Lower side
Screw (hose clamp):
8.8±0.5 Nm {0.9±0.05 kgm}
ZX335-1006123
Fig. 8-138
● Install the hose clamp and tighten the screw according to the illustration on the right.
司
公
销 营
Tube
Hose
Bolt:
245.2~308.9 Nm {25~31.5 kgm}
O-ring seal 2
O-ring seal 1
● Refilling the oil (to hydraulic tank)
Refill hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.
Clamp 2
Clamp 1
ZX335-1006124
Fig. 8-139
● Purging the air
See “Air in Each Component - Purge” on page 6-41.
Shop Manual - April 2014
8-73
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.22 Control Valve AS 8.22.1 Removal Lower the work equipment to the ground in order to ensure safety. Stop the engine. Power on the machine and relieve system pressure. Use the breather valve to release the pressure in the hydraulic tank. Place the hydraulic lockout control in the LOCK position.
1 2
In Ma t rk er n et a in ti o g n De al pt .
● Tag each line so as to ensure correction reinstallation. 1. Remove the engine hood (1).
2. Remove the coverplate (2) on the control valve.
ZXT335-1006125
Fig. 8-140
3. Remove the engine partition (3).
司
公
销 营
3
ZXT335-1006900
Fig. 8-141
4. Remove the pressure sensor guard (4).
4
ZXT335-1006901
Fig. 8-142 8-74
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. Remove the ten (10) pilot hoses (from left to right) and tag them properly. The hoses are for: (5) Left travel (6) Right travel
5 6 7
8 9
10 11
14 12 13
(7) Arm OUT (8) Left swing (9) Bucket DIG (10) Boom DOWN
ZXT335-1006902 ZXT335-1006902
(11) Boom UP
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-143
(12) Right swing
(13) Bucket DUMP (14) Arm IN
6. Remove the two(2) pilot hoses on the control valve and tag them properly. The hoses for:
16
15
(15): Right travel forward
司
公
销 营
(16): Left travel forward
ZXT335-1006903
Fig. 8-144
7. Remove the pressure sensor harness (17).
17
ZXT335-1006904
Fig. 8-145
Shop Manual - April 2014
8-75
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8. Remove the clamp (18) fixing the harness of solenoid valve.
18
ZXT335-1006905
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-146
9. Disconnect the hoses (19) and (20) from the check valve block to the pilot pump and swing motor port (PG).
司
公
销 营
19
20
ZXT335-1006906
Fig. 8-147
23
10. Remove the boom tube clamp (21) on the main valve.
22
11. Remove the tubes (22) and (23) from the main valve to boom cylinder. Seal the ports properly.
21 ZXT335-1006907
Fig. 8-148
8-76
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
12. Disconnect the bucket hoses (24) and (25). Seal the ports properly. 13. Disconnect the arm hoses (26) and (27). Seal the ports properly.
24
25 26
27
ZXT335-1006908
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-149 14. Disconnect the hoses (28), (29), (30) and (31) between the central swivel joint and the main valve. Seal the ports properly.
29
30
28
31
15. Disconnect the swing motor hoses (32) and (33). Seal the ports properly.
16. Disconnect the hose (34) between control valve and swing motor port (M) and the hose (35) between control valve and swivel joint.
35
34
32 33
司
公
销 营
ZXT335-1006909
Fig. 8-150
17. Disconnect the tube or hose (36) of radiator and the oil return tube (37) of hydraulic tank. Seal the ports properly.
37
36
ZXT335-1006137
Fig. 8-151
Shop Manual - April 2014
8-77
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
18. Disconnect the hydraulic pump hoses (38) and (39). 39
38
ZXT335-1006138
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-152
19. Remove the two pilot hoses under the control valve and tag them properly. (40) Right travel backward
41
40
(41) Left travel backward
司
公
销 营
ZXT335-1006139
Fig. 8-153
20. Remove the harness and hoses of the solenoid valve and tag them properly.
42
43
(42) Oil return hose (43) Harness
(44) Negative feedback hose from solenoid valve to front pump
44
(45) Negative feedback hose from solenoid valve to rear pump (46) Oil feed hose from solenoid valve to PT block
8-78
45
46
ZXT335-1006140
Fig. 8-154
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
21. Remove the bolts (48) of the control valve assembly. Lift the control valve assembly in order to dissemble it. Control valve AS: 380 kg 47
ZXT335-1006141
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-155
8.22.2 Installation
● Installation is performed in the reverse procedure of removal. ● Refilling the oil (to hydraulic tank)
Refill hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.
司
公
销 营
● Purging the air
See “Air in Each Component - Purge” on page 6-41.
Shop Manual - April 2014
8-79
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.23 Hydraulic Pump AS 8.23.1 Removal Lower the work equipment to the ground in order to ensure safety. Stop the engine. Press the release button of the breather valve to release remaining pressure in the hydraulic tank. Disconnect the cable from the negative (-) post of the battery before performing the job.
Oil stopper
In Ma t rk er n et a in ti o g n De al pt .
● Tag each line so as to ensure correction reinstallation.
1. Remove the oil inlet filter element from the hydraulic tank and stop oil outflow with an oil stopper.
ZX335-1006142
Fig. 8-156
If no oil stopper is used, remove the drain plug and drain the oil from the hydraulic tank and the lines.
1
Hydraulic oil tank: About 340 L
司
公
销 营
2. Remove the engine hood (1)
WT365081301
Fig. 8-157
3. Remove the rod (2) and bolts (3). Lift the engine hood.
2 ZXT335-1006144
Fig. 8-158
8-80
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. Remove the upper right coverplate (4). 3
4
ZXT335-1006145
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-159
5. Disconnect the hose (5) supplying oil to the lower proportional valve and the hose (6) delivering oil from the pilot pump. Seal the ports properly.
5
6
司
公
销 营
ZXT335-1006146
Fig. 8-160
6. Remove the shutdown device line (7).
7 ZXT335-1006147
Fig. 8-161
Shop Manual - April 2014
8-81
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
7. Remove the right door (8). 8. Remove the hydraulic pump cover (9).
8
9
ZXT335-1006148
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-162
9. Disconnect the oil drain hose (10) and seal the ports properly.
13
10. Disconnect the high-pressure hoses (11) and (12) connected to the control valve, and seal the port properly.
11. Disconnect the harness (13) of the pressure transducer.
11
12. Disconnect the pilot pump oil suction hose (14) and seal the port properly. 13. Disconnect the hydraulic pump oil suction tube (15) and seal the port properly.
12
司
公
销 营
10
14
15
ZXT335-1006149
Fig. 8-163
14. Disconnect the solenoid valve harnesses (16) and (17).
16
17
ZXT335-1006150
Fig. 8-164
8-82
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
15. Remove the four bolts (18) of the hydraulic pump. Lift the hydraulic pump assembly (19) in order to disassemble it.
19
Hydraulic pump assembly: 186 kg
18 ZXT335-1006151
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-165
8.23.2 Installation
● Installation is performed in the reverse procedure of removal.
● After tightening the hose clamping screw, check that the screw should be in the range indicated on the right illustration.
Screw
Upper side Lower side
司
公
销 营
Screw (suction hose clamp):
10~13 N·m {1.0~1.3 kgf·m}
● Install the hose clamp and tighten the screw according to the illustration on the right.
ZX335-1006123
Fig. 8-166
Mating surface (hydraulic pump housing): Gasket sealant: (Loctite 515)
Tube
Hose
● Refilling the oil (to hydraulic tank)
Refill hydraulic oil through the filler opening to the specified level. Start the engine to circulate oil in the hydraulic system, and check the oil level again.
O-ring seal 2
Clamp 2
Hydraulic tank: About 340 L
O-ring seal 1
Clamp 1 ZX335-1006124
Fig. 8-167
● Purging the air See “Air in Each Component - Purge” on page 6-41.
Shop Manual - April 2014
8-83
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft) 8.24.1 Removal 1. Remove the hydraulic pump assembly (1). See “Hydraulic Pump AS” on page 8-80.
1
2. Remove the screw (2). Remove the bearing cover (3).
2 3 4
3. Pry the oil seal (4) out with a screwdriver.
In Ma t rk er n et a in ti o g n De al pt .
● Take care not to damage the shaft while prying the oil seal.
8.24.2 Installation
ZX335-1006152
Fig. 8-168
● Installation is performed in the reverse procedure of removal.
司
公
销 营
4
Seal lip: grease (No.1 Calcium base grease) Seal circumference: grease (No.1 Calcium base grease)
● Apply a thin layer of grease to the oil seal circumference.
ZX335-1006153
Fig. 8-169
8-84
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.25 Pilot Valve AS (Work Equipment) ● This section discusses only the precautions when reassembling the work equipment pilot valve assembly. 8 2
3
4
5
6
7
10
In Ma t rk er n et a in ti o g n De al pt .
1
9
ZXT335-1006154
Fig. 8-170
● Reassembly of the work equipment pilot valve assembly 1. Install the plate (9) in the valve body (8) with O-ring seal. Tighten the socketheaded screw (10).
司
公
销 营
Screw (socket head): 25~33 Nm {2.55~3.36 kgm} 2. Insert the spring (7) into the spool hole in the valve body (8). Put the spool (6) in the spring. Install the plug (5) on the spool. Push the plug (5) to the spool hole.
Apply the thread adhesive (Tianshan 1277) to two points on the inner threads, as indicated in the illustration on the right. The amount of application is approximately 0.02 g. U-joint (3): 98~133 Nm {10~13.5
kgm}
● Tightening is to be made to the specified torque.
5~7 mm
3. Install the plate (4) on the plug (5). Tighten the U-joint (3).
4. Install the plate (2). Align the position of the plate (2) and tighten the nut (1). Nut: 98~133 Nm {10~13.5 kgm}
● Location of each oil port is stamped on the bottom of valve body. Plug (5) circumference: Grease (No.1 Calcium base grease) U-joint working surface: Grease (No.1 Calcium base grease) Threads in valve body: Thread adhesive (Tianshan 1277)
ZX335-1006155
Fig. 8-171 Contact surface between plug (5) and plate (2): Grease 0.3~0.8cc (G2-L1) ● After assembling plate (2) see “Work Equipment and Swing Pilot Valves Adjust” on page 6-33.
Shop Manual - April 2014
8-85
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.26 Travel Pilot Valve AS ● This section discusses only the precautions when reassembling the travel pilot valve assembly.
In Ma t rk er n et a in ti o g n De al pt .
Pushrod
9
8
7
6
4
3
2
5
1
ZXT335-1006156
Fig. 8-172
● Reassembly of pedal pilot valve assembly
司
公
销 营
1. Install the spring (8) into the spool installation hole in the body assembly (9). Install the spool (7). Place the cover assembly (6) on the spool and press the cover assembly (6) with a hand. 2. Install the cover (4) after aligning the holes. Tighten the socket-headed bolts (1). Bolt (socket head): 98~114 Nm {10~11.6 kgm}
3. Install the dust ring (3) on the plug. Install the cover (2) and fix the cover (2) with the camshaft (5). Contact surface between the plug and the dust ring (3): Grease (No.1 Calcium base grease)
8-86
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.27 Hydraulic Cylinder AS Special tools Tool Description
Sketches
Necessity
For pulling out/ pushing in the bushing
■
Quantity
1
In Ma t rk er n et a in ti o g n De al pt .
For press fitting the dust ring
■
1
■
1
■
1
■
1
For O-ring seal correction
司
公
销 营
For insertion
For inserting the cylinder head
For correction
For inserting the piston
Shop Manual - April 2014
8-87
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.27.1 Disassembly 1. Drain the oil and remove the tubing. 2. Fix the cylinder. ● Fix the cylinder in a vertical or level manner. A vertically fixed cylinder can be disassembled and assembled easily.
In Ma t rk er n et a in ti o g n De al pt .
● The pin hole in the head end can be used for fixing of the cylinder. The pin roll can prevent the cylinder from turning. ● Remove the tubing in case of tubing interference while fixing the cylinder.
Secure the cylinder
司
公
销 营
ZX335-1006162
Fig. 8-173
3. Removal of cylinder head
Approx 1.5 m
● Unscrew the bolts with Allen Wrench.
● Using an extension rod, as shown in the illustration on the right, will make the work easy.
ZX335-1006163
Fig. 8-174 8-88
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4. Pulling out the piston rod ● Be sure to have removed the tubing cover. ● Prepare a suitable container to collect oil coming out of the oil port.
1
● After pulling out the piston rod (1) to its limit, slowly loosen the cylinder head and pull it out.
2
Sleeper
● Remove piston rod (1) with cylinder head (2) and place them on a wooden sleeper.
ZX335-1006164
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-175
5. Securing the piston rod
Secure
● Pin hole on the rod end or the flat part of the ear can be used to fix the piston rod and prevent it from turning.
5
司
公
销 营
ZX335-1006165
Fig. 8-176
6. Remove of piston nut (5)
A. Remove the fixing screw (3) from the piston nut (5).
Drill bit
3
● Around the fixing screw there are two points that have been punched against loosening. After removing the riveted part with a hand drill, loosen and remove the fixing screw (3). B. Remove the steel ball (4) inside the fixing screw.
4
ZX335-1006166
Fig. 8-177
Shop Manual - April 2014
8-89
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
C. Remove the piston nut (5).
5
● The piston nut (5) is very tight. To loosen the piston nut (5), prepare a hydraulic jack or a spanner powered by hydraulic cylinder. An extension rod should be ready when removing the piston nut (5) manually.
Hydraulic jack Hydraulic cylinder ZX335-1006167
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-178
7. Removal of piston assembly
Remove in turn the piston (7), buffer sleeve (6) and cylinder head (2).
2
6
7
ZX335-1006168
司
公
销 营
8. Removal of the buffer sleeve (8) on the head end
Fig. 8-179
Threads
A. Remove first the piston nut (5).
B. Use a tool like rubber hammer to tap the piston nut (5) slightly in order to remove it. The piston rod and the buffer sleeve (8) should be kept intact. Remove the elastic retainer (9).
Piston rod
C. Slide the buffer sleeve (8) toward the piston threads in order to remove the two-piece stopper ring. D. Remove the buffer sleeve (8).
9
8
11
(two-piece type) ZX335-1006169
Fig. 8-180
E. There is an opening in the buffer seal (10). Take advantage of this opening to remove the buffer seal (10).
8-90
10
With one opening
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
9. Removal of piston seal
Screwdriver
A. The slide ring (12) and the guard ring (13) can be simply removed with hands. B. The seal (14) can be removed with a hammer and a flat-head screwdriver.
12
14
Piston
Bench clamp
C. Remove the O-ring seal (15) with a pry bar. ● The removed seals should not be reused.
15
13
ZX335-1006170
Fig. 8-181
In Ma t rk er n et a in ti o g n De al pt .
10. Removal of buffer ring (16)
● The buffer ring (16) is installed in the inner groove in the cylinder head. Use a tool with sharp end to pry it out and remove it with a scraper.
18
11. Removal of the U-ring (17) and the dust ring (18).
A. Remove the U-ring (17) with a tool such as screwdriver.
司
公
销 营
B. Press a tool (such as a screwdriver) against the dust ring (18) and hammer the screwdriver to remove the dust ring (18).
17
16
19
20
ZX335-1006171
Fig. 8-182
● The removed seals should not be reused.
Press
12. Removal of bushing (19)
A. Remove the elastic ring (20) from the cylinder head (2) with a screwdriver. B. Push the bushing (19) out with the help of clamps and press.
Block
13. Removal of pin bushing (21) 21
A. Remove the dust ring (22) on the side of cylinder barrel and piston rod with a tool such as screwdriver. B. Remove the bushing (21) with the help of a suitable cushion block.
Support ZX335-1006172
Fig. 8-183
Shop Manual - April 2014
8-91
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.27.2 Assembly Press
1. Installation of bushing (21)
Installation tool
A. Use an installation tool to press the bushing (21) into the bushing (lubricated with hydraulic oil) on the side of piston rod and cylinder barrel.
Block
Piston rod
21
22 21
B. Install the dust ring (22) with the help of a suitable cushion block.
ZX335-1006173
Fig. 8-184
In Ma t rk er n et a in ti o g n De al pt .
2. Assembly of cylinder head (2)
Hydraulic press
A. Use the press to push in the bushing (19).
● Apply hydraulic oil to the inside of cylinder head in advance. Make sure that the bushing (19) pushed in is free from a raised shoulder.
2
Too
司
公
销 营
B. Use the press to push in the dust ring (18). C. Install the guard ring and the U-ring (17) sequentially in the U-groove.
● Install the U-ring (17) in correct direction. Make sure that the U-ring is intact before installation.
19
Under pressure
ZX335-1006174
Fig. 8-185
● Inverse installation will cause leak of oil.
● Make sure that the U-ring is free from any corrugation or permanent deformation after installation. D. Installation of buffer ring (16) ● Make sure that the seal is installed in correct direction. Inverse installation can cause high pressure between the buffer ring (16) and the U-ring (17), which may lead to deformation or breakage of oil cylinder.
Tool
U-groove
Press in
ZX335-1006175
Fig. 8-186
E. Install the elastic ring (20) to prevent the fall of the bushing (19). 8-92
18
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
3. Assembling the piston assembly
Press in
A. Installation of seal (14). ● Install first the O-ring seal and the one-side guard ring (13) on the piston. Place the piston on the press. As shown in the illustration on the right, the seal (14) is installed with the tools indicated.
Press in
Block
Tool
13 Tool
Tool for correction
Piston
B. Correction of seal (14) 12 14
● Install the seal (14) and the guard ring (13) on the other side. In order to prevent the expansion of the seal (14), a corrector must be used to correct the seal (14) which has been stretched during installation. The piston rod may not be able to go in the cylinder barrel if the seal (14) is not corrected timely.
O-ring
In Ma t rk er n et a in ti o g n De al pt .
13
ZX335-1006176
Fig. 8-187
C. Installation of slide ring (12)
● Slightly open the slide ring (12) and install it axially. Excessive opening of the slide ring (12) can fail installation.
司
公
销 营
4. Assembling the piston rod assembly
Assembling tool
A. Fix the piston rod (1).
2
B. Install the cylinder (2) on the piston rod. ● Make sure that the U-ring lip is shoulder of any inder head and the tools.
the dust ring lip or not stopped by the part. Install the cylthe piston rod with
1
ZX335-1006177
Fig. 8-188
Shop Manual - April 2014
8-93
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
C. If the bottom side of cylinder contains a buffer (not for bucket cylinder), install the buffer bearing and the buffer seal in the following order.
The opening faces the threads. Threads
a. Let the notched side of the buffer seal (10) face the piston while installing the buffer seal (10) in the groove.
Piston rod
b. Install the buffer sleeve (8) according to the indication in the illustration on the right.
9
c. Install the stopper ring (11) in the groove. Install the elastic ring after the buffer sleeve (8) is pushed to the bottom. A rubber hammer should be used for the tapping job in order to avoid damaging the piston rod and the buffer bearing.
11
8
10
(Two piece type)
In Ma t rk er n et a in ti o g n De al pt .
With one opening
D. If the head side of cylinder contains a buffer, install the buffer sleeve (6) and the buffer seal (23) according to the following order.
Head end buffering
ZX335-1006178
Fig. 8-189
23
6
司
公
销 营
5
a. The piston nut must be installed after installation of the buffer bearing. b. T h e b u ff e r s e a l ( 2 3 ) m u s t b e installed in the groove, with its notches facing the piston. c. The buffer sleeve (6) must be installed according to the illustration on the right.
The opening faces the piston side. Rod end buffer
ZX335-1006179
Fig. 8-190
E. Tighten the piston nut (5). Piston nut (arm):
9600 Nm {979.6 kgm} Piston nut (boom and bucket): 6200 Nm {632.6 kgm} ● Insufficient tightening can cause oil leakage, loose nut and thread breakage. In addition, excessive tightening can cause expansion of the buffer shaft on the extending side or deformation of 8-94
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
piston on the contact side. ● Thoroughly clean and grease (with banana oil) the threaded portions of the piston, nuts and piston rod before tightening the nuts.
Rivet
Punch
F. Treatment of the piston against loosening ● After the piston nut (5) is tightened, put in the steel ball (4), tighten the setscrew (3) and punch to rivet the two peripheral points.
3 4
In Ma t rk er n et a in ti o g n De al pt .
Setscrew (3):
66.9 Nm {6.8 kgm}
5. Install the piston into the cylinder barrel.
A. Fix the barrel in a vertical or level manner.
ZX335-1006180
Fig. 8-191
B. Install the piston rod into the cylinder barrel.
● If fixed in a vertical manner, the piston rod falls into the barrel under its gravity.
司
公
销 营
● Make sure that the slide ring does not fall while the piston is inserted into the barrel.
Tool Nylon sleeve (two pieces)
(Move the notch 180 degrees away.)
ZX335-1006181
Fig. 8-192
Shop Manual - April 2014
8-95
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Tightening of cylinder head Tighten the bolts following the sequence shown in the illustration on the right.
1
8 4
Bolt: 267 Nm {27.2 kgm} 7. Install the tubing.
9
12
5
6
11
10
In Ma t rk er n et a in ti o g n De al pt .
3 2
7
Bolt tightening sequence
ZX335-1006182
Fig. 8-193
司
公
销 营
8-96
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.28 Work Equipment AS
8.28.1 Removal Fully extend the arm and the bucket. Lower the work equipment to the ground. Move the hydraulic lockout control to the LOCK position. Release remaining pressure in the hydraulic circuit. See “Remaining Pressure in Hydraulic Lines - Relieve” on page 6-36. 1. Disconnect the grease hose (1).
In Ma t rk er n et a in ti o g n De al pt .
5
2. Lift the boom cylinder assembly (2). Remove the lockbolt (3).
1
3
3. Remove the plate (4) and then the pin roll (5 ). ● There are shims installed. Count the shims and check the thickness. Place the shims in a safe place. 4. Start the engine and retract the piston rod.
4
司
公
销 营
● Secure the piston rod with a wire rope in order to prevent the piston from slipping out. Place the cylinder on a bench or support. The grease fitting on the bottom side must be removed in the later case.
2
ZXT335-1006183
Fig. 8-194
● Remove the other boom cylinder in the same way.
5. Remove the two hoses (6) of bucket cylinder and the two hoses (7) of the arm cylinder.
● Cork the hoses to prevent outflow of oil. Tie the hoses to the valve side 6. Remove the mid-connector (8) used for work lamp.
8 7
7
7
6
6 ZXT335-1006184
Fig. 8-195
Shop Manual - April 2014
8-97
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
7. Lift the work equipment and remove the plate (9). Remove the bottom pin roll (10). 10
There are shims installed. Count the shims and mark their locations.
9 ZXT335-1006185
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-196
8. Lift the work equipment assembly (11) in order to disassemble it.
11
Work equipment assembly:
Model
Weight
SY365H-9
5,652 kg
SY365BH-9
7,102 kg
司
公
销 营
ZXT335-1006186
Fig. 8-197
8-98
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.28.2 Installation ● Installation is performed in the reverse procedure of removal. A clearance (a: 0.5 - 1.5 mm) should be left between the plate and the nut when tightening the locknut. Greasing after assembling the pin: Grease (MoS2 G2-L1)
In Ma t rk er n et a in ti o g n De al pt .
WARNING
a
● Never use your finger to align the pin holes.
ZX335-1006187
Fig. 8-198
● Adjust the shim thickness in order to have a desired clearance (a: 0.5 ＜ a ＜ 1 mm) between the piston end (12) and the plate (4).
12
a
4
司
公
销 营
● Standard shim thickness: 1.0 mm and 2.0 mm. Greasing after assembling the pin:
Grease (MoS2 G2-LI)
ZX335-1006188
Fig. 8-199
WARNING
● Never use your finger to align the pin holes. ● Refilling the hydraulic oil
Refill hydraulic oil to the specified level. Start the engine to circulate the oil in the hydraulic system, and check the oil level again. Add more hydraulic oil if necessary. ● Purging the air Purge the air from travel motor. See “Air in Each Component - Purge” on page 6-41.
Shop Manual - April 2014
8-99
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.29 Air Conditioner AS Special tools ID
Part Name
Model
S
Refrigerant refiller
-
Necessity Qty ●
1
8.29.1 Removal NOTICE
In Ma t rk er n et a in ti o g n De al pt .
S
● Always disconnect the cable from negative post of the battery before you proceed.
ZXT335-1006189
Fig. 8-200
1. Drain the coolant.
Coolant: Approx 22.5 L
2. Recover refrigerant from the air-conditioning system with the tool (S).
司
公
销 营
3. Remove the pad on the bottom cover (1).
1
ZXT335-1006190
Fig. 8-201
4. Use the start key to open the left rear cover of the cab. Remove the external air filter element (2).
Cover
2 ZXT335-1006191
Fig. 8-202 8-100
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. Remove the monitor lower covers (3) and (4). Disconnect the wire (M19) of the cigar lighter before removing the cover (3). 6. Remove the air duct (5) on the right side.
4
3
5 ZXT335-1006192
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-203
7. Remove the back cover (6).
6
司
公
销 营
ZXT335-1006193
Fig. 8-204
8. Remove the back air duct (7).
8
7
9. Remove the left air duct (8). 10. Remove the baffle (9).
11. Remove the right air duct (10).
10
9
ZXT365-1308197
Fig. 8-205
Shop Manual - April 2014
8-101
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
12. Remove the cover (11). 13. Remove the cab's center connector (12). 14. Remove the radio antenna(13).
13
12 11
ZXT335-1006195
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-206
15. Remove the air duct (14) and the controller wiring connector (15). Disconnect the wiring connector (16). Remove the air conditioner relay (17). Remove the three (3) mounting bolts (18) and then the board (19).
17
16
司
公
销 营
18
14
15
19
ZXT335-1006196
Fig. 8-207
16. Remove the air conditioner water pipes (20) and (21) as well as the dripping tube (22) under the bottom cover.
22
20
21
ZXT335-1006197
Fig. 8-208
8-102
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
17. Remove the air conditioner unit (23). Also disconnect the two hoses connecting to the bottom of the air conditioner when removing the air conditioner unit.
23
ZXT335-1006198
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-209
8.29.2 Installation
● Installation is performed in the reverse procedure of removal.
Keep the hoses free from contamination by dirt, dust or water while installing the return hose of the air conditioner.
司
公
销 营
Make sure that the O-ring seal is present in the connection before connecting a hose of the air conditioner. Make sure that the O-ring seals are free from any damage or deformation.
● Apply compressor oil (ND8#) to the threads of the parts connected with the refrigerant lines. Tighten the line connections with a double-end spanner. Screw (hose clamp):
8.83~14.7 Nm {0.9~1.5 kgm} Bolt (pressure plate): 13.5±1.2 Nm {1.38±0.12 kgm} ● Refilling refrigerant Refill refrigerant (HFC-134a) into the air conditioner circuit with the tool (S).
Shop Manual - April 2014
8-103
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.30 Counterweight AS 8.30.1 Removal 1. Install lift pin (1) in lift eye of counterweight. Slowly tighten the wire rope (2) with lifting equipment to hold the counterweight.
2
In Ma t rk er n et a in ti o g n De al pt .
1
ZX365-1308163
Fig. 8-210
2. Remove the four mounting bolts (2 ) and washers. 3. Lift the counterweight with lifting equipment.
司
公
销 营
Take care not to damage the engine, radiator and cooler. Counterweight AS: 6800 kg
3
ZX365-1308164
8-104
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.30.2 Installation ● Installation is performed in the reverse procedure of removal. Threads (mounting bolt - counterweight): Thread adhesive (Tianshan 1277) Mounting bolt (counterweight):
In Ma t rk er n et a in ti o g n De al pt .
2,295±200 N·m {214~255 kgf·m} ● Counterweight Installation and adjustment
A. Lift the counterweight with a crane to a suitable position over the frame.
门
c=0±5
B. Push the counterweight and install the bolts. Adjustment is to be made according to the following specification.
Unit: mm
Counterweight
a=10±4
● Clearance with swivel:
司
公
销 营
10±5 mm(L&R)
b=0±5
● Clearance with bodywork door:
Swing frame
10±5 mm(L&R)
● Step difference from swing frame in left to right direction
ZX335-1006202
Fig. 8-211
b: max. 5 mm
● Step difference from bodywork door in left to right direction
a: 10±4
● Step difference from bodywork top cover in upper to lower direction
c: max. 5 mm
Shop Manual - April 2014
8-105
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.31 Cab AS 8.31.1 Removal NOTICE ● Always disconnect the cable from negative post of the battery before you proceed.
1
In Ma t rk er n et a in ti o g n De al pt .
1. Remove the floor mat (1). ZXT335-1006203
Fig. 8-212
2. Remove the back covers (2) and (3).
2
司
公
销 营
3
ZXT335-1006204
Fig. 8-213
3. Disconnect the left harness (4), the monitor harness connector (5) and the window washer harness (6).
4
5
4. Remove the right air duct (7).
6 7 ZXT335-1006205
Fig. 8-214 8-106
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. Remove the fresh air filter element (8).
8 ZXT335-1006206
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-215
6. Remove the fresh air duct (9).
9
司
公
销 营
ZXT335-1006207
Fig. 8-216
7. Remove the storage box (10) of console.
10
ZXT335-1006208
Fig. 8-217
Shop Manual - April 2014
8-107
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8. Disconnect the radio connector (11). 9. Disconnect the radio harness (12). 11
12
ZXT335-1006209
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-218
10. Remove the window washer fluid reservoir (13).
13
司
公
销 营
ZXT335-1006210
Fig. 8-219
11. Remove the window washer hose (14).
14
ZXT335-1006211
Fig. 8-220
8-108
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
12. Remove the decorative cap (15).
15
ZXT335-1006212
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-221
13. Remove the five (5) bolts (16) and the four(4) nuts (17). ● Check the length of bolt before removal.
16
17
司
公
销 营
ZXT365-1308210
Fig. 8-222
14. Lift the cab assembly (18) in order to remove it.
18
Cab AS: 105 kg
8.31.2 Installation
● Installation is performed in the reverse procedure of removal.
ZXT365-1308211
Bolt: 200 Nm {20.4 kgm}
Fig. 8-223
Nut: 210 Nm {21.4 kgm}
Shop Manual - April 2014
8-109
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.32 Cab Window Glass
10
10 9
8
1
2
In Ma t rk er n et a in ti o g n De al pt .
10
7
6
10 11
司
公
销 营
4
5
12
10
3
ZX215-1006218
Fig. 8-224
(1) Right window glass (2) Front window glass (3) Lower front glass (4) Cab door window glass (upper) (5) Cab door window glass (lower) (6) Cab door window glass (upper) (7) Left side rear window glass (8) Rear window glass (9) Roof window glass (10) Rubber sealing strip (11) Center adjusting seal (12) Front window assembly
● Cab window glasses (1), (2), (5), (7) and (9) are adhered to the window frame. ● When replacing front window glass (2), disassemble front window assembly (12). (If the cab is install with a front window assembly, do not only replace the front window glass.) ● For detailed information, See “Front Window AS” on page 8-126.
(Glass and frame) 8-110
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.32.1 Removal CAUTION
3
In Ma t rk er n et a in ti o g n De al pt .
● Be careful with sharp edges that may cut your fingers when handling broken or cracked window glasses. Put a piece of adhesive film (or adhesive tapes ) onto the broken or cracked window glass to prevent possible personal injury before you proceed. Remove all glass fragments. 1. Removal of glass (3)
ZX215-1006219
Fig. 8-225
Glass (3) is hold in place by sealing strips. Pull it upward carefully to remove it. 2. Removal of glass (4) and (6)
A. Remove the sealing strip from the frame of the cab door. B. Push the glass outward carefully from inside of the cab and remove glass (4) and (6) together with the frame.
司
公
销 营
6
4
ZX215-1006220
Fig. 8-226
C. Remove glass (4) and (6) from the frame with a screw driver.
Frame Seal
6 4
ZX215-1006221
Fig. 8-227
Shop Manual - April 2014
8-111
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
3. Removal of glass (8) A. Remove the retainer from the groove on the rubber with an ordinary screw driver.
8
B. Put a thin bamboo chip inside part A of the retaining rubber and detach the retainer along the edge. C. Pat the glass from inside of the cab and remove it. This job requires two people. ZX215-1006222
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-228
4. Removal of glass (1), (2), (5), (7) and (9)
9
1
7
2
司
公
销 营
5
ZX215-1006223
Fig. 8-229
A. Remove the resin board, decor strip and retainer along the edge of the glass.
Cab
Glass
B. Punch a hole through the adhesive with a drill (or a cutter) as illustrated.
Drill
Adhesive ZX215-1006224
Fig. 8-230
8-112
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
C. Pull a piece of piano string (or steel wire) through the hole as illustrated.
Piano string (or metal wire)
ZX215-1006225
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-231
D. Fix both ends of the piano string onto two screw drivers. Pull the wire back and forth in order to cut the adhesive and detach the glass from the cab. This job requires 2-3 people.
Run the string along the center of the adhesive. The string may break when it becomes very hot. Use different sections of the string while cutting the adhesive.
(Outside of cab)
Cab
Glass
司
公
销 营
Adhesive
(Inside of cab)
ZX215-1006226
Fig. 8-232
Shop Manual - April 2014
8-113
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.32.2 Installation 1. Clean the remaining adhesive and rubber on cab frame (contact surface) with a knife or scraper (5). ● Remove the remaining adhesive and rubber so that they will not affect the application of new adhesive. Do not scrape the original paint on the surface. (Scraping of paint reduces the performance of the adhesive.)
In Ma t rk er n et a in ti o g n De al pt .
5 ZXT215-1006227
Fig. 8-233
2. Clean the grease, dust and dirt on the cab (8) and the glass (9) with unleaded gasoline. ● Contaminant on the contact surface reduces the performance of adhesive.
司
公
销 营
● Clean the black part on the back of the glass.
8
● After cleaning, dry the glass for at least 5 minutes.
ZXT215-1006228
Fig. 8-234
9
ZXT215-1006229
Fig. 8-235 8-114
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
3. Priming coat (10) ● Priming paint expires four (4) months after production. Do not use expired paint.
Cab
11
● Use the paint within two (2) hours after it is unsealed.
10
● Use the paint within 24 hours even if it is sealed again immediately unsealing. (Dispose the paint 24 hours after it is unsealed)
Old adhesive edge on cab side
ZX215-1006230
A. Make sure the adhesive paint and glass priming paint are well agitated before application.
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-236
● If the priming paint is stored in a refrigerator, keep it under ambient temperature for at least half a day before agitation.
(If the paint is unsealed immediately after it is taken out of a refrigerator, water will condense on it.)
司
公
销 营
B. Always wash a used brush (11) with unleaded gasoline before using it.
● Check the brush for contaminants after it has been washed.
8
● Prepare two brushes for priming paint, one for painted surface and the other for glass surface.
C. Apply priming paint (for painted surface) evenly onto the surface where sealing rubber is to be adhered and where adhesive agent is to be applied (on the cab (8)).
ZXT215-1006231
Fig. 8-237
Priming paint (for painted surface): Sunrise MSI Primer 24
8
● Do not apply primer more than twice; otherwise, the performance of the primer will be reduced.
6
● Applying location: Cover the whole area of (a)
a
● Dimension of (a): 25mm
ZX215-1006232
Fig. 8-238 Shop Manual - April 2014
8-115
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Besides the above locations, apply primer also onto the right window glass and the cab door lower window glass.
b
● Additional priming area on the right window glass: (b) ● Additional priming area on the cab door lower window glass: (c) ● Dry the primer for at least 5 minutes (within 8 hours). ZX215-1006233
In Ma t rk er n et a in ti o g n De al pt .
● Do not use wrong priming paint. If, for example, glass primer is mistakenly used, wash it with unleaded gasoline.
c
司
公
销 营
ZX215-1006234
Fig. 8-239
D. Apply priming paint (for glass surface) onto the contact surface of window glass (9).
9
Glass primer:
Sunrise MSI Primer 35
● Do not apply the primer more than twice; otherwise, the performance of the primer will be reduced.
ZX215-1006235
Fig. 8-240
8-116
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Priming area: Apply the priming paint on the contact surface of glass (9) (rubber seal (6)adhering location) and along cab frame (8).
8
6
● Leave a 5 mm margin uncoated along the black strip adjacent to the clear area of the glass.
d
● When priming paint has been coated, dry it for at least 5 minutes (within 8 hours).
9 ZX215-1006236
Fig. 8-241
● Do not use wrong primer.
In Ma t rk er n et a in ti o g n De al pt .
If wrong glass primer is used, wash it with unleaded gasoline.
4. Adhere rubber seal (6) (with adhesive tape on both sides) along the inner edge of the contact surface of the glass.
● Do not detach the waxed paper on the rubber seal before the window glass is installed.
司
公
销 营
● Do not touch the cleaned area on the glass before rubber seal is adhered. ● Be careful not to allow the rubber seal on the corners to peel off.
● When sticking rubber seal (6) along the window frame, do not overlap the two ends of the seal. A 5 mm gap (e) between the two ends of the seal is recommended.
6
ZXT225-1006245
Fig. 8-242
A. Stick rubber seal (6) onto the right cab window frame as illustrated.
e
6
ZXT225-1006246
Fig. 8-243
Shop Manual - April 2014
8-117
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Adhere additional rubber seal (6a) onto the right cab window
f 6a
Position of the additional rubber seal: (f): 50 mm h
(f): 90 mm (h): 250 mm g
ZXT225-1006247
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-244
B. Adhere rubber seal (6) on the left cab window as illustrated.
6
司
公
销 营
ZXT225-1006248
Fig. 8-245
C. Adhere rubber seal (6) onto the lower cab door window as illustrated.
6
ZXT225-1006249
Fig. 8-246
8-118
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Adhere additional rubber seal (6b) onto the lower cab door window frame as illustrated.
j
Position of additional rubber seal:
6b
(j): 110 mm (k): 90 mm
m
(m): 200 mm
k
ZXT225-1006250
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-247 D. Adhere rubber seal (6) onto the front window glass as illustrated.
6
司
公
销 营
ZX215-1006243
Fig. 8-248
● Different from the rubber seal (6) on other window, rubber seal (6c) on the bottom of the front window shall be adhered onto the external edge of the lower part of the front window frame. (If it is adhered along the inner edge, the rubber seal will be seen through the clear part of the glass.)
6
6c
ZXT225-1006252
Fig. 8-249
Shop Manual - April 2014
8-119
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. Positioning of new window glass 9
A. Check the clearance between the edge of glass and the cab in 4 directions, and position the glass. Make sure the clearance is even.
n
B. Put a tape [6] across the glass (9) and cab (8) and draw a line (n) on it for alignment.
[6]
Adhere tape [6] at 3 points as illustrated for precise alignment of right window glass, left rear window glass and cab door lower window glass.
8 ZXT215-1006245
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-250
C. Cut the tapes across the glass (9) and the cab (8) and remove the glass.
● Do not remove the tape on the left side of the glass until the glass is installed.
[6]
8
[6]
[6]
司
公
销 营
9
ZX215-1006246
Fig. 8-251
● When positioning front window glass (4), cover it across the width of the window frame in the horizontal direction.
P
Set the clearance (p) between the top edge of the glass and the upper frame at 3 mm when positioning it in the vertical direction.
4
ZX225-1006255
Fig. 8-252
8-120
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Adhesive 13
● Store adhesion agent in dark places where temperature is blow 25℃ . ● Do not heat the adhesive to above 30℃ . ● Before using adhesive that has been unsealed, remove the hardened part at the nozzle.
12
A. Open the aluminum seal (13) on the head of the cylinder (12) and install the nozzle.
ZX215-1006247
Fig. 8-253
In Ma t rk er n et a in ti o g n De al pt .
Adhesive:
Sunrise MSI SR sealant U90 4463876
B. Cut the tip of nozzle as illustrated. Dimension of the cut: (q): 10 mm
r
14
(r): 5 mm
司
公
销 营
q
ZX215-1006248
Fig. 8-254
C. Set the cylinder (12) in the gun [7].
An electrical caulking gun is more efficient.
12
[7]
ZX215-1006249
Fig. 8-255
Shop Manual - April 2014
8-121
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
4) Remove the waxed paper of the rubber seal on the surface where adhesive is to be applied.
15 6
5) Apply adhesive (15) along the external edge of the rubber seal (6).
ZX215-1006250
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-256
● Adhesive (15) for rubber seal (6) on cab (8) shall be applied as illustrated:
8
s
Dimension of (s): 10 mm Dimension of (t): 15 mm
● Adhesive (15) shall be thicker that the rubber seal (6).
6
t
司
公
15
销 营
● Apply adhesive of the same thickness evenly.
ZX215-1006251
Fig. 8-257
8-122
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● Apply adhesive (15) onto the additional rubber seal of the right window (6a) and additional rubber seal of the cab door lower window (6b).
6a 15
ZX215-1006252
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-258
6b
15
司
公
销 营
ZX215-1006253
Fig. 8-259
7. Install window glass
A. Install window glass (9) and align it with the mark on the cab. (See step 5)
● Since the glass can not be remove once installed, be very careful when performing this task. ● Install the glass properly within 5 minutes after adhesive has been applied. B. Press the perimeter of the glass (9) after is has been put in place until it is securely stuck to the rubber seal. ● Press the corners of the glass hard.
9
ZXT215-1006254
Fig. 8-260
Shop Manual - April 2014
8-123
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
● After the front window glass has been installed, fill the clearance between the glass on area (s) and the center adjusting seal (16) to the dimension of (t) and (u). Coat primer onto glass (4) on section A-A and apply the adhesive as fillers.
A
A
● Dimension of (t): 2 mm
S
● Dimension of (u): 5 mm ● Use a rubber spatula to cover the edge of the glass and trim the adhesive.
t 4
In Ma t rk er n et a in ti o g n De al pt .
● Remove surplus adhesive. Glass primer：
Sunrise MSI Primer 35
Adhesive：
Sunrise MSI SR Sealant U90 4463876
u
16
A-A
ZX215-1006255
司
公
销 营
Fig. 8-261
8. Fix the glass
A. After the right window glass (1) has been adhered to the cab, put positioning chips (a) (1 or 2 pcs) beneath the glass in order to fix it.
1
a
ZXT215-1006256
8-124
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
B. Use foam polystyrene blocks [9] and rubber band [10] to fix the glass and the rubber seal as illustrated.
[10]
9. After the glass has been fixed, remove all the remaining primer and adhesive on the cab and on the glass. ● Clean the adhesive with unleaded gasoline before it is hardened. ● Do not apply impacting force onto the glass when cleaning it.
[9]
10. Protection of fixed window glass
ZX215-1006257
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-262
A. Remove the positioning chips, foam polystyrene blocks and the rubber band after 10 hours.
(Condition: Temperature: 20; humidity: 60%)
B. Wait for another 14 hours after the removal of positioning chips, foam polystyrene blocks and rubber band before operating the machine.
司
公
销 营
Shop Manual - April 2014
8-125
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.33 Front Window AS Lower the work equipment onto the ground and shut down the engine. ● The front window assembly must be removed from the cab in order to replace the front window glass. Disassembling and assembling method of front window assembly (frame and glass) is illustrated in the following part.
In Ma t rk er n et a in ti o g n De al pt .
8.33.1 Disassembly 1. Raise the front window assembly to the roof and secure it with the rear locks (at both sides).
2. Remove left corner plate (1) and right corner plate (2).
2
● Mounting bolt (4) and washer (3) of the left corner plate will be used in Step 6 to hang the pull rod.
4
3
1
司
公
销 营
ZX215-1006258
Fig. 8-263
3. Release the rear lock of the cab.
4. Lower the front window assembly carefully a bit. Take out and hold the rollers (5) and (6) at the bottom of the front window from the removed parts in Step 2. 5. Remove roller (5) and (6) from both sides of the bottom of the front window.
6
5 ZX215-1006259
Fig. 8-264
8-126
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
6. Remove pin (7) at the lower left side.
9
● Plate (8) at the end of the pull rod (9) will come out by removing of pin (7).
8
● Hang plate (8) onto the mounting bolt of left corner plate (using the washer) and fix it.
6
NOTICE 7
ZX215-1006260
In Ma t rk er n et a in ti o g n De al pt .
● A return load of 58.8 N {6 kg}is applied onto the rear of the cab. Be very careful when removing pin (7) to disconnect pull rod (9).
9
8
司
公
销 营
ZX215-1006261
Fig. 8-265
7. Pull out the front window assembly (10) from the opened part of the guide rail and lower the assembly gradually.
10
ZX215-1006262
Fig. 8-266
Shop Manual - April 2014
8-127
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8. Lower the front window assembly (10) completely. 10
● Be careful not to allow the front window assembly to damage the machine monitor.
ZX215-1006263
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-267 9. Move the front window assembly (10) to the right and the left and remove the two upper rollers (11) and (12) from the guide rail. Then, remove the front window assembly (10).
10
司
公
销 营
ZX215-1006264
Fig. 8-268
12
10
Fig. 8-269 8-128
Shop Manual - April 2014
11
ZX215-1006265
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.33.2 Assembly ● Reverse the disassembling sequence.
● Adjust the opening and closing of the front window assembly as per the following instruction. 1. Open and close the front window assembly and check if it interferes with the guide rail. Check if the roller is jammed.
In Ma t rk er n et a in ti o g n De al pt .
2. If the front window can not be opened or closed properly, loosen the mounting bolt of the roller adjusting bracket (13) and adjust the condition of the front window. Tighten the mounting bolt after adjusting.
13
ZX215-1006266
Fig. 8-270
● Make sure bracket (13) is installed without an angle.
Mounting bolt ： 34.3 N·m {3.5 kgf·m}
司
公
销 营
3. Raise the front window assemble and fix it with rear locks (at both sides). ● Check if the locks at the rear of the cab are securely fixed.
a
4. Install the right corner plate (2).
2
● After the "locked" position is adjusted in Step 6, tighten the corner plate. ● Install the right corner plate. Clearance (a) between the guide rail and the right corner plate (2) is 0 – 2.0 mm.
a
ZX215-1006267
Fig. 8-271
● Install the right corner plate. Keep the surface (R) of the roller without a level error.
R
ZX215-1006268
Fig. 8-272
Shop Manual - April 2014
8-129
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
5. Install left corner plate (1) ● After the "locked" position is adjusted in Step 6, tighten the corner plate.
b
● Install left corner plate. Clearance (b) between the guide rail and the left corner plate (1) is 0 – 2.0 mm. ● Install left corner plate and keep the surface (R) of the roller without a level error. (See the previous illustration).
b
1 ZX215-1006269
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-273
6. Adjust the "locked" position of the lock of front window assembly as per the following instruction.
A. Tighten the left corner plate (1) and the right corner plate (2) in a nearly correct position so that front window glass (14) is pressed closely against the adjusting seal (19) on the cab.
15
司
公
销 营
14
ZX215-1006270
Fig. 8-274
8-130
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
B. Open and close the front window assembly and check the working condition of left lock (16) and right lock (17). ● If left lock (16) and right lock (17) do not work properly,
17
16
a. Loosen the mounting bolt (18) of the lock and move the lock (16) forward. Tighten the bolt after that. Adjust the right lock with the same method.
ZX215 1006271
In Ma t rk er n et a in ti o g n De al pt .
b. C h e c k a g a i n t h e a d a p t a b i l i t y between the front window assembly (14) and the adjusting seal (15) on the cab. (Checked in Step 1)
Repeat Step a) and Step b) until the condition of front window glass and lock (16) and (17) is satisfactory. Tighten the mounting bolts of the left and right corner plates.
7. After adjustment is finished, flush the front window glass with abundant water and check if any water penetrates into the cab.
司
公
销 营
16
18
ZX215-1006272
8. Adjust the "locked" position of the lock of front window assembly
A. After the "locked" position of the lock of front window assembly is adjusted in Step 6 and Step 7, raise the assembly to the roof.
B. Set the locks of the front window assembly at the rear of the cab at the "locked" position, and check the following items:
19
18
● Check the conditions of left lock (16) and right lock (17). ● The front window assembly must contact the left and right rubber stopper (18), and the rubber stoppers must be pushed backward by 1.5 – 3.0 mm.
ZX215-1006273
● The front window assembly shall push the limit switch 4 – 7mm backward.
Shop Manual - April 2014
8-131
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
C. Close the front window assembly (10). D. Loosen the retaining nut (20) at the left and right side of rubber stopper (18), and pull the two rubber stoppers (18) inward so that they can not contact the "unlocked" front window assembly.
20
18
ZX215-1006274
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-275 E. Adjust the position of latch bolt (21).
Latch bolt(21): M10, Inner diameter of plate (23): ø14.5 mm
21
司
23
公
销 营
ZXT225-1006284
Fig. 8-276
F. Adjustment of left and right rubber stopper (18) a. Allow front window assembly (10) to contact the left and right rubber stopper (18). (when the lock is "unlocked")
10
17
19
21 ZX215-1006276
Fig. 8-277
8-132
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
b. Lock front window assembly (10). c. Turn the left/right rubber stopper (18) to the left by one and a half round. ● Turning the rubber stopper (18) leftward for one round is equivalent to pressing it by 1.5 mm. 18
● When front window assembly is “unlocked”, it must move the left/ right rubber stopper (18) by 1.5 – 3.0 mm.
ZX215-1006278
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-278
d. Tighten the retaining nuts (20) at both sides of the rubber stopper (18).
18
20
司
公
销 营
ZX225-1006287
Fig. 8-279
Shop Manual - April 2014
8-133
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
9. Adjust the front window assembly retainer (24). A. Adjust and lock both sides of the retainer (24) so that surface (d) of stopper (D) of front window assembly contacts surface (c) of retainer (24) when front window assembly is raised.
24 10
D
ZX215-1006279
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-280
24
D d
司
公
销 营
c
ZX215-1006280
Fig. 8-281
10. Check the locking ability of front window assembly.
A. After the adjustment from Step 6 to Step 9 is finished, check the locking force of left lock (16) and right lock (17).
16
17
● Check the locking force at the "locked" side (front of cab) and the "unlocked" side (rear of cab).
ZX215-1006271
Left lower pin:
Fig. 8-282
27 – 34 N·m {2.75 – 3.47 kgf·m} Mounting bolt：adhesive(LT-2)
8-134
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.34 Monitor - Remove and Install 8.34.1 Removal NOTICE
3
● Always disconnect the cable from negative post of the battery before you proceed.
4 5
2 1
In Ma t rk er n et a in ti o g n De al pt .
1. Unscrew the three (3) bolts (4). Remove the mounting plate and the monitor assembly from the bracket (3).
2. Remove the nut (1) and the gasket (2) to separate the monitor (5) from the mounting plate.
ZX335-1006215
Fig. 8-283
8.34.2 Installation
● Installation is to be performed in the reverse order of removal.
司
公
销 营
Shop Manual - April 2014
8-135
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.35 Controller AS 8.35.1 Removal NOTICE
1
● Always disconnect the cable from negative post of the battery before you proceed. 2
1. Remove the back plates (1) and (2).
In Ma t rk er n et a in ti o g n De al pt .
2. Remove the controller wiring connectors (3) and (4).
ZXT335-1006216
3. Remove the two(2) bolts. Remove the controller assembly (5).
Fig. 8-284
2
司
公
销 营
4
3
ZXT335-1006217
Fig. 8-285
8.35.2 Installation
● Installation is to be performed in the reverse order of removal.
8-136
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.36 Radio 8.36.1 Structure
In Ma t rk er n et a in ti o g n De al pt .
1. Main structure
司
公
销 营
ZX335-1006218
Fig. 8-286
Shop Manual - April 2014
8-137
8-138 销 营
司
公
Fig. 8-287
Shop Manual - April 2014 RADIO ANTENNA
BLACK — L. SOUND TRACK OUTPUT –
WHITE — L. SOUND TRACK OUTPUT +
LIGHT — R. SOUND TRACK OUTPUT – BLACK
GRAY — R. SOUND TRACK OUTPUT +
BLACK — GROUND
YELLOW — BATT POWER SUPPLY
RED — ACC IGNITION
WHITE — R. SOUND TRACK INPUT
RED — L. SOUND TRACK INPUT
In Ma t rk er n et a in ti o g n De al pt . AUDIO INPUT
Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator
2. Wiring
BACK PANEL
POWER, GROUND AND AUDIO OUTPUT
ZX335-1006219
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.36.2 Removal and installation Console cover
Removal 1. Remove the console cover (1).
NOTICE ● The power must be turned off before removal.
Radio ZX335-1006220
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-288 2. Remove the radio connector CN-003F.
司
公
销 营
Connector CN-003F
Cab harness
ZX335-1006221
Fig. 8-289
3. Remove the four(4) screws and the washers in order to remove the radio and the radio mounting brackets from the console cover.
Console
4. Remove the four(4) screws and the washers in order to remove the radio from the radio mounting brackets.
Radio bracket
Washer
Radio
Screw ZX335-1006222
Installation
Fig. 8-290
● Installation is to be performed in the reverse order of removal.
Shop Manual - April 2014
8-139
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.36.3 Connector model and wiring
1
5
3
6
7
2
3
20b
R+
L+
0
20b
R-
L-
4
5
6
7
In Ma t rk er n et a in ti o g n De al pt .
4
2
1
Harness socket terminals Model: Deutsch DJ7072-3-21
Radio wiring terminals
Fig. 8-291
司
公
销 营
8-140
Shop Manual - April 2014
ZX335
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.37 Battery 8.37.1 Structure
C
E
In Ma t rk er n et a in ti o g n De al pt .
6
J
10
11
A
B
2
D
I
G
H
F
8
司
公
销 营
7
5
9
4
3
1 ZX335-1006224
Fig. 8-292 (1) (2) (3) (4) (5) (6)
Spinning post Charge densimeter Heat-sealing cover PP casing Central polar ear Forged grid
(7) Paste (active material) (8) "Bag-type" screen (9) Polar group (10) Liquid-gas separator (11) Central busbar
Shop Manual - April 2014
8-141
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.37.2 Removal and installation NOTICE ● Turn the start switch to the OFF position before removal.
Removal
In Ma t rk er n et a in ti o g n De al pt .
● Do not remove the charge densimeter. Tighten the densimeter clockwise, if it is loosened, with a suitable tool.
Bolt
3. Removal of battery grounding wire
● Open the tarpaulin, unscrew the bolt, and remove the terminal from the battery wiring post.
Terminal
Grounding cable
A VART
CAUTION
Battery
● Battery gas can cause explosion. No sparks or flames are allowed near the battery.
MAINTE
NANGE-
TTER FREE BA
Y
司
公
销 营
ZX335-1006225
Fig. 8-293
2. Disconnect the battery wiring cable and the battery breaker cable.
Cable
VARTA
VARTA
Battery
Breaker cable ZX335-1006226
Fig. 8-294
8-142
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
3. Remove the four(4) bolts and washers. Remove the battery assembly from the bottom plate. Remove the battery.
In Ma t rk er n et a in ti o g n De al pt .
VAR TA
VAR TA
Battery
Bolt
Washer
Battery box ZX335-1006227
Fig. 8-295
Installation
● Installation is to be performed in the reverse order of removal.
司
公
销 营
8.37.3 Replacement
There are two 12V batteries with grounding negative (-) posts in the machine. If one battery fails in the 24V system, it must be replaced with one of the same type. Batteries of different types are probably charged at different speeds, which may cause one of them to fail due to overloading.
NOTICE
● Apply Vaseline, when required during installation, to battery terminals to prevent corrosion.
Shop Manual - April 2014
8-143
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.38 Start Switch 8.38.1 Structure 22
20
18
17
15
13
12,11
28
6
10,9,8,7
In Ma t rk er n et a in ti o g n De al pt .
23
25,24
21
1
14
19
16
26
司
公
销 营
5
4,3,2
1 2 3
4 5 6
27
ZX335-1006228
Fig. 8-296 (1) (2) (3) (4) (5) (6) (7)
Housing Key Ring Dial Nut Cylinder Cap
8-144
(8) Shield (9) Pin (10) Spring (11) Disc (12) Spring (13) Plug (14) Rotor
(15) (16) (17) (18) (19) (20) (21)
Cover Spring Ball Spring Contact SPR-B Contact A Seat
Shop Manual - April 2014
(22) (23) (24) (25) (26) (27) (28)
Contact SPR-A Contact B Terminal Bolt O-ring seal Harness AS Washer
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.38.2 Removal 1. Unscrew the setscrew to remove the console cover.
;
0$
7
67$5
/2
&.
2))
21
0,1
Start switch
Console cover
Setscrew ZX335-1006229
Fig. 8-297 2. Remove both setscrews in order to remove the mounting plate and the start switch from the console cover.
Console cover
In Ma t rk er n et a in ti o g n De al pt .
Setscrew
NOTICE
● Disconnect the power supply of the start switch before removal.
司
公
销 营
Mounting plate
Start switch
ZX335-1006230
Fig. 8-298
3. Remove the nut so as to remove the start switch from its mounting plate.
Start switch
Mounting plate
Nut ZX335-1006231
Fig. 8-299 Shop Manual - April 2014
8-145
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.38.3 Working principle
On/off status Gear position
Battery (B)
Battery relay (BR)
Preheat plug
Accessory (ACC)
(R1)
(R2)
Start relay (C)
3B OFF 1B 2B ZX335-1006232
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-300
8.38.4 Wiring
1
B
BR
ACC
3
1
22
13
3
4
16
11
6
司
公
销 营
4
R1
R2
C
6
Start switch wiring terminal Jacket model: Yazaki 7222-7464-30
Fig. 8-301
8-146
Shop Manual - April 2014
Harness plug terminal Jacket model: Yazaki: 7123-7464-30
ZX335-1006233
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.39 Fuse Box Removal Cover
1. Remove the cover.
In Ma t rk er n et a in ti o g n De al pt .
ZX335-1006234
Fig. 8-302
2. Remove the bolts and take off the back cover along with the fuse box.
Back cover
Fuse box cover
司
公
销 营
Bolt
ZX335-1006235
Fig. 8-303
3. Remove the bolts so as to separate the fuse box and harness from the back cover.
Harness
Bolts
Back cover
ZX335-1006236
Fig. 8-304
Shop Manual - April 2014
8-147
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.40 Wiper 8.40.1 Structure
Wiper blade
In Ma t rk er n et a in ti o g n De al pt .
Driving mechanism
Wiper arm
Wiper motor
Connector
司
公
销 营
Mounting bracket
ZX335-1006237
Fig. 8-305
8-148
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.40.2 Working principle
Green (low speed) Yellow (reset)
M Blue (high speed)
In Ma t rk er n et a in ti o g n De al pt .
Red (power +)
Black (power -)
司
公
销 营
ZX335-1006238
Fig. 8-306
Shop Manual - April 2014
8-149
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.40.3 Removal 1. Remove the decorative button in order to remove the interior decoration.
Decorative button
Interior decoration
ZX335-1006239
Fig. 8-307
In Ma t rk er n et a in ti o g n De al pt .
2. Remove the moving mechanism and the motor.
● Unscrew the bolts to remove the wiper motor and moving mechanism from the cab.
Bolt
Moving mechanism
Wiper motor
司
公
销 营
Bolt
ZX335-1006240
Fig. 8-308
3. Remove the arm and the blade.
● Unscrew the nut to remove the wiper arm and blade from the cab.
Arm bracket
8.40.4 Installation ● Installation is to be performed in the reverse order of removal.
Guard Locknut
Cab
Fig. 8-309 8-150
Shop Manual - April 2014
ZX335-1006241
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.40.5 Angle adjustment of wiper arm ● The arm should stops moving when the blade reaches the stopper.
Mechanical stopper
● If the arm is still working when the blade reaches the stopper or the arm already stops working before the blade reaches the stopper, the moving angle of wiper should be adjusted to prevent breakdown of the wiper.
Wiper blade
Arm
In Ma t rk er n et a in ti o g n De al pt .
● Adjust the wiper in such a way. Loosen the locknut; adjust the arm working angle according to actual condition. Make sure that the wiper motor stops working at the moment that the blade reaches the mechanical stopper.
Locknut
司
公
销 营
ZX335-1006242
Fig. 8-310
Shop Manual - April 2014
8-151
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.41 Relays
S
8.41.1 Engine relays 1. Starter relay - check
B
● Check the conduction and action. Replace the relay in case of any failure.
AA2A
S B
SW
1 SW(-) L(-) 2
L
ZX335-1006243
Fig. 8-311
In Ma t rk er n et a in ti o g n De al pt .
2. Mains relay - check
1(+)
● Check the conduction and action. Replace the relay in case of any failure.
2(-)
3
4
Battery terminal (+)
司
公
销 营
3
4
1(+) 2(-)
ZX335-1006244
Fig. 8-312
3. Heater relay
5(-)
● Check the conduction and action. Replace the relay in case of any failure.
1
4. Safety relay
5 (-)
● Measure the resistance between terminal 2 and terminal 3. Standard Value
Approx. 200W
● Check the conduction and action. Replace the relay in case of any failure.
8-152
Fuse
2
1
2 3 4 (+)
4(+) 3 ZX335-1006245
Fig. 8-313
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.41.2 Other relays Function and location
Relay harness Horn relay
Start control relay Pilot cotnrol relay
In Ma t rk er n et a in ti o g n De al pt .
Headlight relay
司
公
销 营
Parking relay
Work lamp relay
Mounting plate
ZX335-1006246
Fig. 8-314
Shop Manual - April 2014
8-153
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.41.3 Removal and installation
Relay harness
Mounting plate
Removal 1. Remove relay from its seat. 2. Remove the screw in order to remove the relay seat and harness from the mounting plate. Installation ● Installation is to be performed in the reverse order of removal. Setscrew
In Ma t rk er n et a in ti o g n De al pt . Relay seat
Relay
ZX335-1006247
Fig. 8-315
8.41.4 Relay connector and wiring
5
4
1
2
司
公
销 营
3
Relay wiring terminal
Relay model：HELLA 4RD 007 903-027
Headlight K2
Sart switch K3
77 ③ ① 74
④
⑤ 73
27 ③
11 ③
②
0
②
①
620
④ 105
27
⑤
④ 105 606
②
①
31
⑤
11a
④
Shutdown delay K8
21 ③
34 ③
32 ③
②
①
Work lamp K6
Horn K5
Pilot valve K4
0
②
①
33
④
0
①
621 ④
⑤
⑤
⑤
23
24
15a
② 0
Relay socket Jacket 8JA003526-00
Wiring socket terminal Relay socket model: Jacket 8JA003526-00
Fig. 8-316 8-154
Shop Manual - April 2014
ZX335-1006248
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.42 Sensors 1. Water temperature sensor - check 1
● Put the sensor into a vessel containing engine oil. ● Heat the oil to the specified temperature. Stir the oil at the same time.
Sensor body
● Measure the resistance value between the terminal 1 and the sensor body at different temperatures. 80±10Ω
60℃
56.3Ω(ref.)
80℃
29.5Ω(ref.)
100℃
16.5Ω(ref.)
ZX335-1006249
In Ma t rk er n et a in ti o g n De al pt .
50±0.2℃
Standard Value
Fig. 8-317
106±0.3℃ 14.3±1.0Ω 120℃
10Ω(ref.)
● Replace the sensor if the measured value exceeds the standard one.
司
公
销 营
2. Engine speed sensor - check
● Measure the resistance between terminal 1 and terminal 2. Std. Value(25℃ )
2.3±0.2kΩ
● Replace the sensor if the measured value exceeds the standard one.
2
NOTICE
1
ZX335-1006250
Fig. 8-318
● Insufficient tightening of the engine speed sensor may cause signal output failure. Tighten the sensor to specified torque.
Shop Manual - April 2014
8-155
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
3. Pressure sensor - check Pressure joint
● Input volt: 4.75~5.25 VDC
Body
Connector
● Output volt: 0.5~4.5 V ● Pressure range: 0~50 BAR Terminal B Terminal A
Terminal C
W365813081
In Ma t rk er n et a in ti o g n De al pt .
Fig. 8-319 4. Fuel level sensor - check
● Swing the float up and down in order to measure the effective angle of radial swing, i.e. the line through the float and the turning point will swing 105° . ● Swing the float up and down. The vertical distance between the upper limit and the lower limit of the float should be 500 mm.
Float
司
Lever
公
销 营
● Move the float to its upper limit. Measure the resistance between the sensor terminal R and ground with a multimeter. The measured resistance should be Ru ≦ 9.6Ω.
Terminal R
Shell
● Move the float to its lower limit. Measure the resistance between the sensor terminal R and ground with a multimeter. The measured resistance should be Rd ≧ 86Ω.
Connector
ZX335-1006252
Fig. 8-320
8-156
Shop Manual - April 2014
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.43 Connector Terminals 8.43.1 Insertion
In Ma t rk er n et a in ti o g n De al pt .
1. Hold tightly a wire terminal at a distance of about 25 mm from its end.
ZX215-1006320
Fig. 8-321
2. Hold the connector. Let the rear seal face you.
司
公
销 营
ZX215-1006321
Fig. 8-322
3. Align the terminal with a hole on the seal and push it perpendicularly to the bottom. Slightly pull back the wire in order to ensure that the terminal is locked in place.
ZX215-1006322
Fig. 8-323
Shop Manual - April 2014
8-157
Disassembly and Assembly
SY365(B)H-9 Crawler Hydraulic Excavator
8.43.2 Removal 1. Hold the connector, with its back end facing you. Select a suitable tool and clip on the wire.
In Ma t rk er n et a in ti o g n De al pt .
ZX215-1006323
Fig. 8-324
2. Push the tool along the wire into the connector so that the tool can expand the terminal lock shoulder and reach its flanged part.
司
公
销 营
ZX215-1006324
Fig. 8-325
3. Pull out the tool to remove the wire with terminal.
ZX215-1006325
Fig. 8-326
8-158
Shop Manual - April 2014
Disassembly and Assembly
BLMaInt e r AkNe rn a tKi t i ng o PAD nal eGp tE.
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
Shop Manual - April 2014
8-159
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
In Ma t rk er n et a in ti o g n De al pt .
System Schematics 9 System Schematics 9.1 9.2 9.3 9.4 9.5 9.6
Diagram of Hydraulic Lines...................................................................................... 9-3 Electrical diagram of chassis ................................................................................... 9-4 Electrical diagram of control switches...................................................................... 9-5 Electrical diagram of operator station ...................................................................... 9-6 Electrical diagram of air conditioner......................................................................... 9-7 Electrical diagram of monitor ................................................................................... 9-8 司
公
销 营
Shop Manual - April 2014
9-1
System Schematics
In Ma t rk er n et a in ti o g n De al pt .
SY365(B)H-9 Crawler Hydraulic Excavator
司
公
销 营
9-2
Shop Manual - April 2014
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
Swing
9.1 Diagram of Hydraulic Lines
Arm
Bucket
Boom
Left travel
Right travel
SH D
D
PG MB
MA
VA
(4) Right swing To XBs
IN
(10)Arm in
g
(3)Arm out To XAa1 lower
To XBa1 XBa2 PaL Arm hold valve
To XBc
XBb2 PbL Boom hold valve
Arm 1
Backward (2)Right travel
XAa1
Backup
LCAP2
ARC
Pna1
LCa
XBo
司
公
销
Boom 2
4 T P
Swing
na Right travel
To XAtL upper
io
XAc XBc Drb PbL Ab (HEAD) Bb (ROD)
XBb2
XBb1 LCb
Lcb2
Bs As XAs Xbs Dr4 Pns Px Btr Atr XAtr
XAtL XBtL
LCs CT2
CP2
Φ0.7
PH
CMR1
CMR2
Φ0.7 R3
PG
Pz
MR
P1 rear pump
T PH1
A1
a2
a1
A2
PH2 Psv2
(COOLER)
P1
A1 2nd bost
Travel speed change
A2
A3
Front pump adjuster
A4
PPC lock valve
A6
A5
2.5bar
cc
A7
电液控转换
bb 变功率调节
C
Pf
Rear pump adjuster
电液比例阀
A8
4.5bar
Pf
dd Pi1
负压调节
P1
Engine
FRONT
P2
B
Pi2 A4
A
REAR As
DR
10μm
In
te
rn
at
P2 front pump
Left travel
(PTa)
(PTb) CT1
Φ0.7
Boom 1
CpG
XBtr
Py
Bucket
XAb1 AtL BtL
cp1
Psv1
10μm
Forward 2
Left travel
PAcs
BbR
Dr2
l
1
To XBtL lower
Bc(HEAD)
HVb
Ccb
XAb2
Backward (1)Left travel
Ac(ROD)
LCk
LCo
Arm 2
AcR
XAo
营
To XAtr upper
XAa2
BcR
BoR
AoR
AbR
Forward
XBa2
LCAT2
(Bo) (Ao)
To XBtr lower
Ba2(HEAD)
BaR
Dr3
PAcs
Dr1
CCk
P2
4 3
XAb1 lower DOWN (7)Boom up ToXAb2
CC0
AaR
B1
B3
A3
10μm
2
3
T P
UP
(6)Boom down To XBb1 upper
XBp2
HVa
Aa (ROD) Ba1 (HEAD) XBa1
(9)Bucket dump To XAc lower
rk e
XBp2
DIG
Central swivel joint
N2 N1 XBp1
Dra PaL
Ma
(5)Bucket dig DUMP
Right travel
(R4) (P4)
R1 R2
Bucket
Boom
P4
RS2
RS1
ti n
XAa2
1
Arm
OUT
2
P
4
3
T
VB
1
De
A
B
To XAs
(8) Left swing
Swing
VA
pt
PA
PB
Transitional block
MA
MB
REG
VB
.
P
P
DB
M
GER
80~150目
WX365-1309001
9-3
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
9.2 Electrical diagram of chassis
CN-501M
To cab harness CN-506M
CN-502F
CN-506F
5
103
509
0
508
F-300
106
510
1
0 15 20 21
2
42
66
T-501 To power supply T-500 grounding wire
CN-113M
T-101
511
pt
12
T-100
200 201 202
204 205 206
T-107
21 16
208
g
17
602
606 607 608 609
502 702 703 511 108A
22 64 63 0 65
108B
To preheat resistance To rpm sensor CN-125F
50A 1 507 2 MT- 3 4 00 5 MT+ 6
rk e
501
T-107
108A 108B
ti n
603
To compressor clutch
T-134 To preheat fuse T-109
207
1 2 3 4 5 6
To throttle motor CN-124F
To parking motor CN-801F
609 1
司
公
营
106 510
销
0 606
2
CN-137F
1
To pilot SV
508 0 S 66 103 509 704
608
0
0 702 0 602 0
34
32
0#
1
1
B
1
2
CN-102M
F-104 F-103
To work lamp
To horn C
2
CN-507M
1
2
CN-503F
D
0
0 00
502
50
A B C
00 501
A B C
50
00
200
A B C
50
00
201
A B C
50
00
202
50
00
208
50
00
205
50
00
207
50
00
206
A B C
A B C
A B C
A B C
A B C
CN-122M
CN-123M
CN-124M
CN-125M
CN-126M
50
00
204
A B C
50
00
21 1
2
CN-504F
12 1
20
CN-116F
2
R. pump main pressure sensor
CN-115F
F. pump main pressure sensor
CN-133F
2 1 2
CN-120M
Left travel pressure sensor
CN-121M
Right travel pressure sensor
Arm OUT pressure sensor
Bucket DIG pressure sensor
Swing pressure sensor
Boom DOWN pressure sensor
Boom UP pressure sensor
CN-128M
Bucket DUMP pressure sensor
To R. pump SV CN-134F
To F. pump SV CN-132F
1 2
2
CN-138F
Hi/Lo travel SV CN-131F
1 2
CN-135F
203 704
A B C
1
Power limit SV 0
16 17
2
607 1
603
50
CN-136F
1
1
rn 0
In
te
2
2
703
at
3
A
T-102 T-101 To battery T-104 relay KB T-120
57
De
203
io
4
21
F-301
CN-101F
Ma
17 18 19 20 21 22 23 24 25 26 27 28 29 30 32
6
60
T-102 T-135 CN-103M
Oil press High-temp Low-temp Hydraulic oil switch Temp sensor switch switch temp sensor
l
7
14
Air plugging Fuel level Start motor switch sensor
na
8
21
0
42 34 60 14 15 32
22 65 50A 64 63 MT- MT+ 507 50 00 57
1 2 3 4 5 6 7 8 9 10 11 13 14 15 16
T-103 T-116 CN-800F
345678
2 3 4 5 6 7 8 9 10 11 12
To cab harness CN-501F
Alternator terminals
.
To cab harness CN-502M
9
CN-129M
2
CN-114F
Arm IN pressure sensor
CN-505M
E
F
G
H
I
J
K
L
M
N
9-4
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
9.3 Electrical diagram of control switches
9
22
13
62
61
33
3
5
CN-507F
CN-505F
7
1
24
35H
3
5
25 35L
7
1
36
3
37
5
7
25
108B 506 50 61
De
8
1
.
TERMINAL B BR ACC R1 R2 C HEAT OFF ON START
Washer switch
Wiper switch
CN-503F
pt
Wrok lamp switch
Start switch
11
62
g 14
1
5
506
00
2
74
3
73 74
1
司
5
F-507
F-505
F-508
F-509
25 33
7
5
35L 60
6
1
A
10A
Charging indicator
F3
5A
Horn loop
F4
15A
work lamp
F5
5A
wiper & washer
F6
10A
Radio
F7
10A
Cab lamp
F8
20A
Air conditioner
5A
Access lamp
5A
Monitor
F11
20A
Controller
F12
15A
Head lamp
F13
10A
F14
10A
F15
15A
F1
22
7 8 9 10 11 12 CN-203M
20
13
F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 14 23 24 25 20b 26 38 28 29 42 73 43 27 100
13
1
14
2
29 42 20 20 21
3
21
4 5 6 7 8 CN-222F
To cab harness CN-122M
te
F9 F10
B
l
na
F2
io
Start loop
4
To cab harness CN-203F
rn
20A
2
24
27 28
In
3
20
System
Rated value
F1
at
Fuse No.
22
21
Fuse box harness
2
37
13 14
Head lamp switch
1 3
11
CN-508F
4
11 12
35H 36
销
CN-501F
To fuel control dial
9 10
CN-202F
73
3
5
To cab harness CN-202M
公
营
4
8
ti n 69
Ma
50 14
60
3
7
rk e
6
2
6
69 7
1
38 73 22 100 43 20b 23 24
1 2 3 4 5 6 7 8
Aux. controller
9
25
26
10 11 12 CN-221M
Solenoid valve GP Cigarette lighter
C
D
To cab harness CN-121F E
F
G
H
I
J
K
L
M
N
9-5
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
9.4 Electrical diagram of operator station To chassis harness CN-502F
To control switch harness CN-202F
4
36
5
37
6 7
35L
8 10
14
11 12
7
6
4
To chassis harness CN-506F
4
108 B 506 50A
5
6
61 62
0
2
10 11 12 69 73 74
3
4
5
6
7
8 9
1
50 00 57
65 50A 63 64 MT- MT+ 507
22
10 11 12 2
1
3 45
2
0
74
1
3 45
77
1
73
0 11a
14
1
68
60
2
2
14
15 32
66 61 68
1
To alternator
To safety relay
2
3
0
4
69
0
1
A
2
0
1
3 45
1
606 31
27
64
2
3
4
65
2
3 4 5
2
3 4 5
0 32
23
1
2
3 45
1
33
2
3 45
0 34
24
1
2
1
621
2
0
2
3 45
13
3 45
21 15a
CN-201F To horn button
1
15
2
15a 15
1 2
37
2
0#
203
105
0# 20b
R+ L+ 20b
5
2
3
0# R-
4
5
25
7
35H
CN-112M C 0-S
B
C
B
To wiper harness
CAN-
A
CN-115 CAN+
销
57
1
207
60a
l
61a
208
42
42
1
607
2
0
0
3
0-S CAN-CAN+
703 208 502
38
702
702 501 201
23
00
00 206 207
28 29 30 31
7
8
205 00 50 00
9
511 202
00
0
200
510 204
10 11 12 19 21 22 23 30 32 33
203
38
108 A 108 B 106 510
27
28
1
2
38 73 22 100 43 20 b 23
3
103
4
5
6
7
8 9
24
25
26
26
8 CN-140M
0#
7 77
Access lamp
B
C
D
42 20
2
4
20
5
6
21
7
21
42
8
43
1
CN-122M CN-505M
To fuse box harness CN-222M F
G
100 11 13 607 MT- MT+
2
3
4
5
6
7
0
8 9
0#
620 621
10 11 12
103
1
106 506 507 508 509 50A 704 60a 61a
2
3
4
5
6
7
8 9
10
To cab radio harness
2 1
108 A 108 B
1
2
CN-114F
20 12 1 2
E
3
R+
14
CN-150M
4
L+
1
To fuse box harness CN-221M
5
L-
CN-121F
704
6
0#
R-
13
10 11 12
To A/C panel
8
34 35
rn
703 511
CN-207F
7
at
502
5
0#
CN-141M
501
4
6
00
8 10 11 12 17 18 19 20 22
io
606
28 29 30 32
4
CAN- CAN+
206
66
CN-110M
司
204
508
3
35 L 5
120Ω
A
To pilot switch
2
36 CN-003F To radio control panel
CN-106F
2
1
L-
6
1
公
营
205
26
1
0
1
Ma
202
te
2
1
3 45
To parking relay CN-180M
201
In
17 18 19 20 21 22 23 24 25
To chassis harness CN-501F
2
27
62 63
1
5 6
200
CN-501F 3
11a
14
1
3
4
13 14
1
3 45
11
60
na
5
3 45
2
105
620
CN-181M To preheat relay
1 2 3 4 5 6 7 8 9
2
1
23
To washer motor
34
6 7 8
3
24
42
5
2
22
3 CN-506M
1
11 13
Shutdown delay relay
31
60
9
Work lamp relay
Horn relay
.
35H
Pilot valve relay
pt
3
Start control relay
De
To control switch harness CN-203M
33
Head lamp relay
CN-502M
g
CN-203F 8
2
CN-202M
ti n
9
25
rk e
1
CN-113F
CN-111M
To monitor harness CN-7-113M To start motor H
I
To monitor harness CN-7-111M
J
K
L
To monitor harness CN-7-114M
M
N
9-6
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
9.5 Electrical diagram of air conditioner Control panel
CN-M29
pt
.
0.5GO
0.5BrY 0.5LO 0.5VR 0.5PB 0.5YB 0.5VW 0.5WY 0.5WR 0.5Sb 0.5BR 0.5B
0.5GW 0.5PG 0.5BY 0.5RW 0.5RY
0.5R
0.5BL 0.5BrW 0.5OW
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
0.5WO 0.5BG 0.5BW 0.5LgR
CN-M30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
ACM 9
De
0.5B 0.5GO
0.5Sb 0.5BR
1 2 3 4 5 6 7 8
CN-M27
g
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
ti n
0.5B 0.5GO
0.5Sb 0.5BR
0.5WY 0.5WR
0.5YB 0.5VW
0.5LO
0.5VR 0.5PB
0.5BrY
0.5RW 0.5RY
0.5PG 0.5BY
0.5OW 0.5GW
0.5R
0.5BL 0.5BrW
0.5WO 0.5BG 0.5BW 0.5LgR
7
Diffuser conversion servo motor FOOT FACE(DEF) Pt GND
THI
2 1
2 1
0.5BW
0.5WY 0.5WR 0.5BrW
Ma
S S
0.5BR
050 CN-P15
0.5GO 0.5Sb 0.5OW
0.5BR 0.5GW
1 2
7 6 5 4 3 2 1
1 2
CN-M34
7 6 5 4 3 2 1
rk e
6
2
MV
Internal temp sensor
Vz
1 2 3 4 5 6 7 8 9 10 11 12
SWP CN-M33
SWP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12
SWP CN-M28
0.5WY 0.5WR
0.5YB 0.5VW
0.5LO
0.5VR 0.5PB
0.5BrY
0.5RW 0.5RY
0.5PG 0.5BY
0.5OW 0.5GW
0.5BL 0.5BrW
0.5R
0.5WO 0.5BG 0.5BW 0.5LgR
8
5
司
公
营
M
S CN-M26
rn In
1
A
B
C
D
0.5BW
3
0.5BR
2 1
1 2
1 2
GND
FRE REC Pt Vz
Diffuser conversion servo motor MV
I
Fresh air/recirculation conversion sero motor
GND
Mcool Mhot Pt
A/M servo motor
Vz GND MA
M
Low-temp sensor
0.5BY 0.5BR
0.5B
0.5lgR
C
R LB
Compressor cltch relay
2 1
TRANSACTION OF INPUT SIGNEL
VOLTAGE CORRECTION
MB
M
Blower relay
F
2 1
2 1 RL
2 1
PROTECTION FOR TEMP. DRIVING CIRCUIT
E
7 6 5 4
Vz
1.25RL 3 3
0.5BL 2
2 1 2 1
2
3 4 2 1 3 4 2 1
2G 2RL
2Br 2RL 0.5LO 0.5R
3 4 2 1 3 4 2 1
2B
1.25RL
1.25RL 72C 40C 1.25G
RL R L C
2 1
FACE FOOT Pt
THF
0.85W 2Br 0.5BrY 0.5R
te
2
3
7 6 5 4 3 2 1
7 6 5 4 3 2 1
0.5BR 0.5PG
2G
24V
5A
4
0.5RY 0.5BR
1
2 1
4
3 3
2 1
1
TO CN-P15-2 TO CN-A30-1
7 6 5 4
7 6 5 4 3 2 1
1.25G
20A TO CN-M26-2 TO CN-M26-1
2 1
0.5PB 0.5VR 0.5BG
2G
TO CN-P15-1 TO CN-A30-2
TO CN-M26-7 TO CN-M26-7
0.85W 2B 0.5BW 0.5RW 2Br 1.25R
0.5BR
0.5BR
at
TO CN-E06-1
TO CN-M26-A 3
12 12 11 11 10 10 9 9 8 8 7 7 6 6 5 5 4 4
3
0.5BW
io
CN-E06
1
1
ECC EC
0.5BW
0.5YB 0.5VW 0.5WO
na
TH A
4
2 1
2RL
2 1
l
CN-A30
销
7 6 5 4
G
Blower motor
THW
SPH L
BLC
Coolant temp sensor
Hi/Lo pressure switch
H
I
J
K
L
M
N
9-7
System Schematics
SY365(B)H-9 Crawler Hydraulic Excavator
9.6 Electrical diagram of monitor
.
9
CN-7-707M
pt
Sunlight sensor
Cigar lighter
CN-7-706M
8
1
2
100
0#
60a
2
De
1
61a
7
g
CN-7-113M CN-142M
GND
6
CAN bus low RPM sensor signal Coolant temp high switch Eng oil press sw input RPM sensor GND Oil level sensor signal Fuel control dial signal Start control signal Hi/Lo travel speed ctrl sgnl
5 24 V power supply 5V power output
GND Motor driving signal + Motor driving signal -
4
Shutdown delay control
507
704 0 CAN108A
42
106 508 108B 509 506 620 607
1
43
2
100
3
11
4
13
5
607
6
MT-
7
MT+ 0
8 9
0#
10
620
11
621
12
司
公
营
43 50 A
销
0 MT+ MT621 CAN+
CN-7-111F
To cab harness CN-111M 103 106
io
CAN bus high
ti n
Pwr lmt vlv ctrl sgnl
42
rk e
thrttl mtr position fdbck sgnl
13 103
Ma
Air block sw sgnl input
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
To cab harness CN-113F
l
24V power supply
11
na
Start signal Power-on signal
507 508
rn
at
3
506
108A 108B A
S
C
te
2
B
CAN+ CANA
B
1 2 3 4 5
509
6
50 A
7
704
8
60 a
9
61 a
10
0-S C
CN-7-114M
CN-7-112F
To cab harness CN-114F
In
To cab harness CN-112M
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
9-8
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