SM Sy365 (B) H-9 2014-04-16

www.sanygroup.
com Quailty Changes the World
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: crd@sany.com.cn
Documentation No.: ZJSYF0301EN(07-12)-SY55C3/55C9/60C1
Shop Manual
SY365(B)H-9 Crawler Hydraulic Excavator
CA
SY365(B)H-9
RI
Crawler Hydraulic Excavator
E
AM
Shop Manual
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TI
LA
NY
SA
WARNING
● Read and follow the safety precautions and instructions in this manual and on the ma-
chine decals. Failure to do can cause serious injury, death or property damage. Keep
this manual with the machine for reading and future reference.
Shop Manual - April 2014

Sany Group
Sany Heavy Machinery Limited
318A, Lianggang Avenue, Lingang Industrial Park,
Fengxian District, Shanghai, P. R. of China 201413
http://www.sanygroup.com
C A
Tel: 0086-21-57008518 Fax: 0086-21-58596210
RI
Service hotline: 0086-21-58592902
Complaint hotline: 0086-21-58590631
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E-mail: sanyservice@sany.com.cn
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TI
LA
NY
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© 2012 by Sany Group. All right reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as de-
scribed herein. All information included within this publication was accurate at the time
of publication. Product improvements ,revisions, etc., may result in differences between
your machine and what is presented here. Sany Group assumes no liability. For more in-
formation, Contact Sany Group.
SY365(B)H-9 Crawler Hydraulic Excavator Table of Contents
Table of Contents
1 Introduction
1.1 How to Read the Manual ......................................................................................... 1-3
1.1.1 Shop manual organization ............................................................................. 1-3
1.1.2 Revision and distribution ................................................................................ 1-4
1.1.3 Symbols ......................................................................................................... 1-5
A
1.1.4 Units ............................................................................................................... 1-5
C
1.2 Technical Terms ....................................................................................................... 1-6
RI
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
E
1.2.4 Repair limit and allowable value .................................................................... 1-8
AM
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
N
1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9

TI
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
LA
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
NY
1.3.2.2 Disassembly and maintenance work in the field ................................. 1-18

1.3.2.3 Sealing openings ................................................................................ 1-18
SA
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
A
2.2 General Shop Safety ............................................................................................... 2-5
C
2.2.1 Rules and shop behavior ............................................................................... 2-6
RI
2.2.2 Housekeeping ................................................................................................ 2-6
2.2.3 Shop Liquids Storage..................................................................................... 2-7
2.2.4 Cleaning the Parts ......................................................................................... 2-7
E
2.2.5 Cleaning the Machine .................................................................................... 2-8
AM
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
N
2.2.9 Fire Extinguisher and Emergency Exits ......................................................... 2-9

2.2.10 Electrical Dangers ...................................................................................... 2-10
TI
2.2.11 Hoisting a Load .......................................................................................... 2-10

2.3 Before Repair..........................................................................................................2-11
LA
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
NY
2.3.5 Safety Partners ............................................................................................ 2-15

2.4 Repair Precautions ................................................................................................ 2-16
SA
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

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
A
2.4.19 Avoiding fire and explosion ........................................................................ 2-26
C
2.4.20 Chemical hazard ........................................................................................ 2-27
RI
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
E
2.5.1 Sling work and giving signals ....................................................................... 2-29
AM
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
N
3 Specifications
TI
3.1 Specific Dimension .................................................................................................. 1-3

3.1.1 Dimension ...................................................................................................... 1-3
LA
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
NY
3.5 Engine Performance Curves.................................................................................... 1-9

SA
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

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
A
4.4.1 Deployment of hydraulic parts ..................................................................... 4-24
C
4.4.2 Hydraulic tank and filter ............................................................................... 4-26
RI
4.4.3 Hydraulic pump ............................................................................................ 4-28
4.4.3.1 Outline................................................................................................. 4-29
4.4.3.2 Function .............................................................................................. 4-31
E
4.4.3.3 Structure ............................................................................................. 4-31
AM
4.4.3.4 Operating principle .............................................................................. 4-32
4.4.3.5 Oil delivery control .............................................................................. 4-33
4.4.4 Pilot pump .................................................................................................... 4-34
N
4.4.5 Regulator .................................................................................................... 4-35

4.5 Hydraulic system, Part 2 ........................................................................................ 4-48
TI
4.5.1 Main control valve ........................................................................................ 4-48

4.5.1.1 Overview ............................................................................................ 4-48
LA
4.5.1.2 Main valve structure ............................................................................ 4-50

4.5.2 Hydraulic circuit (With bucket confluence function) .............................................. 4-56
4.6.1 Swing motor ................................................................................................. 4-79
NY
4.6.2 Swing holding brake..................................................................................... 4-81

4.6.3 Relief valve section ...................................................................................... 4-82
SA
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

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
A
4.6.15 Pilot oil filter.............................................................................................. 4-121
C
4.6.16 Hydraulic cylinders ................................................................................... 4-122
RI
4.6.16.2 Lubrication at every 100 service hours ........................................... 4-123
4.7 Work Equipment .................................................................................................. 4-124
E
4.7.1 Component dimensions ............................................................................. 4-124
AM
4.7.2 Arm dimensions ......................................................................................... 4-126
4.7.2.1 Bucket dimensions ............................................................................ 4-128
4.8 Operator Station and Its Attachments .................................................................. 4-130
N
4.8.1 Air conditioner lines .................................................................................... 4-130

4.8.1.1 Layout of A/C components ................................................................ 4-132
TI
4.8.1.2 A/C control panel............................................................................... 4-133

4.8.1.3 Diagram of electrical circuit ............................................................... 4-134
LA
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
NY
4.8.1.8 Expansion valve ................................................................................ 4-141

4.8.1.9 Evaporator ........................................................................................ 4-141
SA
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 V

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
A
4.10.4 Pump control function .............................................................................. 4-177
C
4.10.4.1 Constant power control ................................................................... 4-180
RI
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
E
4.10.7 Engine preheat/overheat alarm ............................................................... 4-185
AM
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
N
4.11 Monitoring System ............................................................................................. 4-195

4.11.1 Monitor ..................................................................................................... 4-196
TI
4.11.2 Monitor panel ........................................................................................... 4-197

4.11.2.1 Alert and signal indicators .............................................................. 4-197
LA
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
NY
4.11.3.3 Main menu ...................................................................................... 4-202

4.11.3.4 Engine & throttle signals ................................................................. 4-203
SA
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

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
5 Table of Standard Values
A
5.1 Standard Values for Engine-Related Parts .............................................................. 5-3
C
5.2 Standard Values for Chassis-Related Parts ............................................................ 5-4
RI
6 Testing and adjusting
6.1 Engine Speed - Test and Adjust............................................................................... 6-3
E
6.2 Exhaust Gas Color - Test ......................................................................................... 6-5
AM
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
N
6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13

TI
6.5.1 Testing.......................................................................................................... 6-14

6.5.2 Adjusting ...................................................................................................... 6-18
LA
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
NY
6.8 Track Tensioner - Test and Adjust .......................................................................... 6-21

6.8.1 Testing.......................................................................................................... 6-21
SA
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

6.13 Work Equipment and Swing Pilot Valves - Adjust ................................................ 6-33
6.14 Hydraulic Drift of Work Equipment - Test ............................................................. 6-34
6.15 Remaining Pressure in Hydraulic Lines - Relieve................................................ 6-36
6.16 Oil Leakage Amount - Test................................................................................... 6-37
6.17 Air in Each Component - Purge ........................................................................... 6-41
7 Troubleshooting
7.1 Checks before Troubleshooting ............................................................................... 7-5
A
7.2 Failure Symptoms and Troubleshooting Codes ....................................................... 7-6
C
7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-9
RI
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
E
7.3.4 SWP connectors .......................................................................................... 7-22
AM
7.3.5 A/AMP connectors ....................................................................................... 7-23
7.3.6 DT connectors.............................................................................................. 7-24
7.4 Troubleshooting with an Event Code ..................................................................... 7-25
N
7.5 Troubleshooting Electrical System (E-Mode)......................................................... 7-49

7.6 Troubleshooting Hydraulic and Mechanical Systems (H-mode) ............................ 7-81
TI
8 Disassembly and Assembly

LA
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
NY
8.3.1 Removal ......................................................................................................... 8-9

8.3.2 Installation ...................................................................................................... 8-9
SA
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

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
A
8.9.2 Installation .................................................................................................... 8-30
C
8.10 Final Drive AS ..................................................................................................... 8-31
RI
8.10.1 Removal ..................................................................................................... 8-31
8.10.2 Installation .................................................................................................. 8-32
8.11 Final Drive AS ...................................................................................................... 8-33
E
8.11.1 Disassembly ............................................................................................... 8-33
AM
8.11.2 Assembly .................................................................................................... 8-36
8.12 Swing Motor and Swing Drive AS ....................................................................... 8-42
8.12.1 Removal ..................................................................................................... 8-42
N
8.12.2 Installation .................................................................................................. 8-43

TI
8.13.1 Disassembly............................................................................................... 8-44

8.13.2 Assembly.................................................................................................... 8-49
LA
8.14 Idler AS ............................................................................................................... 8-54

8.14.1 Disassembly............................................................................................... 8-54
8.14.2 Assembly.................................................................................................... 8-55
8.15 Sprocket .............................................................................................................. 8-58
NY
8.15.1 Removal ..................................................................................................... 8-58

8.15.2 Installation .................................................................................................. 8-58
SA
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 IX

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
A
8.21.2 Installation .................................................................................................. 8-73
C
8.22 Control Valve AS .................................................................................................. 8-74
RI
8.22.1 Removal ..................................................................................................... 8-74
8.22.2 Installation .................................................................................................. 8-79
8.23 Hydraulic Pump AS ............................................................................................. 8-80
E
8.23.1 Removal ..................................................................................................... 8-80
AM
8.23.2 Installation .................................................................................................. 8-83
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft) ..................................................... 8-84
8.24.1 Removal ..................................................................................................... 8-84
N
8.24.2 Installation .................................................................................................. 8-84

8.25 Pilot Valve AS (Work Equipment) ....................................................................... 8-85
TI
8.26 Travel Pilot Valve AS ........................................................................................... 8-86

8.27 Hydraulic Cylinder AS ......................................................................................... 8-87
LA
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
NY
8.28.2 Installation .................................................................................................. 8-99

8.29 Air Conditioner AS ............................................................................................. 8-100
SA
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

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
A
8.35 Controller AS ..................................................................................................... 8-136
C
8.35.1 Removal ................................................................................................... 8-136
RI
8.35.2 Installation ................................................................................................ 8-136
8.36 Radio ................................................................................................................. 8-137
8.36.1 Structure .................................................................................................. 8-137
E
8.36.2 Removal and installation .......................................................................... 8-139
AM
8.36.3 Connector model and wiring .................................................................... 8-140
8.37 Battery ............................................................................................................... 8-141
8.37.1 Structure .................................................................................................. 8-141
N

8.37.3 Replacement ............................................................................................ 8-143
TI
8.38 Start Switch........................................................................................................ 8-144

8.38.1 Structure ................................................................................................. 8-144
LA
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
NY
8.40 Wiper ................................................................................................................. 8-148

8.40.1 Structure .................................................................................................. 8-148
SA

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
8.41.4 Relay connector and wiring...................................................................... 8-154
Shop Manual - April 2014 XI

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

8.43 Connector Terminals ......................................................................................... 8-157
8.43.1 Insertion ................................................................................................... 8-157
8.43.2 Removal ................................................................................................... 8-158
9 System Schematics
9.1 Diagram of Hydraulic Lines...................................................................................... 9-3
9.2 Electrical diagram of chassis ................................................................................... 9-4
A
9.3 Electrical diagram of control switches...................................................................... 9-5
C
9.4 Electrical diagram of operator station ...................................................................... 9-6
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9.5 Electrical diagram of air conditioner......................................................................... 9-7
9.6 Electrical diagram of monitor ................................................................................... 9-8
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XII Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Introduction
Introduction
C A
RI
1 Introduction
1.1 How to Read the Manual ......................................................................................... 1-3
E
1.1.1 Shop manual organization ............................................................................. 1-3
AM
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
N
1.2.1 Standard size and tolerance .......................................................................... 1-6

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

1.2.3 Standard interference .................................................................................... 1-7
LA
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
NY
1.3.1 Points to remember when handling electric components .............................. 1-9

1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9
SA
1.3.1.2 Main failures occurring in wiring harness ............................................ 1-10

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

1.3.2.7 Cleaning operations ............................................................................ 1-20
1.4 Hose Connector ..................................................................................................... 1-20
1.4.1 Type of hose connector................................................................................ 1-21
1.4.2 Hose connector tightening torque table ....................................................... 1-21
1.4.3 Connection of O-rings .................................................................................. 1-22
1.5 Table of Standard Tightening Torques .................................................................. 1-23
1.6 Type of Bolts .......................................................................................................... 1-24
A
1.7 Tightening Sequence ............................................................................................. 1-24
C
1.8 Maintenance of Half Flanges ................................................................................. 1-25
RI
1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25
1.8.2 Temperature ................................................................................................. 1-31
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1-2 Shop Manual - April 2014

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.
CA
1.1.1 Shop manual organization
RI
This shop manual contains the necessary
technical information for services performed
in a workshop. For ease of understanding, the
E
manual is divided into the following sections.
Introduction
AM
This section provides an overview of what is
covered in the rest of this manual and how to
use this manual,.
N
TI
Shop Safety
This section covers basic shop safety infor-
mation relating to this equipment. It also de-
LA
scribes what the hazard alerts mean that are

used throughout the manual.
Specifications
NY
Technical specification of work equipment and

optional parts are given in this section.
SA
Structure and functions

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

Standard Values
This section explains the standard values for
a new machine and judgement criteria for test-
ing, adjusting, and troubleshooting. This stan-
dard value table is used to check the standard
values in testing and adjusting and to judge
parts in troubleshooting.
Testing and adjusting
A
This section details the inspection before and
after repair work as well as the adjustment
C
during inspection and repair work. Trouble-
RI
shooting table that involves “Fault”and
“Cause”are also included in this section.
E
Troubleshooting
This section explains the way to detect faulty
parts and the method to repair them. This sec-
AM
tion is divided into the following parts: Electri-
cal system, Engine, Hydraulic and mechanical
system and Monitoring system.
N
TI
Disassembly and assembly

This section explains the procedures as well
as precautions for removing, installing, disas-
LA
sembling and assembling of each component.

Engine
This section provides information the cooling
system, lubricating system, electrical system
NY
and alternator in addition to disassembly and

reassembly of the engine.
SA
System Schematics
This section provides hydraulic circuit dia-
grams and electrical circuit diagrams.
1.1.2 Revision and distribution

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

1.1.3 Symbols
Important safety and quality portions are marked with the following symbols so that the shop
manual will be used practically.
Symbol Item Remarks
Special safety precautions are necessary when performing

Safety
work.
A
Special technical precautions or other precautions for pre-
★ Caution
serving standards are necessary when performing work.
C
Weight of parts of component or parts. Caution necessary
RI
Weight when selecting hoisting wire, or when working posture is
important, etc.
Tightening Places that require special attention for tightening torque
E
torque during assembly.
AM
Coat Places to be coated with adhesives, etc. during assembly.
Oil, Coolant Places where oil, etc. must be added, and capacity.
N
Places where oil, etc. must be drained, and quantity to be

TI
Drain
drained.
LA
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 { }.
NY
SA

1.2 Technical Terms

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

● To be accurate, the finishing size of parts
is a little different from one to another.
A
● To specify a finishing size of a part, a tem-
C
porary standard size is set and an allow-
able difference from that size is indicated.
RI
● The above size set temporarily is called
the "standard size" and the range of differ-
ence from the standard size is called the
E
"tolerance". AM
● The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
N
Example
TI
Standard size Tolerance

–0.022
LA
120
–0.126
Std.size F 60
★ The tolerance may be indicated in the text
Tolerance of hole
and a table as [standard size (upper limit
NY
(upper):+0.046
of tolerance/lower limit of tolerance)]. Ex- Std.clearance (max.):0.122
ample) 120 (–0.022/–0.126) Std.clearance (min.):0.030

Tolerance of shaft
SA
● Usually, the size of a hole and the size (lower):-0.076

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

Example
Tolerance
Standard size
Shaft Hole
-0.030 +0.046
φ60
-0.076 0
1.2.2 Standard clearance and value
A
● The clearance made when new parts are
assembled is called the "standard clear-
C
ance", which is indicated by the range from
RI
the minimum clearance to the maximum
clearance.
E
● When some parts are repaired, the clear-
ance is generally adjusted to the standard AM
clearance.
● A value of performance and function of

new products or equivalent is called the
"standard value", which is indicated by a
N
range or a target value.

TI
● When some parts are repaired, the value

of performance/function is set to the stan-
LA
dard value.
1.2.3 Standard interference
● When the size of a hole is smaller than the

NY
size of a shaft because of the standard

size and tolerance, the difference between
these sizes is called the "interference".
SA
● The range (A – B) from the difference (A)

between the minimum size of the shaft and
the maximum size of the shaft to the differ-
ence (B) between the maximum size of the
shaft and the minimum size of the hole is
the "standard interference".
● After repairing or replacing some parts,

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

1.2.4 Repair limit and allowable value
● The size of a part changes due to wear

and deformation while it is used. The limit
of changed size is called the "repair limit".
● If a part is worn to the repair limit must be

replaced or repaired.
● The performance and function of a product
A
lowers while it is used. A value below which
the product can be used without causing a
C
problem is called the "allowable value".
RI
● If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
E
ous tests or experiences in most cases, AM
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
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1.2.5 Clearance limit

TI
● Parts can be used until the clearance be-

tween them is increased to a certain limit.
The limit at which those parts cannot be
LA
used is called the "clearance limit".
● If the clearance between the parts exceeds

the clearance limit, they must be replaced
or repaired.
NY
1.2.6 Interference limit

SA
● The allowable maximum interference be-

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

of the part of smaller tolerance.
● If the interference between the parts ex-

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

1.3 Handling Electrical and Hy-

draulic Components
To maintain the performance of the machine
over a long period, and to prevent failures or
other troubles before they occur, correct "oper-
ation", "maintenance and inspection", "trouble-
shooting", and "repairs" must be carried out.
This section deals particularly with correct re-
pair procedures for mechatronics and is aimed
A
at improving the quality of repairs. For this
C
purpose, it gives sections on "Handling electric
components" and "Handling hydraulic equip-
RI
ment" (particularly gear oil and hydraulic oil).
E
1.3.1 Points to remember when han-
dling electric components
AM
1.3.1.1 Handling wiring harnesses and
connectors
N
Wiring harnesses consist of wiring con-

TI
necting one component to another compo-

nent, connectors used for connecting and
disconnecting one wire from another wire,
LA
and protectors or tubes used for protecting

the wiring.
Compared with other electrical compo-
nents fitted in boxes or cases, wiring har-
NY
nesses are more likely to be affected by

the direct effects of rain, water, heat, or
vibration. Furthermore, during inspection ZX215-1000004
SA
and repair operations, they are frequently Fig. 1-2

removed and installed again, so they are
likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.

1.3.1.2 Main failures occurring in wiring

harness
1. Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely Improper insertion
to occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors
is deformed or the position is not correctly
A
aligned, or because there is corrosion or
C
oxidation of the contact surfaces.
RI
ZX215-1000005
Fig. 1-3
E
2. Defective crimping or soldering of connec- AM
tors
The pins of the male and female connec- Crimped portion
tors are in contact at the crimped terminal

or soldered portion, but if there is exces-
N
sive force brought to bear on the wiring,

the plating at the joint will peel and cause
TI
improper connection or breakage.

LA
ZX215-1000006
Fig. 1-4
NY
3. Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
SA
a crane with the wiring still connected, or a

heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
ZX215-1000007
Fig. 1-5

4. High-pressure water entering connector

The connector is designed to make it dif-
ficult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
splash water over the connector. The con-
nector is designed to prevent water from
A
entering, but at the same time, if water
does enter, it is difficult for it to be drained.
C
Therefore, if water should get into the con- ZX215-1000008
nector, the pins will be short-circuited by
RI
Fig. 1-6
the water, so if any water gets in, immedi-
ately dry the connector or take other ap-
propriate action before passing electricity
E
through it. AM
5. Oil or dirt stuck to connector
If oil or grease are stuck to the connec-
tor and an oil film is formed on the mating
surface between the male and female pins,
N
the oil will not let the electricity pass, so

TI
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
LA
compressed air and spray it with a contact

restorer.
★ When wiping the mating portion of the
connector, be careful not to use exces- ZX215-1000009
NY
sive force or deform the pins. Fig. 1-7

★ If there is oil or water in the com-
pressed air, the contacts will become
SA
even dirtier, so remove the oil and wa-

ter from the compressed air completely
before cleaning with compressed air.

1.3.1.3 Removing, installing, and drying

connectors and wiring harnesses
1. Disconnecting connectors
A. Hold the connectors when disconnect-
ing.
Press lightly
When disconnecting the connectors, when removing
hold the connectors. For connectors Lock stopper
held by a screw, loosen the screw fully,
then hold the male and female connec-
A
tors in each hand and pull apart. For
C
connectors which have a lock stop-
per, press down the stopper with your
RI
ZX215-1000010
thumb and pull the connectors apart.
Fig. 1-8
★ Never pull with one hand.
E
B. When removing from clips AM
● Both of the connector and clip have
stoppers, which are engaged with each Both stoppers
other when the connector is installed.
N
TI
LA
ZX215-1000011
Fig. 1-9
NY
● When removing a connector from a clip,

pull the connector in a parallel direction
to the clip for removing stoppers.
SA
★ If the connector is twisted up and

down or to the left or right, the hous-
ing may break.
ZX215-1000012
Fig. 1-10

C. Action to take after removing connec-

tors
After removing any connector, cover
it with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
★ If the machine is left disassembled
for a long time, it is particularly easy
for improper contact to occur, so al-
A
ways cover the connector. ZX215-1000013
C
Fig. 1-11
RI
2. Connecting connectors
E
A. Check the connector visually
Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
AM Clicks into position
tion).
Check that there is no deformation, de-
fective contact, corrosion, or damage to
N
the connector pins.

TI
Check that there is no damage or ZX215-1000022

breakage to the outside of the connec-
tor. Fig. 1-12
LA
★ 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
NY
the wiring with a dryer, but be care-

ful not to make it too hot as this will
cause short circuits.
SA
★ If there is any damage or breakage,

replace the connector.
B. Fix the connector securely.
Align the position of the connector cor-

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
A
clamp is out of position, adjust it to its ZX215-1000014
correct position.
C
Fig. 1-13
★ If the connector cannot be corrected
RI
easily, remove the clamp and adjust
the position.
E
● If the connector clamp has been
removed, be sure to return it to its AM
original position. Check also that
there are no loose clamps.
3. Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
N
wire connectors have 2 latches respective-

TI
ly, push them in until they click 2 times. ZX215-1000015
● Male connector: 1 Fig. 1-14

LA
● Female connector: 2
● Normal locking state (Horizontal): a, b,
d 2 a 1 c
● Incomplete locking state (Diagonal): c
NY
SA
d
b
ZX215-1000016
Fig. 1-15

4. Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high-pressure water or steam directly
on the wiring harness. If water gets directly
on the connector, do as follows.
A. Disconnect the connector and wipe off
A
the water with a dry cloth. ZX215-1000009
C
★ If the connector is blown dry with Fig. 1-16
compressed air, there is the risk that
RI
oil in the air may cause defective
contact, so remove all oil and wa-
ter from the compressed air before
E
blowing with air. AM
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,
N
but regulate the time that the hot air

TI
is used in order not to make the con-

ZX215-1000017
nector or related parts too hot, as
this will cause deformation or dam- Fig. 1-17
LA
age to the connector.

C. Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
NY
disconnected and carry out a continuity

test to check for any short circuits be-
tween pins caused by water.
SA
★ After completely drying the connec- T adapter

tor, blow it with contact restorer and
reassemble.
ZX215-1000018
Fig. 1-18

1.3.1.4 Handling the integrated control

monitor
1. The integrated control monitor contains
a microcomputer, an electronic control
circuits, an LCD monitor and GPS position-
ing circuit. They control all of the electronic
circuits on the machine, so be extremely
careful when handling the integrated
control monitor.
A
2. Do not place objects on the integrated
C
control monitor. ZX135-1000001
3. Cover the control connectors with tape or
RI
Fig. 1-19
a vinyl bag. Never touch the connector
contacts with your hand.
E
4. Do not leave it where it may be exposed to
rain. AM Tool
5. Do not place the integrated control monitor Box
on oil, water, or soil, or in any hot place,

even for a short time.
N
6. Precautions for arc welding

When welding on the controller, disconnect
TI
all wiring harness connectors connected

to the controller. Fit an arc welding ground ZX215-1000020
close to the welding point.
LA
Fig. 1-20
NY
SA
ZX215-1000021
Fig. 1-21

1.3.1.5 Electric circuits troubleshooting

precautions
1. Always turn the power OFF before discon-
necting or connecting connectors.
2. Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
★ Disconnect and connect the related
connectors several times to check.
A
3. Always connect any disconnected connec-
C
tors before going on to the next step.
RI
★ If the power is turned ON with the con-
nectors still disconnected, unnecessary
abnormality displays will be generated.
E
4. When carrying out troubleshooting of AM
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 read-
N
ing of the tester.

★ If there is any change, there is probably
TI
defective contact in that circuit.

LA
NY
SA

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.
A
1.3.2.1 Be careful of the operating environ-
C
ment
RI
Avoid adding hydraulic oil, replacing filters,
or repairing the machine in rain or high
winds, or places where there is a lot of
E
dust. AM
1.3.2.2 Disassembly and maintenance work
in the field
If disassembly or maintenance work is ZX215-1000023
N
carried out on hydraulic equipment in the Fig. 1-22

field, there is danger of dust entering the
TI
equipment. It is also difficult to check the

performance after repairs, so it is desir-
able to use unit exchange. Disassembly
LA
and maintenance of hydraulic equipment

should be carried out in a specially pre-
pared dust-proof workshop, and the perfor-
mance should be checked with special test
NY
equipment.
1.3.2.3 Sealing openings

SA
After any piping or equipment is removed,

the openings should be sealed with caps,
tapes, or vinyl bags to prevent any dirt or
dust from entering. If the opening is left
open or is blocked with a rag, there is
danger of dirt entering or of the surround-
ing area being made dirty by leaking oil so
never do this. Do not simply drain oil out
onto the ground, but collect it and ask the
customer to dispose of it, or take it back
with you for disposal. ZX215-1000024
Fig. 1-23

1.3.2.4 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
A
even more effective method.
ZX215-1000025
C
Fig. 1-24
RI
1.3.2.5 Change hydraulic oil when the
temperature is high
E
When hydraulic oil or other oil is warm, it
flows easily. In addition, the sludge can AM
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 hy-
draulic oil must be drained out. (Drain the
N
oil from the hydraulic tank; also drain the

TI
oil from the filter and from the drain plug in

the circuit.) If any old oil is left, the contam-
inants and sludge in it will mix with the new
LA
oil and will shorten the life of the hydraulic

oil.
1.3.2.6 Flushing operations

NY
After disassembling and assembling the

equipment, or changing the oil, use flush-
ing oil to remove the contaminants, sludge,
SA
and old oil from the hydraulic circuit. Nor- Flushing oil
mally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and
secondary flushing is carried out with the
specified hydraulic oil.
ZX215-1000026
Fig. 1-25

1.3.2.7 Cleaning operations

After repairing the hydraulic equipment
(pump, control valve, etc.) or when run-
ning the machine, carry out oil cleaning to
remove the sludge or contaminants in the
hydraulic oil circuit. The oil cleaning equip-
ment is used to remove the ultra fine (about
3 μ) particles that the filter built in the hy-
draulic equipment cannot remove, so it is
A
an extremely effective device.
ZX215-1000027
C
Fig. 1-26
RI
1.4 Hose Connector
Hose connector is used to connect hoses with
E
a small diameter. The metal sealing surface (4)
of the joint (1) must be in close contact with AM 1 4 3 5 2
the metal sealing surface (5) of the hose (2) to
seal pressurized oil.
NOTICE
N
TI
● Do not over-tighten the nut (3). Exces- Connector

sive force applied on the metal sealing
ZX215-1000028
surface (4) and (5) may cause the joint
LA
(1) to break. Be sure to tighten nut (3) Fig. 1-27

according to technical specifications.
● Scratches or other damages on seal-
ing surface (4) and (5) may cause leaks
NY
at the joint. Be extremely careful not

to damage the sealing surfaces during
connecting and disconnecting work.
SA

1.4.1 Type of hose connector
24°
24°
Male Female
A
ZX215-1000029
C
Fig. 1-28
RI
1.4.2 Hose connector tightening torque table
E
Wrench size mm Wrench size mm Tightening torque
Type AM
Connecting nut Hose joint N·m(kgf·m,Ibf·ft)
19 19 59(6,44)
22 22 98(10,72)
27 27 118(12,87)
N
36 36 235(24,173)
24° Male
TI
41 41 295(30,218)
50 50 490(50,361)
60 60 670(68,494)
LA
70 70 980(100,723)
19 17 44(4.5,32)
22 19 59(6,44)
27 22 118(12,87)
NY
24° Female
36 30, 32 235(24,173)
41 36 295(30,218)
SA
50 46 490(50,361)
NOTICE
● The torque values listed in the table are

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

1.4.3 Connection of O-rings
Place O-ring (6) in contact with the contact

surface of the joint (7) to seal the pressurized
7 6 9
oil.
NOTICE
● Replace o-rings (6) with new ones
A
Hose connector
when re-connecting hoses. 8 10
C
● Before tightening nut (9), make sure the
o-ring (6) has been placed into the o- ZX215-1000030
RI
ring seat (8).Displacement of the o-ring Fig. 1-29
may have it damaged and cause leaks.
E
● Be careful not to damage the o-ring
seat (8) or the sealing surface (10). AM
Damaged o-ring (6) may cause oil leak-
age.
● If oil leakage due to loosened nut (9) is
detected, do not try to stop the leakage
N
by tightening nut (9). Instead, replace

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

sure it is well positioned, and tighten
nut (9).
LA
NY
Wrench size mm Wrench size mm Tightening torque

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

1.5 Table of Standard Tightening Torques
Table of tightening torques for bolts and nuts

★ Unless specified otherwise, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
Bolt di- Bolt Wrench Hex wrench Hexagonal bolt Hexagonal socket head bolt
ameter grade size size N·m kgf·m lbf·ft N·m kgf·m lbf·ft
A
M6 10.9 10 4 13.2 1.37 9.74 13.2 1.37 9.74
C
M8 10.9 13 6 31 3.16 22.87 31 3.16 22.87
M10 10.9 17 8 66 6.73 48.7 66 6.73 48.7
RI
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
E
M16 10.9 24 14 279 28.47 205.9 279 28.47 205.9
M18 10.9 27 14 382
AM
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
N
M12 12.9 19 8 137 13.98 101.1 137 13.98 101.1

TI
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
LA
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
NY
the friction coefficient. Thrust bolts do not require greasing.

● Torque tolerance is ±10%.
SA
● 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.

1.6 Type of Bolts
Tighten nuts and bolts properly to specified

Hex bolt Socket head hex bolt
torque values. The type and grade of bolts are
illustrated on the right.
8.8 10.9 12.9
Use correct bolts and tighten them properly
when assembling machines or components.
A
ZX215-1000031
C
Fig. 1-30
RI
1.7 Tightening Sequence
When two or more bolts are being tightened,
E
Cross tightening Diagonal tightening
follow the tightening sequence shown on the AM 1 1
right to ensure even tightening. 6 3
3 4
4 5
CAUTION 2 2
Central and diagonal tightening

● Always use suitable tools for specific
N
work. Use of improper tools and meth- 12 9 4 1 6 7 14

TI
ods may cause a hazardous situation.

● Use tools of correct sizes when loosen- 13 8 5 2 3 10 11
ing or tightening the nuts or bolts. Oth-
LA
ZX215-1000032
erwise, the tools may slide and cause
personal injury. Fig. 1-31
NY
SA
ZX215-1000033
Fig. 1-32

1.8 Maintenance of Half Flanges
1. Clean the sealing surface of the flange and

check it carefully. Scratches and coarse-
ness cause leaks or abrasion of seals.
Uneven surface may squeeze the seal out.
If these faults are not corrected properly,
parts may have to be replaced.
A
2. Always use specified O-rings. Check that ZX215-1000034
the O-rings are not damaged. Do not file
C
Fig. 1-33
the surface of the O-ring. Apply grease
RI
onto the O-ring to locate it.
E
3. Tighten the half flanges carefully. Locate
the opening at the center so that it is AM
perpendicular to the oil opening. Tighten Improper
the bolt manually to maintain the location
of the components.
N
TI
ZX215-1000035
LA
Fig. 1-34
1.8.1 Table of tightening torques for half flange bolts

NY
★ Unless specified otherwise, tighten the half flange bolts to the torques below.
SA
Thread diameter of bolt Width across flats Tightening torque

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

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
A
Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a
horizontal line from (A).
C
Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line
RI
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.
E
Convert 550 mm into inches AM
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.
N
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.
TI
LA
NY
SA

Millimeters to Inches
(B) 1mm=0.03937in
0 1 2 3 4 5 6 7 8 9
0 0.000 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.535
A
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
C
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
RI
(A) 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
E
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 AM 3.740 3.780 3.819 3.858 3.898
Millimeters to Inches
N
1mm=0.03937in
TI
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
LA
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
NY
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
SA
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

Kilogram to Pound
1kg=2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 90.39 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 112.43 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 134.48 55.12 57.32 59.52 61.73 63.93
30 66.14 68.34 70.55 72.75 156.53 77.16 79.37 81.57 83.77 85.98
40 88.18 90.39 92.59 94.80 178.57 99.21 101.41 103.62 105.82 108.03
C A
50 110.23 112.43 114.64 116.84 200.62 121.25 123.46 125.66 127.87 130.07
RI
60 132.28 134.48 136.69 138.89 222.66 143.30 145.50 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 244.71 165.35 167.55 169.75 171.96 174.16
80 176.37 178.57 180.78 182.98 266.76 187.39 189.60 191.80 194.00 196.21
E
90 198.41 200.62 202.82 205.03 288.80 209.44 211.64 213.85 216.05 218.26
AM
Liters to U.S. Gallons
N
1 L=0.2642 U.S.Gal
TI
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.114 2.378
LA
10 2.642 2.906 3.170 3.435 3.699 3.963 4.227 4.491 4.756 5.020
20 5.284 5.548 5.812 6.077 6.341 6.605 6.869 7.133 7.398 7.662
30 7.926 8.190 8.454 8.719 8.983 9.247 9.511 9.775 10.040 10.304
NY
40 10.568 10.832 11.096 11.361 11.625 11.889 12.153 12.417 12.682 12.946
50 13.210 13.474 13.738 14.003 14.267 14.531 14.795 15.059 15.324 15.588
SA
60 15.852 16.116 16.380 16.645 16.909 17.173 17.437 17.701 17.966 18.230
70 18.494 18.758 19.022 19.287 19.551 19.815 20.079 20.343 20.608 20.872
80 21.136 21.400 21.664 21.929 22.193 22.457 22.721 22.985 23.250 23.514
90 23.778 24.042 24.306 24.571 24.835 25.099 25.363 25.627 25.892 26.156

Liters to U.K. Gallons

1 L=0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.739 3.959 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.779
A
50 10.999 11.218 11.438 11.658 11.878 12.098 12.318 12.538 12.758 12.978
C
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
RI
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.038 18.258 18.477 18.697 18.917 19.137 19.357 19.577
E
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
AM
1 kgm=7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
N
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
TI
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
LA
50 361.7 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7
60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
NY
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
SA
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.6 1048.8 1056.0 1063.3 1070.5 1077.7
150 1085.0 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1229.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.2 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

kg/cm2 to lb/in2
1 kg/cm2=14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.3 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.0 654.3 668.5 682.7 696.9
C A
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
RI
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 996 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
E
90 1280 1294 1309 1323 1337 1351
AM 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
N
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
TI
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
LA
150 2133 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2390 2404
170 2418 2432 2446 2461 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
NY
190 2702 2717 2731 2745 2759 2774 2788 2802 2816 2830
200 2845 2859 2873 2887 2902 2916 2930 2944 2958 2973
SA
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3342 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

1.8.2 Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading
into a Centigrade temperature reading or vice versa is to enter the accompanying table in the
center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or
Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to
be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to
A
be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
C
RI
℃ ℉ ℃ ℉ ℃ ℉ ℃ ℉
-40.0 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
E
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 AM8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20
-2 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
N
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2

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

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
LA
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2

-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
NY
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2

-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
SA
-19.4 -3 26.6 0.0 32 89.6 19.4 67 152.6 43.3 110 230.0

-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.8 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
E CA
GERI
M
PAA
K IN
AT
AYNL
BSLAN

SY365(B)H-9 Crawler Hydraulic Excavator Shop Safety
Shop Safety
C A
RI
2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3
E
2.2 General Shop Safety ............................................................................................... 2-5
AM
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
N
2.2.5 Cleaning the Machine .................................................................................... 2-8

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

2.2.7 Personal Protective Equipment...................................................................... 2-8
LA
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
NY
2.3 Before Repair..........................................................................................................2-11

2.3.1 Safe Work Preparations ................................................................................2-11
SA
2.3.2 Preparing yourself ........................................................................................ 2-12

2.3.3 Lockout/Tagout............................................................................................. 2-13
2.3.4 Two people when engine running ................................................................ 2-15
2.3.5 Safety Partners ............................................................................................ 2-15
2.4 Repair Precautions ................................................................................................ 2-16
2.4.1 Running the Machine ................................................................................... 2-16
2.4.2 Mounting and Dismounting .......................................................................... 2-17
2.4.3 Removing Attachments ................................................................................ 2-18
2.4.4 Jacking Up the Machine............................................................................... 2-18
2.4.5 Adding Fluids to a System ........................................................................... 2-18
Shop Safety SY365(B)H-9 Crawler Hydraulic Excavator
2.4.6 Aligning Parts or Components ..................................................................... 2-19

2.4.7 Driving Pins .................................................................................................. 2-19
2.4.8 When compressed air is used...................................................................... 2-19
2.4.9 Welding operation ........................................................................................ 2-20
2.4.10 Track Recoil Springs .................................................................................. 2-20
2.4.11 High-Pressure Fluid Lines .......................................................................... 2-21
2.4.12 Air-conditioning system maintenance ........................................................ 2-22
2.4.13 High voltage precautions ........................................................................... 2-22
A
2.4.14 Disconnecting the System Power .............................................................. 2-23
C
2.4.15 Accumulator ............................................................................................... 2-23
RI
2.4.17 Battery Hazards ......................................................................................... 2-24
2.4.18 Jump-Start Safety ...................................................................................... 2-25
2.4.19 Avoiding fire and explosion ........................................................................ 2-26
E
2.4.20 Chemical hazard ........................................................................................ 2-27
AM
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
N
2.5.1 Sling work and giving signals ....................................................................... 2-29

2.5.2 Using mobile crane ...................................................................................... 2-31
TI
2.5.3 Using overhead hoist crane ......................................................................... 2-31

2.5.4 Selecting wire ropes..................................................................................... 2-33
LA
NY
SA

2 SHOP SAFETY
2.1 Hazard Alert Information
Most accidents are usually caused by the failure to follow fundamental repair procedures and
safety rules for the system under repair. To avoid accidents it is important to read and understand
all information outlined in this manual before performing repairs on the machine system.
The following (ANSI/ISO) signal words are used to inform you that there is a potentially hazard-
ous situation that may lead to damage, personal injury or even death. In this manual, on the ma-
chine, part or component decals and different signal words are used to express the potential level
A
of a hazard.
C
RI
DANGER WARNING
● Indicates an imminent hazard which ● Indicates a potentially hazardous situa-
E
WILL result in serious injury or death if AMtion which COULD result in serious in-
message is ignored. jury or death if message is ignored.
CAUTION NOTICE
N
TI
● Indicates a potentially hazardous situ- ● Indicates THE MACHINE MAY BE DAM-

ation which COULD RESULT IN MINOR AGED if improperly operated or main-
OR MAJOR INJURY if message is ig- tained.
LA
nored.
This is to alert the user of a hazard. It is This symbol is used in a graphic to alert
usually used in a graphic. the user to not do something.
NY
SA
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.

WARNING
● Improper repair procedures on this machine can be hazardous and could result in serious in-
jury or even death.
● All personnel involved with the repair of this machine must read this manual thoroughly before
performing any procedures on this equipment.
● Some actions involved in the operation or repair of this machine could cause a serious acci-
dent if they are not performed in the manner described in this manual.
A
● All precautions outlined in this manual apply only to intended repair procedures of the ma-
chine or system. If you perform any repairs not specifically prohibited, you must be sure that it
C
is safe for you and others. In no event should you or others engage in prohibited uses or ac-
RI
tions 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 pur-
E
chased in another country or purchased from someone in another country, it may lack
AM
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 stan-
dards and regulations of your country, contact your SANY representative before per-
forming repairs on this machine.
N
TI
LA
NY
SA

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
A
discuss any questions or confusion with them.
Always keep in mind, shop safety is NOT
C
something to be studied at the start of a proj-
RI
ect and then forgotten; most accidents are
caused by carelessness, being in a hurry or by
simply disregarding safety rules. Remember
E
this, if you are DILIGENT and follow instruc-
tions outlined in this shop manual with care,
repair operations can be safe and enjoyable.
AM
Safe work practices, should become a force of
habit.
N
TI
WARNING
● Mistakes in operation are extremely

LA
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.
NY
SA

2.2.1 Rules and shop behavior

● Study all shop rules relating to the proce-
dure carefully and constantly apply them.
When in doubt about any task, get help!
DO NOT take chances.
● Know your job. It is foolish, and often di-
sastrous, to make repairs to a machine
without first receiving proper instructions.
Always use the shop manual when per-
A
forming any repair tasks. Get additional
help if you are NOT sure what must be
C
done or how a task should be performed.
RI
● 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
E
everyone. Daydreaming or socializing on AM
the job also increases your chances of in-
jury. Fig. 2-2
● If you must smoke, smoke only in the area
provided for smoking. Never smoke while
N
on the shop floor or work area.

TI
2.2.2 Housekeeping
● Oils, grease, fuel, antifreeze or any fluid
LA
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.
NY
● Keep the shop clean. Scrap or old parts

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

2.2.3 Shop Liquids Storage

● Liquids, cleaning solvents or machine flu-
ids should be properly stored in an area
away from work locations. These storage
areas should be ventilated to an outdoor
location to avoid any vapor accumulation
in a confined shop area. Follow all OSHA
regulations regarding fluid storage.
● Never leave open containers of liquids sit-
A
ting around. These could spill or catch fire.
Always read the container label for infor-
C
mation on storage and handling of the liq-
RI
WX235R-1200002
uids.
● Never store liquids in containers that are Fig. 2-3
not properly labeled for that liquid. Confu-
E
sion could result in equipment damage, fire AM
or an unexpected explosion.
● Never smoke or bring open flames around
liquids, doing so could result in an unex-
pected fire or explosion.
N
● Never handle liquids without using person-

TI
al protective equipment. Treat all liquids

with caution.
LA
2.2.4 Cleaning the Parts

Never use gasoline, diesel fuel or similar flam-
mable liquids to clean parts. Always use ap-
proved non-flammable solvents to clean parts.
NY
Failure to do so could result in explosion or

fire.
SA
WX235R-1200003
Fig. 2-4

2.2.5 Cleaning the Machine

● Always use high-pressure hot water and
mild, nonflammable grease-cutting soaps
or cleaning agents to clean the machine
parts. Never use flammable or caustic
cleaning agents.
● Never use high-pressure steam cleaners
to clean the machine. Steam cleaners will
damage the paint, hoses or electrical sys-
A
tem.
C
● Never pressure-wash or flood the inside of
an operator cab. This will damage sensi-
RI
WX235R-1200007
tive electrical components.
Fig. 2-5
E
2.2.6 Appropriate Working Apparel AM
Improper or loose clothing, casual dress cloth-
ing, jewelry, incorrect shoes or long hair can
result in possible injury.
Make a list of the types of clothing that are not
N
allowed in the shop area. Go over the list with

TI
personnel before they start a job.

LA
WX235R-1200005
Fig. 2-6
NY
2.2.7 Personal Protective Equipment

SA
If your shop specifies the use of safety equip-

ment, OSHA requires this equipment to be
used when on the shop floor or in the area
where this equipment is required.
Never allow personnel in the shop area with-
out the proper personnel protective equipment
even for a moment.
Always keep personnel protective equipment
in good condition and replace them as re-
quired. CZ335-1102002
Fig. 2-7

2.2.8 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
A
car, etc.
C
● Keep your tools clean, and when the job is ZX215-1000033
RI
complete, take inventory of the tools you Fig. 2-8
were using to be sure no tools were left in
the machine.
E
● Always put shop tools back in there proper AM
storage location when finished.
● If welding repairs are needed, always have
a trained, experienced or certified welder
carry out the work.
N
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2.2.9 Fire Extinguisher and Emergency

Exits
LA
● It is important to know where all emergen-

cy exits and fire extinguishing equipment
are located if a fire should occur in the
shop.
NY
● Before preparing for work, take time and

walk around the shop to make a mental
note of where all exits and fire equipment
SA
are located. If you are performing repairs

in the field, always have a fire extinguisher
handy and within reach.
● If you do not know how to use a fire extin-
WX235R-1200006
guisher contact someone who can instruct
you in the proper use of this equipment. Fig. 2-9

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
A
to be sure it is off before performing any
repairs.
C
● When working around flammable liquids or
RI
explosive systems, use only approved anti-
explosion proof work lamps. Non-approved
work lamps can cause an explosion or fire.
E
AM
Fig. 2-10
2.2.11 Hoisting a Load

N
If you will be lifting parts or components that

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

to follow some basic rules.
● Always use the appropriate lifting equip-
LA
ment 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
NY
about to lift.
● If straps are to be used, ensure they are in
good condition and rated for the load to be
SA
lifted with them.

● If you must lift the load by hand, keep your
Fig. 2-11
back straight and parallel with the load,
and lift the load using your leg muscles to
avoid back injuries. Always ask for a lifting
assistant.

2.3 Before Repair

2.3.1 Safe Work Preparations
Before starting any repairs, be sure the ma-
chine is sitting on a level stable surface.
Lower all the work equipment to a safe and
stable position on the ground. Turn the engine
OFF and neutralize the work equipment con-
trols by rotating them to the left and right (joy-
A
stick control) or moving them back and forth
C
(lever control). This function will relieve system
pressure.
RI
Block the tracks (if equipped) or wheels (if
equipped) with chocks to prevent the machine
from moving.
E
If equipped, set the hydraulic lock lever in the AM
LOCKED position. If equipped, set the parking
brake in the PARK position.
Fig. 2-12
Be sure all personnel and equipment is clear
of your work area and you can be seen by all
N
working personnel especially if performing re-

TI
pairs in the field.

LA
NY
SA

2.3.2 Preparing yourself

Only approved personnel can maintain or
repair the machine. An observer may be as-
signed if necessary.
● Wear protective clothing and shoes neces-
sary for the job.
● Wear rubber apron and rubber gloves
when handling corrosive materials. Wear
heavy gloves when handling wooden ma-
A
terials, wire ropes or sharp-edged metals. CZ335-1102069
C
Fig. 2-13
● Wear a face shield when removing spring
RI
or elastic parts, or adding acid to battery.
Wear safety hat and goggles when you
weld or cut with a torch.
E
● Never carry out grinding, flame cutting or AM
welding without an aspirator and ventilation
equipment. If you have to weld on the ma-
chine, refer to related instructions and un-
derstand the correct operating procedure.
N
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CZ335-1102070
Fig. 2-14
LA
NY
SA

2.3.3 Lockout/Tagout
Due to the size and complexity of this ma-
chine, Lockout and Tagout procedures may
be required by your company to ensure the
safety of yourself and others involved in the
repair process of the machine. While work
is in progress, all power sources must be
disabled, locked and tagged with a warning
label. Lockout/Tagout procedure establishes
A
the minimum requirements used to isolate all
power sources from potentially hazardous en-
C
ergy, and to ensure that the machine is“locked
RI
out and tagged out” before anyone performs
repairs on the machine.
E
Sequence of procedures
Only authorized employees performing repairs
AM
on the machine shall perform Lockout/Tagout
in accordance with this procedure listed below. DA
NG
If the employee performing repairs to the ma- ER
DO
N
chine is issued a lock and key, the employee

shall not share the lock or key with other em- OP NO
ER T
TI
ployees until all repair procedures are com- AT

plete and the machine is ready to put back into E
service.
LA
The following steps shall be performed in the

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

1. Notify all employees who may be poten-
SA
tially affected by the repair process on the

machine.
Fig. 2-15
2. Secure the machine in a safe position.
If equipped, set the parking brake or hy-
draulic lock lever in the PARK or LOCKED
position.
3. Identify, remove or disconnect all power

or energy sources and be sure to install

a Lockout/Tagout device on them. If the
machine is equipped with a Maintenance
Alert Tag, attach this tag to the machine
controls. DANGER
4. Be sure all employees involved in the
repairs have installed there lock on the
DO NOT OPERATE
power source before performing any When this is not being used,
repairs. Once an employee has completed keep it in the storage compartment.
A
there repair procedure, they must remove
there lock and not access the machine in
C
any manor. Fig. 2-16
RI
Returning to service
1. The authorized person who performed the
E
Lock out/Tagout procedure shall check the
area around the machine to ensure that no AM
one is exposed to any hazard before start-
up.
2. The authorized person who performed
the Lock out/Tagout shall ensure that
N
all guards have been reinstalled to their

TI
proper place, all tools and equipment have

been removed and all locks are removed.
3. The authorized person who performed the
LA
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.
NY
4. Remove the Lockout/Tagout equipment

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

2.3.4 Two people when engine running
In order to prevent injury, do not perform the

service while the engine is running. If the ser-
vice must be performed while the engine is
running, operate only when two people are on
the spot and follow the regulations below:
● Always have one operator sit on the op-
eration seat and be ready to turn off the
engine at any time. All the operators must
A
keep in touch with each other.
C
● Set the safety lock control lever to the lock
RI
position.
● Do not touch any control lever. If some
control lever must be operated, send signal
E
to other people and warn them to transfer AM
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.
N
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2.3.5 Safety Partners

LA
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
NY
the shop might not be able to get emergency

help in the event of a shop accident.
When working together always maintain clear
SA
contact with each other at all times to avoid

the occurrence of unexpected incidents.
When carrying out any operation with two or
more workers, always agree on the operating Fig. 2-17
procedures and signals before starting.

2.4 Repair Precautions
2.4.1 Running the Machine

Run the machine during repair procedures
ONLY if directed to do so in this shop manual.
If the machine must be run when making re-
pairs, it is important to follow some basic safe-
ty rules.
● Always be aware of rotating components.
A
● During repair operations while the engine
C
is running, one worker must remain in the
RI
operator seat of the machine with clear
contact between the person performing the CZ335-1102077
repairs on the machine at all times.
Fig. 2-18
E
● If equipped, all lock levers must be in the
LOCK position or the parking brake must
be in the PARK position.
AM
● The person in the cab must never touch
any controls. If a control lever must be op-
erated, always maintain a clear view to the
N
person doing the repair and signal them

TI
when you are about to move the control le-

ver.
● Be aware of hot surfaces. During running
LA
operations, most surfaces will be hot, and

some surfaces will be extremely hot. If
necessary, use personnel protective equip- CC13031805
ment when working around high tempera- Fig. 2-19
NY
ture surfaces.
● Keep in mind that during running opera-
tions, hydraulic systems, cooling systems
SA
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

2.4.2 Mounting and Dismounting

It is important to follow these procedures when
mounting or dismounting the equipment:
● Use all hand-holds and step plates on your
equipment.
● Never jump off or onto the equipment.
● Wipe off any oil, grease, or mud from your
shoes, rails, steps or platforms before get-
A
ting on the equipment; always keep these
areas clean and in good condition.
C
● Never get on or off moving equipment.
RI
These actions may lead to serious injury. Fig. 2-21
Always bring the equipment to a full stop
and turn the engine OFF.
E
● When getting on or off the equipment, AM
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
N
that you support yourself correctly.

● Never climb on areas of the machine that
TI
are not designated walk areas.

● Never climb on or off the machine with
LA
tools, parts or similar objects in your

hands.
● Never use machine controls or non-spec-
ified points on the equipment to get on or
NY
off the machine.

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

2.4.3 Removing Attachments

● If you will be removing large heavy attach-
ments from the machine, always be sure to
use the correct lifting equipment rated for
the capacity of the load you will be lifting.
● After the attachment or part has been
removed, store it where it cannot fall or
move. Always be sure what you are stor-
ing is sitting stable on a stable surface and
A
clear of all walkways or fire exits.
C
RI
WX235R-1200009
Fig. 2-23
2.4.4 Jacking Up the Machine
E
● If you will be working under the machine AM
always use approved jack stands that will
support the weight of the machine you are
working on.
● Never rely on the hydraulics of the ma-
N
chine or a hydraulic jack to support the

TI
machine during repairs.

● Always lower the work equipment to the
ground and check the stability of the ma-
LA
chine before going under the machine. CZ335-1102078
Fig. 2-24
NY
2.4.5 Adding Fluids to a System

If it should be necessary to add fluids to a
SA
system during running operations, always be

aware that these systems may be hot and un-
der high pressure.
Before adding fluids, shut the machine down
and allow the systems to cool down to outdoor
ambient temperatures before removing any
caps. Failure to do so may result in serious
burns or a sudden loss of fluid.
Fig. 2-25

2.4.6 Aligning Parts or Components

● Be careful when installing or aligning parts
or components.
● Avoid using your fingers or hands to posi-
tion holes or part mating surfaces, serious
injury could result if your hand or fingers
should get ought between the surfaces.
● Always use tools to align a part or compo-
nent to avoid any finger or hand injuries.
CA
RI
WX235R-1200012
Fig. 2-26
E
2.4.7 Driving Pins
When using a hammer to drive pins, metal
AM
particles may fly off. This may lead to serious
eye injuries. Always do the following:
● Always wear a face shield or goggles when
N
striking a metal object with a metal ham-

mer.
TI
● Before performing any of these proce-

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

● If possible, avoid using a steel hammer to CZ335-1102069
drive a component or pins in place. Dam- Fig. 2-27

age to the component may result. Always
use a soft or non-ferrous hammer to drive
NY
a component or a pin.
SA
2.4.8 When compressed air is used

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

2.4.9 Welding operation

There is possibility of fire or electrocution dur-
ing welding. Therefore, welding must be per-
formed by qualified personnel with suitable
equipment. Never allow other people to do the
welding.
C A
CZ335-1102070
RI
Fig. 2-28
E
2.4.10 Track Recoil Springs AM
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
N
may fly out and cause serious injury.

TI
Be careful when removing or installing tracks

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

Always stand clear of the track travel path
Fig. 2-29
when separating the master link section of the
track.
NY
SA

2.4.11 High-Pressure Fluid Lines

Always keep in mind that these systems are
under high pressure. When inspecting or re-
placing piping or hoses, always check to be
sure the pressure in the system has been
relieved before proceeding. Working on a sys-
tem still under pressure could lead to serious
injury, always do as follows:
● If you will be removing a line or component
A
with fluid in the system, always cap and
seal the opening to avoid leakage or sys-
C
tem contamination.
RI
● Never carry out inspections or replace
items while the system is under pressure.
E
● Never use any part of your body to check
or feel for leaks. Always wear safety AM
glasses and leather gloves when checking
for leaks and use a piece of wood or card-
board when checking for leaks from small
holes.
N
● If high pressure fluids should penetrate

TI
your skin or get into your eyes, seek medi-

CZ335-1102082
cal attention immediately.
Fig. 2-30
LA
NY
SA

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
A
splashed on your skin.
C
RI
● Keep fire source away when servicing air-
conditioning system.
● In maintenance of air-conditioning system,
E
observe the instruction on the refrigerant AM
cylinder and use it correctly. The type of
refrigerant is R134a. Use of other refriger-
ants may damage the air-conditioning sys-
tem.
N
● Obey local material disposal regulations.

Never discharge refrigerant directly into the
TI
CZ335-1102083
air.
Fig. 2-31
LA
2.4.13 High voltage precautions

You must understand the elements before
testing electric circuit. High voltage or current
NY
could lead to machine damage, spark, explo-

sion or fire.
SA
You must know the voltage before repairing

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

2.4.14 Disconnecting the System

Power
Before starting any repair operations, remove
the battery leads from the battery or set the
main disconnect on the machine in the OFF
position.
For the location of the machine main electri-
cal disconnect switch, refer to the machines
Safety, Operation & Maintenance Manual for
A
location and procedures.
C
If the battery must be disconnected, remove
the negative (-) terminal clamp first then re-
RI
move the positive (+) clamp last.
When reconnecting the battery, be sure every Fig. 2-33
E
electrical system switch is in the OFF position,
connect the positive clamp (+) first, then the AM
negative clamp(-) last.
2.4.15 Accumulator
N
If the machine is equipped with an accumula-

TI
tor charged with high-pressure nitrogen gas, it

is important to follow these basic precautions.
LA
● Do not disassemble the accumulator.

● Never expose the accumulator to high heat
or open flames.
● Never weld on the accumulator.
NY
● Never drill or cut on the accumulator.

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

2.4.17 Battery Hazards

Working around batteries always poses a haz-
ard, especially if the battery has been in ser-
vice for a long period of time.
Listed below are some basic precautions to
be aware of when servicing or working around
batteries.
● Always wear personal protective equip-
ment when working around batteries.
A
● Battery gasses are extremely explosive.
C
When opening a battery compartment, al- CZ335-1102061
RI
ways allow ample time for the gasses to Fig. 2-35
escape before servicing the battery.
E
● When working with batteries, always work AM
in a well ventilated area.
● If the battery is corroded, flush the area
with a baking soda and warm water mix.
N
TI
LA
CZ335-1102062
Fig. 2-36
NY
● If battery acid should get on your skin or in

your eyes, flush the area immediately with
fresh water and seek medical attention.
SA
CZ335-1102083
Fig. 2-37

2.4.18 Jump-Start Safety
CAUTION
● Never use a welder or a machine with a

higher voltage system to jump-start the
machine. Doing so may damage the ma-
chine’s electrical system or cause an
unexpected explosion or fire resulting
A
in minor or major injury.
C
RI
When using jumper cables to start the ma-
chine, connect the positive (+) jumper first, Fig. 2-38
then the negative (-) jumper to a remote loca-
E
tion on the chassis away from the battery.
AM
N
TI
LA
NY
SA

2.4.19 Avoiding fire and explosion
WARNING
● Never smoke when handling the fuel or

maintaining the fuel system. The gases
in empty fuel tank can cause explosion
easily. Never carry out flame-cutting or
welding operation on fuel pipe, fuel tank
or fuel vessels, which can lead to fire,
A
explosion, injury or death.
C
RI
● Then engine must be shut down and elec-
trical equipment must be switched off when
refueling the tank. Be extremely care-
E
ful when adding fuel to a hot engine. No AM
sparks shall occur around the grounding
nozzle.
● Handle all solvents and dry chemicals in a
place with good ventilation according to the
N
steps indicated on vessel.

TI
● Clean the machine of all dust and residu- CZ335-1102014
als. Never place greasy rag or other flam- Fig. 2-39

mable materials on machine.
LA
● When cleaning the parts and components,

use nonflammable solvents instead of gas-
oline, diesel oil or other flammable fluids.
● Store flammable liquids and materials in
NY
suitable vessels as required by safety laws

and regulations.
● Check fire extinguishers, fire-fighting sys-
SA
tem and fire detectors (if equipment) and

make sure they are ready for use.

2.4.20 Chemical hazard

Exposure to hazardous chemicals pose a
serious danger if released or mishandled.
Handling hazardous materials often releases
substances that could pose a hazard. Tempo-
rary implication or possible residual injury may
result unless proper precautions are observed
while working with these materials. All work-
ers involved in handling hazardous materi-
A
als should use approved personal protective
equipment and follow all environmental safety
C
regulations.
RI
2.4.21 Material Safety Data Sheets
E
(MSDS)
Material Safety Data Sheet (MSDS) informa-
AM
tion relating to the materials the workers could
be exposed to.
● MSDS data sheets provide both workers
N
and emergency personnel with the proper

procedures for handling or working with a
TI
particular substance. Information includes

physical data, health effects, first aid, re-
activity, storage, disposal and protective
LA
equipment required.
● Be sure all personnel involved are familiar Fig. 2-40
with all MSDS-related information as it re-
lates to the hazardous materials they could
NY
be exposed to. Keep MSDS data sheets

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

2.4.22 Proper disposal of wastes

Improper disposal of wastes harms the envi-
ronment and ecology. Consult local environ-
mental protection department or Sany dis-
tributors for methods of recycling and waste
disposal.
● Potential harmful substances used in Sany
products include hydraulic oil, fuel, cooling
liquid, refrigerant, filter and batteries etc..
A
● Use leak-proof vessels to hold discharged
C
fluids. Never use food or beverage contain- CZ335-1102086
ers.
RI
Fig. 2-41
● Never dump waste fluids directly to the
ground, sewage or water source.
E
● Leaking of refrigerant from air conditioner AM
can spoil the atmosphere of the globe.
Related laws and regulations must be fol-
lowed to recover or regenerate the refriger-
ant.
N
TI
LA
CZ335-1102087
Fig. 2-42
NY
SA

2.5 Other Precautions

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

pointed signal person must give specified kN
kg
19.6
signals clearly at a place where he is seen 2000 18.6
16.7
well from the operator's seat and where he 19.6
1900
1700 13.7
1400
can see the working condition easily. The
A
2000 9.8
1000
signal person must always stand in front of 9.8 4.9
C
500
1000
the load and guide the operator safely.
RI
● Do not stand under the load. 30 60 90 120 150
Hanging angle (Deg.)
● Do not step on the load.
ZX215-1000001
E
2. Check the slings before starting sling work. Fig. 2-43
3. Always wear gloves during sling work.
(Wear leather gloves, if available.)
AM
4. Measure the weight of the load by the eye
and check its center of gravity.
N
5. Use proper sling according to the weight of

the load and method of slinging. If too thick
TI
wire ropes are used to sling a light load,

the load may slip and fall.
LA
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.
NY
Do not sling a heavy load with ropes

forming a wide hanging angle from the
hook. When hoisting a load with 2 or more
SA
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
at a lifting angle of 150 ° , each of them

is subjected to a force as large as 39.2 kN
{4,000 kg}.
8. When installing wire ropes to an angular
load, apply softeners to protect the wire
ropes. If the load is slippery, apply proper
material to prevent the wire rope from slip-
ping.
9. Use the specified eyebolts and fix wire
A
ropes, chains, etc. to them with shackles,
etc.
C
100% 88% 79% 71% 41%
10. Apply wire ropes to the middle portion of
RI
the hook.
● Slinging near the tip of the hook may ZX215-1000002
E
cause the rope to slip off the hook dur- Fig. 2-44
ing hoisting. The hook has the maxi- AM
mum strength at the middle portion.
11. Do not use twisted or kinked wire ropes.
12. When lifting up a load, observe the follow-
ing.
N
● Wind in the crane slowly until wire

TI
ropes are stretched. When settling the

wire ropes with the hand, do not grasp
them but press them from above. If
LA
you grasp them, your fingers may be

caught.
● After the wire ropes are stretched, stop
the crane and check the condition of
NY
the slung load, wire ropes, and soft-

ener.
SA
● If the load is unstable or the wire rope

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

● 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
A
● Read the Operation and Maintenance
C
Manual of the crane carefully in ad-
RI
vance and operate the crane safely.
E
2.5.3 Using overhead hoist crane
1. Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
AM
wind stop device, electric shock prevention
earth leakage breaker, crane collision
prevention device, and power application
N
warning lamp, and check safety.

TI
2. Observe the signals for sling work.

3. Operate the hoist at a safe place.
LA
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
NY
the crane while the slung load is swinging.

6. Do not raise or lower a load while the
crane is moving longitudinally or laterally.
SA
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.

11. After operating the hoist, do not swing the

control switch.
12. Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
13. If the hoist stops because of a power
failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth leak-
A
age breaker, check that the devices related
to that switch are not in operation state.
C
14. If you find an obstacle around the hoist,
RI
stop the operation.
15. After finishing the work, stop the hoist at
E
the specified position and raise the hook to
at least 2 m above the floor. Do not leave AM
the sling installed to the hook.
N
TI
LA
NY
SA

2.5.4 Selecting wire ropes

Select adequate ropes according to the weight of parts to be hoisted. See the table below.
Wire Rope
(Standard Z or S type of strand, ungalvanized)
Nominal Diameter Allowable Load
mm kN t
A
10 9.8 1.0
C
11.5 13.7 1.4
12.5 15.7 1.6
RI
14 21.6 2.2
16 27.5 2.8
E
18 35.5 3.6
20
22.4
43.1
54.9
AM 4.4
5.6
30 98.1 10.0
40 176.5 18.0
N
50 274.6 28.0
TI
60 392.2 40.0
LA
CAUTION
● The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
NY
SA

E CA
G RI
ME
PAA
IN
AT
K
ANL
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BSLAN

SY365(B)H-9 Crawler Hydraulic Excavator Specifications
Specifications
C A
RI
3 Specifications
3.1 Specific Dimension .................................................................................................. 1-3
E
3.1.1 Dimension ...................................................................................................... 1-3
AM
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
N
3.5 Engine Performance Curves.................................................................................... 1-9

TI
LA
NY
SA

Specifications SY365(B)H-9 Crawler Hydraulic Excavator
C A
E RI
AM
N
TI
LA
NY
SA

3 SPECIFICATIONS
3.1 Specific Dimension
3.1.1 Dimension
A
D
I
C A
C
RI
E
L
H
G F
E
B
J
AM K
CZ425-1103002
Fig. 3-1
N
TI
Item Unit SY365H-9 SY365BH-9

A Shipping length mm 11,360 11,380
LA
B Overall width mm 3,190 3,190

C Shipping height mm 3,550 3,640
D Top width mm 3,150 3,150
E Overall height (to cab top) mm 3,320 3,320
NY
F Standard width of track shoe mm 600 600

G Gauge mm 2,590 2,590
SA
H Min. ground clearance mm 550 550

I Tail swing radius mm 3,380 3,380
J Track grounding length mm 4,140 4,140
K Track length mm 5,065 5,065
L Upper-structure ground clearance mm 1,250 1,250

3.1.2 Working ranges
C A
RI
a
E
g
b
AM
N
TI
LA
c
NY
SA
CZ425-1103004
Fig. 3-2


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
C A
RI
3.2 Technical Specifications
E
Bucket capacity m3
AM
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
N
Swing speed rpm 9.5 9.5

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

Gradeability Degree 35 35
Specific ground pressures KPa 63 63
LA
NY
SA

Machine Model SY365H-9 SY365BH-9

Model
ISUZU AA-6HK1XQP-01
Type 6 cylinders, 4 cycles, water cooling, in-line, and direct injection
No. Of cylinder-bore × 6-Φ115mm×125mm
mm
stroke 7.8
L
Total displacement
Engine
Rated power kW/rpm 190.5/ 2000

Performance
Max. torque N·m/rpm 873 / 1700
A
Max. speed at zero load rpm 2200±25
Min. speed at zero load rpm 1000±25
C
Min. fuel consumption g/kWh 237
Start motor 24V/5kW
RI
Alternator 24V/50A
Carrier roller (each side) 2
Undercarriage
E
Track roller (each side) 9
Track shoe (each side)

AM 49
Hydraulic pump
Type KAWASAKI (two variable swash plate plunger pumps, constant

Max main pump delivery
N
power control and proportional solenoid valve)

L/min
Main safety valve pres- 2×158
Mpa
TI
sure 34.3
Control valve
LA
Type X No. KMX32NA/P45001×1

Control method Hydraulic type
Hydraulic system
Angle type variable plunger motor A6VE107HZ3/63W-

NY
VZL22XB-S
Hydraulic motor
Travel motor
Planetary gear reducer F80/121/OM/MB
(Including brake valve and parking brake)×2
SA
Angle type plunger motor - planetary gear reducer (upright)

Swing motor M5×180CHB-10A-3NA/265 - RG20D25G2-140
(Swing stop controller)×1
Hydraulic cylinder
Boom Arm Bucket Boom Arm Bucket

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

3.3 Weight Table
Unit: kg
Machine Model SY365H-9 SY365BH-9
Engine 720 720
Radiator assembly 118 118
Hydraulic tank assembly (excluding
234 234
hydraulic oil)
A
Fuel tank assembly (excluding fuel) 235 235
Swing platform 3040 3040
C
Operator station 150 150
RI
Operator seat & console 76 76
Counterweight 6800 6800
E
Hydraulic pump 186 186
Main control valve 380 AM 380
Swing reducer assembly 422 422
Travel reducer assembly 389×2 389×2
Swivel joint 45 45
Track frame
N
4612 4612
Swing bearing 544 544
TI
Idler 175×2 175×2

Tensioning device 190×2 190×2
Carrier roller 35×4 35×4
LA
44×18 44×18
Track roller
Boom assembly 2574 2574
Arm assembly 1165 1200
Bucket assembly 1620 1582
NY
Boom cylinder assembly 264×2 264×2

Arm cylinder assembly 484 484
SA
Bucket cylinder assembly 150 150

Connecting rod 114 105
Rocker arm 35×2 40×2
Note: The weight table is only used as a reference for handling the components or transporting
the machine.

3.4 Engine oil, Fuel and Coolant

Ambient temperature
Liquid
Reservoir -22 -4 14 32 50 68 86 104 122 ℉
type
-30 -20 -10 0 10 20 30 40 50℃
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
A
Engine oil
C
SAE 15W-40
RI
Carrier roller
Idler
Track roller SAE 30
E
Swing drive
Gear oil
Final drive AM
SAE 10W
Engine oil SAE 10W-30

N
SAE 15W-40
TI
Hydraulic sys-
tem
HDZ32 low temp, wear-resistant
LA
Hydraulic
oil HDZ46 wear-resistant
HDZ68 wear-resistant
NY
GB252 super 0#
Fuel tank Diesel oil GB252 super -20#

SA
GB252 super -35#
Grease fitting Grease NLGI No.2
Cooling sys-
Coolant TEEC-L35 antifreeze
tem
Note: 1) Sany recommends using API CF-4 or above, not lower than API CD.
2) Sany recommends using gear oil GL-5.
3) To ensure oil quality, always buy genuine oil from Sany or your Sany distributor.

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
A
872.8 or more Ｎｍ/approx.1700 min-1 1050
(872.8～/approx.1700 min -1)
C
950
RI
850
750
E
650
Max output power

183.9±2.9 kW/2000 min-1
AM
200 (181.0～186.8kW/2000min-1 )
N
150
TI
LA
100
50
NY
Max speed without load

2275±25 min-1
-1
(2250～2300min )
SA
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

E CA
G RI
ME
PAA
IN
AT
K
ANL
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BSLAN

SY365(B)H-9 Crawler Hydraulic Excavator Structure and Functions
Structure and Functions
C A
2
E RI
4 Structure and Functions AM
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
N
4.2.1 Overview ........................................................................................................ 4-7

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

4.2.3 Swing reducer mechanism........................................................................... 4-10
LA
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
NY
4.3.3 Carrier roller ................................................................................................. 4-18

4.3.4 Track roller ................................................................................................... 4-19
SA
4.3.5 Track ........................................................................................................... 4-20

4.3.6 Tri-grouser track shoe .................................................................................. 4-23
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
Structure and Functions SY365(B)H-9 Crawler Hydraulic Excavator
4.4.3.5 Oil delivery control .............................................................................. 4-33

4.4.4 Pilot pump .................................................................................................... 4-34
4.4.5 Regulator .................................................................................................... 4-35
4.5 Hydraulic system, Part 2 ........................................................................................ 4-48
4.5.1 Main control valve ........................................................................................ 4-48
4.5.1.1 Overview ............................................................................................ 4-48
4.5.1.2 Main valve structure ............................................................................ 4-50
4.5.2 Hydraulic circuit (With bucket confluence function) .............................................. 4-56
A
C
4.6.1 Swing motor ................................................................................................. 4-79
RI
4.6.2 Swing holding brake..................................................................................... 4-81
4.6.3 Relief valve section ...................................................................................... 4-82
4.6.4 Anti-jerk valve............................................................................................... 4-84
E
4.6.4.1 Operation diagram .............................................................................. 4-84
AM
4.6.4.2 Effect illustration.................................................................................. 4-84
4.6.5 Central Swivel Joint ..................................................................................... 4-86
4.6.6 Travel motor ................................................................................................. 4-87
N
4.6.7 Reducer ....................................................................................................... 4-89

4.6.8 Travel motor (Nabtesco) .............................................................................. 4-91
TI
4.6.9 Operating principle of the basic components ............................................... 4-93

4.6.9.1 Double-balanced valve ....................................................................... 4-93
LA
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
NY
4.6.12 Travel pilot valve .......................................................................................4-114

4.6.12.1 Operating principle ...........................................................................4-116
SA
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
4.7 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
A
4.8.1.6 Clutch ................................................................................................ 4-139
C
4.8.1.7 Condenser ........................................................................................ 4-140
RI
4.8.1.8 Expansion valve ................................................................................ 4-141
4.8.1.9 Evaporator ........................................................................................ 4-141
4.8.1.10 Dehydrator ..................................................................................... 4-142
E
4.8.1.11 Pressure switch .............................................................................. 4-143
AM
4.8.1.12 Fresh air sensor .............................................................................. 4-144
4.8.2 Refrigerant ................................................................................................. 4-145
4.8.2.1 Compressor oil .................................................................................. 4-163
N
4.9 Engine Control ..................................................................................................... 4-164

4.9.1 System operation ....................................................................................... 4-165
TI
4.9.1.1 Engine starting .................................................................................. 4-165

4.9.1.2 Engine speed control ........................................................................ 4-165
LA
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
NY
4.10 Electrical Control System................................................................................... 4-170

4.10.1 Control function ........................................................................................ 4-170
SA
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
A
4.11.3.1 Default page .................................................................................... 4-201
C
4.11.3.2 Password entry to system information ............................................ 4-202
RI
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
E
4.11.3.6 Main pump & main valve signals..................................................... 4-204
AM
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
N
4.11.3.10 System clock setup ....................................................................... 4-206

4.11.3.11 GPS information ............................................................................ 4-207
TI
4.11.3.12 System setup ................................................................................ 4-208

4.11.3.13 Machine configuration ................................................................... 4-208
LA
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
NY

SA

4 STRUCTURE AND FUNCTIONS

4.1 Engine and Cooling System
4.1.1 Engine-related parts
A
2
C
RI
M6
M6 Ⅱ
俁
2
4 Ⅰ
E
AM 3
4
N
TI
Ⅱ
Coupling installation
4×M18×60-10.9
5
Tightening torque 320N•m
LA
6
2×M16
Tightening torque 120N•m
AA-6HK1XQA
7
NY
SA
W365413091
Fig. 4-1
(1) Air cleaner Specification

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

4.1.2 Radiator and intercooler
3
4
C A
5
RI
1 2 6 7
E
AM
N
TI
W365413092
LA
Fig. 4-2
(1) Coolant tank Specification

(2) Water inlet pipe
Radiator AS: H1260×460×1100-S105Y100Z30
NY
(3) Water outlet pipe

(4) Air intercooler Aluminum ribbon-tublar radiator
(5) Condenser Tank capacity: 8.4 L
SA
(6) Oil radiator

(7) Water radiator

4.2 Power Train

4.2.1 Overview
3 2 1
C A
E RI
AM
N
4 5 6 7 8 9
TI
10
LA
NY
SA
ZX365-1304003
Fig. 4-3
(1) Swing motor (M5×180CHB-10A-3NA/265) (6) Accumulator

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

4.2.2 Travel reducer AS

10
C A
E RI
7
AM
6
N
1
TI
9
LA
8
NY
2 3 4 5
SA
11
12°
12 ZX335-1002050
Fig. 4-4

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

(2) No.1 planetary gear (8) No.2 sun gear
(3) No.1 planetary carrier pin (9) No.2 planetary carrier
(4) No.1 sun gear (10) Motor
(5) No.1 planetary carrier (11) Check port
(6) No.2 planetary gear (12) Filler/drain port
No. Check item Criteria Remedy
A
Clearance between No.2 planetary gear and
C
13 0.100 ～ 0.356 1.10
gear hub
RI
Clearance between No.1 planetary gear and
14 0.133 ～ 0.386 1.00
gear hub
Replace
Clearance between No.1 sun gear and
E
15 0.05 ～ 0.286 1.10
No.1 planetary gear AM
Clearance between No.2 sun gear and
16 0.076 ～ 0.304 1.00
No.2 planetary gear
N
TI
LA
NY
SA

4.2.3 Swing reducer mechanism
A
19 20
C
RI
21
8
E
24
AM 22
6 10
23
11
N
12
5
26
TI
7 4
13
LA
14
3
15 1
NY
SA
17
16
18
28
ZX335-1002004
Fig. 4-5

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

(2) Oil seal (12) No.2 planetary gear (teeth: 23)
(3) Self-aligning bearing (13) Spring pin
(4) Gear ring (teeth: 66) (14) Screw plug
(5) No.2 planetary carrier (15) Grease fitting
(6) No.1 planetary carrier (16) Self-aligning bearing
(7) No.2 sun gear (teeth: 18) (17) Bearing seal
(8) No.1 sun gear (teeth: 15) (18) Pinion gear
(9) Swing motor (19) Dipstick
A
(10) No.1 planetary gear (teeth: 25) (20) Oil-filling tube
C
RI
Specification
Reduction ratio: 25.2
E
No. Check Item
AM Criteria Remedy
Clearance between swing motor Standard clearance Clearance limit

21 Replace
shaft and No.1 sun gear 0.18- 0.28 —
Clearance between No.1 sun gear
N
22 0.16- 0.50 1.00

and No.1 planetary gear
TI
Clearance between No.1 planetary

23 0.18- 0.59 1.10
gear and gear ring
24 0.39- 0.71 1.20
LA
carrier and No.2 sun gear

Clearance between No.2 sun gear Replace
25 0.16- 0.50 0.90
and No.2 planetary gear
26 0.18- 0.59 1.00
gear and gear ring
NY

27 0.07- 0.23 —
carrier and swing pinion gear
Clearance between swing pinion
28 0.22- 1.32 2.00
SA
gear and swing bearing

4.2.4 Swing bearing
b
●
● ●
A
A
C
A
E RI
AM 1
2
N
3
TI
LA
NY
927±103 Nm 927±103Nm
SA
A-A
ZX335-1002005
Fig. 4-6
(1) Inner race (teeth: 78) Specification

(2) Steel ball Reduction ratio: 78/11= 7
(3) Outer race Grease volume filled: 27±1 Kg
a. Location S (soft zone of inner race)

b. Location S (soft zone of outer race)

Check Item Criteria Remedy
Bearing axial clearance Standard clearance Clearance limit

Replace
(Mounted on chassis) 0.5-1.6 3.2
C A
E RI
AM
N
TI
LA
NY
SA

4.3 Undercarriage Travel System

4.3.1 Track frame and tensioning mechanism
1 2 3 4
C A
RI
11
9 8 7 6 5
E
Ɣ
AM 10
12
N
X
TI
X
LA
ZX365-1304006
Fig. 4-7
NY
(1) Idler ● Dimension and number of track rollers may

(2) Track frame vary depending on the machine model, but
(3) Carrier roller their basic structures are the same.
SA
(4) Sprocket ● Number of track rollers on one side: 9

(5) Track roller
(6) Track
(7) Long guard
(8) Short guard
(9) Guide seat

Unit: mm
No. Check Item Standard Remedy

Standard
Tolerance Repair limit
Vertical width of size
10 idler guide +3
Track frame 123 —
-1 Build-up
Idler support 120 ±0.5 — welding
+4 or replace
Track frame 266 —
Horizontal width -1
11
of idler guide 0
A
Idler support 261 —
-0.5
C
Standard size Repair limit
Free
RI
length Installation Installation Free Installation
12 Tension spring × Outer length load length load Replace
diameter
E
{21280kg}
1225x 262 655 AM 795 —
208.5KN
Standard track shoe

N
Model
TI
SY365H-9/SY365BH-9
Item
Shoe width (mm) 600
LA
Link pitch (mm) 216

Number of track
49
shoes on one side
NY
SA

4.3.2 Idler
4
3
7
A
8
C
RI
157~255 Nm 9
E
AM
1 2
N
TI
LA
NY
SA
ZX215-1002010
Fig. 4-8

Unit: mm
1 Protrusion outer dia.
635 —
2 Tread outer dia. 590 578 Build-up
3 Tread thickness 30 24 welding
4 Tread difference 22.5 26 or replace
5 Overall width 190 —
A
6 Tread width 44 —
C
Standard Tolerance Standard Clearance
RI
Clearance between size Shaft Hole clearance limit
7
shaft and bushing
φ80 — — — —
E
Standard Tolerance Standard Interference
8
Interference be-
tween idler and
size Shaft
AM
Hole interference limit Replace
bushing
bushing
φ86 — — — —
Clearance between Standard clearance Clearance limit

N
bushing and support

9
(Sum of clearances 0.5-1.0 —
TI
at both sides)
LA
NY
SA

4.3.3 Carrier roller
5 3
A
8
C
RI
4
E
AM 6 7
2 1
N
TI
ZX215-1002011
Fig. 4-9
LA
Unit: mm
1 Flange outer dia.
NY
190 —
2 Tread outer dia. 150 136
3 Tread width 57 —
SA
4 Tread thickness 39 32
5 Flange width 16 —

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

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

4.3.4 Track roller

10
8 9 2 1
C A
RI
549±59 Nm
E
AM
7 5 6
4
ZX215-1002012
N
Fig. 4-10
TI
Unit: mm
Standard clearance Repair limit
LA
1 Flange outer dia.

216 —
2 Tread outer dia. 180 168
Build-up
3 Tread thickness 51.5 40.5 welding or
replace
NY
4 Overall width 250 —

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

4.3.5 Track
A
4
C
E RI
20 AM
22 24
N
8
16 12
13
TI
11 21
LA
23 25
7 6 15 2 9 3 14
10
NY
SA
18 17 19
ZX215-1002013
Fig. 4-11

Unit: mm

1 Link pitch
216 219
Reverse or replace
Standard size Reverse
2 Bushing outer diameter
66.9 60.23
3 Bushing metal thickness 11.1 —
A
4 Link height Repair or replace
116 104.4
C
Link metal thickness (bushing press-
5 30.65 22.5
RI
fitting portion)
6 178.4
7 Shoe bolt pitch 140.4
E
8 76.2
9 Inside width
AM 102
10 Link Overall width 23.2
11 Tread width 21.3
Adjust or replace
12 Pin protrusion 4.2
N
13 Bushing protrusion 5.3

TI
Overall length
14 242
of pin
Overall length
15 158.9
of bushing
LA
16 Spacer thickness —
17 Bushing 88.2 -245 kN{9-25 ton}
Press-fitting
18 Regular pin 127.4 -274.4 kN{13-28 ton} —
force
19 Master pin 78.4 -147 kN{8-15 ton}
NY
SA

Unit: mm

Tightening torque(Nm{kgm}) Retightening angle (deg)
a. Regular
link Tri-grouser 1100±55
120±10
track shoe {112.2±5.6}
20 Shoe bolt Tightening Lower torque Retighten
b. Master torque Retightening angle (deg) limit
link (Nm) (Nm{kgm})
— — —
A
Tolerance Standard inter-
C
Standard size
Interference between Shaft Hole ference
21
RI
bushing and link +0.46 +0.074
66.5 0.36-0.464
+0.41 0
Interference between pin +0.19 –0.188 Adjust or
E
22 44.6 0.285-0.485 replace
and link +0.09 –0.20
Tolerance
AM Standard clear-
Standard size
Clearance between pin Shaft Hole ance
23
and bushing +0.19 +1.35
44.6 0.18-0.83
+0.09 +0.85
N
TI
LA
NY
SA

4.3.6 Tri-grouser track shoe
5 6 7
1
8
C A
RI
2
3 4
E
ZX215-1002014
Fig. 4-12
AM
Unit: mm

N

TI
1 Height
30 20
2 Thickness 11
LA
3 29
Length of base
4 24 Build-up welding
5 22 or replace
6 Length at tip 16
NY
7 22
8 Thickness
41 31
SA

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
A
(5) Hydraulic oil filter
(6) Main control valve
C
(7) Main pump
RI
(8) Radiator
(9) Accumulator
E
(10) Left travel motor
(11) Right travel motor 1
AM
(12) Swing motor
(13) Hydraulic lockout control
(14) Left pilot valve
N
(15) Central swivel joint

TI
(16) Right pilot valve

(17) Travel pilot valve
(18) Solenoid valve AS
LA
18A. Hi/Lo travel speed shift solenoid valve

ZX335-1002007
18B. Negative flow solenoid valve (front
pump) Fig. 4-13
NY
18C. Negative flow solenoid valve (rear

pump)
18D. Pilot lockout solenoid valve
SA

C A
3 4 5 6 7 8
E RI
AM
N
TI
A
LA
NY
SA
10
18F18E A৥
11 18D
12 18C
13 17 18B
14 18A
15
16
18
W365-1304008
Fig. 4-14
4.4.2 Hydraulic tank and filter
1 2 B
6<++&
C A
E RI
B
4 5 6
AM B-B
7
3
N
TI
LA
NY
W365-1304009
Fig. 4-15
SA

(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)
A
Specification
C
Tank capacity: 340 L
RI
Breather valve
Filter fineness: 10μm
E
Ambient temp: -30℃ -100℃
Pressure setting: Air inlet side → 0.005 MPa
AM
Air outlet side → 0.05 MPa
N
TI
LA
NY
SA

4.4.3 Hydraulic pump
Type: K5V160DTH1×4R-9T06-V
B1
a5(16N·m)
C A
a2(36N·m)
RI
1 a1(36N·m)
2
E
B3
AM
N
Dr1(170N·m) Dr4(170N·m)
5 PH1 4
TI
A2
A3
LA
NY
Dr2(170N·m) PH2 A1 Dr4(170N·m)

SA
Psv2 a3(36N·m) Psv1
a4(36N·m)
ZX335-1002010
Fig. 4-16

4.4.3.1 Outline
● This pump consists of 2 variable swash
plate plunger pumps, 2 adjustors, and 1 pi-
lot gear pump.
a1: Main pressure detection port (front pump)

a2: Main pressure detection port (rear pump)
a3: Regulator pressure detection port (front
pump)
A
a4: Regulator control pressure detection port
C
(rear pump)
RI
a5: Delivery pressure detection port (pilot gear
pump)
PH1: Pressure sensor mounting port (front
E
pump) AM
PH2: Pressure sensor mounting port (rear
pump)
A1: Oil delivery port (front pump)
A2: Oil delivery port (rear pump)
N
A3: Oil delivery port (pilot gear pump)

TI
Psv1: Regulator control port (front pump)

Psv2: Regulator control port (rear pump)
LA
Dr1: Drain plug (front pump)

Dr2: Drain plug (rear pump)
Dr4: Oil drain port
NY
B1: Oil suction port (pump)

B3: Oil suction port (pilot gear pump)
SA
(1) 1: Front pump

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

2 3 13 6 7 14 8 9 16 10
15
C A
RI
1
12
E
4 5
AM 11
ZX215-1002019
Fig. 4-17
N
(1) Front shaft (9) End cap

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

(3) Front casing (11) Rear casing
(4) Swash plate (12) Gear pump
LA
(5) Slipper (13) Piston

(6) Plunger (14) Max. delivery adjusting screw
(7) Cylinder block (15) Gear pump shaft
(8) Oil distributor (16) Driving pin
NY
SA

B 6 13 7 8
C A
RI
1
E
18
18 4 5
A 17 AM
ZX215-1002020
Fig. 4-18
N
4.4.3.2 Function
TI
● The torque of the engine is transmitted ● Swash plate (4) has flat surface (A), and
to the pump shaft (1), and drives cylinder slipper (5) is always pressed against this
block (7) to rotate. At the same time, nine surface while sliding in a circular move-
LA
plungers (6) slide along the oil distributor ment.

(8). Plunger (6) moves back and forth in- ● Swash plate (4) conducts high pressure oil
side cylinder block (7) and pressurized oil to cylinder surface (B), and forms a static
is sucked in and discharged alternatively. pressure bearing when it slides.
NY
● It is possible to change the displacement ● Plunger (6) carries out relative movement
by changing the swash plate angle. in the axial direction inside each cylinder
chamber of cylinder block (7).
SA
4.4.3.3 Structure
● Cylinder block (7) seals the pressurized oil
● Cylinder block (7) is supported to shaft (1) to oil distributor (8) and carries out relative
by spline (17). rotation.
● Shaft (1) is supported by front and rear ● This surface is designed so that the oil
bearings (18). pressure balance is maintained at a suit-
● Tip of plunger (6) is shaped as a concave able level.
ball and slipper (5) is caulked to it to form ● The oil inside the respective cylinder cham-
one unit. bers of cylinder block (7) is sucked in and
● Plunger (6) and slipper (5) constitute the delivered through oil distributor (8).
spherical bearing.

4.4.3.4 Operating principle

● Cylinder block (7) rotates together with
1 4 5 7
shaft (1), and slipper (5) slides on flat sur- A
face (A).
● When this happens, swash plate (4) moves
along cylindrical surface (B), so angle (a)
between central line (X) of swash plate (4)
and the axial direction of cylinder block (7) a
changes. X
A
B ZX215-1002021
● (a) stands for the angle of the swash plate.
C
Fig. 4-19
● With central line (X) of swash plate (4) at
RI
a swash plate angle (a) in relation to the
axial direction of cylinder block (7), flat sur- 4 5 6
A F
face (A) acts as a cam in relation to slipper
E
(5).
● In this way, plunger (6) slides on the in-
side of cylinder block (7), so a difference
AM
between volumes (E) and (F) is created a
inside cylinder block (7). X
E
N
● A single plunger sucks and discharges the 7 ZX215-1002022

oil by the amount (F) – (E).
Fig. 4-20
TI
● As cylinder block (7) rotates and the vol-

ume of chamber (E) becomes smaller, the
pressurized oil is discharged.
LA
● On the other hand, the volume of chamber

(F) grows larger and, in this process, the
oil is sucked in.
NY
● As central line (X) of swash plate (4) over-

laps the axial direction of cylinder block (7)
(swash plate angle (a) = 0), the difference
SA
between volumes (E) and (F) inside cylin- F

der block (7)becomes 0.
● Suction and discharging of pressurized
oil is not carried out in this state. Namely
pumping action is not performed. (In real-
ity, however, the swash plate angle is not
set to 0)
E
4 7 ZX215-1002023
Fig. 4-21

4.4.3.5 Oil delivery control 13 16 F
● If swash plate angle (a) becomes larger,

the difference between volumes (E) and
(F) becomes larger and pump delivery (Q)
increases.
● Piston (13) is used for changing swash
plate angle (a).
● Piston (13) makes linear reciprocal move- a
ment under the control of the regulator.
A
● This linear motion is transmitted to swash
C
plate (4) via drive pin (16). The sliding of 4 E
RI
ZX215-1002024
the swash plate changes the swash plate
angle and changes the displacement of the Fig. 4-22
main pump.
E
AM
N
TI
LA
NY
SA

4.4.4 Pilot pump
435 433 710 700 354 351
434
A
310
355
C
732
RI
311
E
312
AM
309 307 308 434 850 466 725 435 361 353
ZX215-1002025
Fig. 4-23
N
TI
307: Valve stem 361: Body

308: Valve base 433: Screw
309: Retainer 434: Screw
LA
310: Spring 435: screw

311: Adjusting screw 466: Plug
312: Nut 700: Washer
351: Body 710: O-ring
NY
353: Gear shaft 725: O-ring

354: Gear shaft 732: O-ring
355: Filter element 850: Washer
SA
Function
The engine drives the main pump shaft and the pilot pump shaft through the gearbox. The pilot
pump is operated through gear engagement.

4.4.5 Regulator
755 541
545
543
ൟো
TYPE
ᑣ߫ো
SERIAL NUMBER
Pm
E E-E
铭牌
DETAIL OF STAMP FOR TYPE
AND SERIAL NUMBER
A
601
C
E
642 753 467,727 F向
D-D
RI
F
B
496 418 079
E
757 413 AM 646 438
438 439
656 D
N
TI
D
B 924
755
722 543 755 545 541 438 466
LA
730 643 708 644 645 728 801

724 725 B-B
C向 A-A
734
897 876 874 755 653 654 836 651 652 601 624 629 630
NY
A 655
412 612 858 641 628
615 814 802
SA
C
614
613
611 627
A 631
875 753
898
756
732
763
733
622 625 626 887
621 623
W365P130701
Fig. 4-24

No. Part name Material Quantity Part code Remark

— Regulator Alloy steel 1
412 Screw, socket head Alloy steel 2 60150559 JIS B1176 M8-50
439 Screw, socket head Rolled steel 3 60150558 JIS B1176 M6-35
466 Plug Rolled steel 1 60008724 G1/4
A
467 Plug Carbon steel 1 60008507 G3/8×M8
C
496 Plug Alloy steel 15 60008728
RI
497 Plug Alloy steel 4
541 Seat Alloy steel 2 60008884
543 Stopper 1 Alloy steel 2 60008885
E
545 Steel ball Bearing steel 2 AM
601 Housing Cast iron 1 60197213
611 Feedback rod block Alloy steel 1 60075481
612 Lever（1） Alloy steel 1 60008532
613 Lever（2） Alloy steel 1 60008522
N
614 Pivot pin Carbon steel 1 60008533

TI
Compensation pis-
615 Carbon steel 1 60008534
ton
621 In-cavity piston Alloy steel 1 60008535
LA
622 Piston shell Cast iron 1 60008536

623 Compensation piece Alloy steel 1 60008524
624 Spring seat（C） Alloy steel 1 60008494
625 Outer spring Spring steel 1
NY
626 Inner spring Spring steel 1 60075415

627 Adjusting ring（C） Carbon steel 1 60008526
SA
628 Adjusting bolt（C） Carbon steel 1 60008497

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

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
A
708 O-ring seal NBR 1 60008694 JISB 2401
C
RI
724 O-ring seal NBR 8 JISB 2401
E
728 O-ring seal NBR 1
AM 60008702 JISB 2401
N

TI

LA

801 Nut, hexagon Rolled steel 2 60150561 JIS B1181 RN-M8
802 Nut, hexagon Rolled steel 1 60008506 M10
NY
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
SA
874 Pin Bearing steel 1 60008734 Φ4×11.7L

875 Pin Bearing steel 2 60008733 Φ4×8L
887 Pin Carbon steel 1 60008546
898 Pin Bearing steel 1 60150562 Φ8.5×10L
924 Screw, socket head Alloy steel 1 60008743
Pressure-reducing
079 1 60125194
solenoid valve
041 Check valve block 2 60117792

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

with a regulator. Primary components of P2 6
the regulator are electromagnetic propor-
tional pressure-reducing valve (1), electro- 5
A
hydraulic converter valve (2), variable 3
power regulator (3), positive flow regulator
C
(4), servo piston (5) and servo directional
RI
a3
valve (6). The regulator opens or closes 4
the oil passage of servo piston (5) accord- B
ing to various pressure signal commands, W365P130702
E
change the inclination of swash plate, and Fig. 4-25
control the flow of pump as a result. AM
Components of control mechanism
Electric current flow control: when normal

N
By changing the value I of command current flowing to the electromagnetic proportional pres-
TI
sure 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
LA
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
NY
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.
SA
● When power shifting is being performed, the rising of self-pump output pressure Pd1 automat-
ically reduces the inclination (output flow) of the pump. As a result, the input torque is limited
under certain value. (In case of constant speed, the input power becomes constant too.)
● When power control is exercised, regulator of each pump is controlled to the same inclina-
tion (output flow). Therefore, power control is performed irrelevant to the load of both pumps.
Overload of prime mover is prevented as a result. In addition, the normal pressure for power
shift is 0 MPa. So the power control is inactive in normal hours.
● With this mechanism, optimum power can be achieved in butting operation.
Although the regulator has the two control mechanisms described above, each control in joint ac-
tion can put small inclination (flow) command to priority via mechanical calculation.

Regulator adjustment
● Adjusting the adjusting screws (953, 954) at the pump body side can obtain the minimum flow
and the maximum flow. Power control characteristics can be changed by adjusting the screw
(C) (628) and the wheel (C) (627) of this adjustor. The flow control characteristics can be
achieved by adjusting the socket-headed setscrew (924).
532 548 531 808 954

806
953
C A
E RI
AM
N
ZX335-1002014
Fig. 4-26
TI
531: Inclination pin

LA
532: Servo piston

548: Feedback pin
806: Retaining nut
808: Retaining nut
NY
953: Adjusting screw (min. flow)

954: Adjusting screw (max. flow)
SA

Maximum flow adjustment (pump body

side)
Output flow Q
● Loosen the hex nut (808). Tighten (or
loosen) socket-headed setscrew (954). No
control characteristics except the maximum
flow changes.
C A
Command current I
W365P130703
RI
Fig. 4-27
Minimum flow adjustment (pump body
E
side)
● Loosen the hex nut (806). Tighten (or AM
Output flow Q
loosen) the socket-headed setscrew (953).

Though this action is the same as the ad-
justment of maximum flow and all the other
control characteristics do not change,
N
power required for maximum output pres-

sure (at relief) is likely to increase if over-
TI
tightened. Be careful in this case.

LA
Command current I
W365P130704
Fig. 4-28
Input power
NY
1) Adjustment of the outer spring

SA
Loosen the nut (630) and tighten or loosen the

Output flow Q
screw (C) (628) to perform adjustment. When

screw (C) (628) is tightened, the control line,
as shown in the right figure, moves rightward.
The input power increases. Moreover, When
the screw (C) (628) is turned by N turns, in-
ner spring (626) also changes along with its
setting. So turn the adjusting wheel (C) (627)
in the opposite direction by N×A turns. (For
value of A “Annexed Table: Regulator ad-
Output pressure (Pd1)
justing values” on page 4-47.) W365P130705
Fig. 4-29

2) Adjustment of inner spring

After hex nut (802) is loosened, tighten (or
Output flow Q
loosen) the adjusting roller (C) (627) to carry
out adjustment. When adjusting roller (C) (627)
is being tightened, the flow (as shown) will in-
crease and input power will also increase.
C A
W365P130706
RI
Fig. 4-30
E
Adjustment of flow control characteristics
Loosen the hex nut (801) and tighten (or
loosen) the socket-headed setscrew (924) for
AM Output flow Q
adjustment. When the setscrew (924) is being

tightened, The control lines will move right-
ward as shown by the illustration.
N
TI
LA
Command current I
W365P130707
Fig. 4-31
NY
Operating principle
Pump displacement Q
SA
Flow control
As shown in the illustration on the right, the
outflow of pump can be controlled indefinitely
via feedback pressure value.
Command current I
W365P130708
Fig. 4-32

Increasing the flow

When the negative feedback pressure Pi2
reduces, the pilot plunger (643) will move in Port C1 connected with
direction A until a relative balance between head end of servo piston
P2 and the resilient force of the guide spring 652

(646) is achieved. The movement of the pilot
plunger is transmitted to lever (2) (613) via pin 646
613
(875) and rotates towards the arrow direction B
876
with B as the pivot. The movement of lever (2) D F
897
875
A
is transmitted to the feedback rod (611)via pin
611
shaft (897) and rotates in the same direction of A
C
643
B with C as the pivot. Along with this, the spool
C
(652) connected to the feedback rod moves to-
RI
wards direction D. The spool moving in direc- 532
E
tion D connects port C1 with the oil tank port, W365P130709
and the pressure inside the large diameter end
E
Fig. 4-33
of the servo piston is relieved. As a result, the AM
output pressure Pd1 inside the small diameter
end moves the servo piston (532) in direction Psv A
E and flow is increased. Since the feedback

rod is connected with the servo piston and the
spool, movement of the servo piston in direc-
N
Pz
tion E makes the feedback rod rotate with F
TI
as the pivot. In this way, the spool is moved to

the original position. Through this movement, P2
the opening portion between the spool and the
LA
valve block is closed slowly. The servo pis-

ton stops moving when the opening portion is
completely closed.
Pd1
NY
a3
B
W365P130710
SA
Fig. 4-34

Decreasing the flow

When the negative feedback pressure Pi2 613
Port C1 connected with
rises, the pilot plunger (643) will move in di- head end of servo piston
rection G until a relative balance between P2
and the resilient force of pilot spring (646) is 652 G
achieved. The movement of pilot plunger is
646
transmitted to the feedback rod (611) via pin
(897) and rotates in the same direction as H H
J 876 L
with I as the pivot. Along with this, spool (652) 897
875
A
connected to the feedback rod moves in direc-
611
tion J. If the spool moves in direction J, output
C
pressure Pd1 enters the large diameter end I 643
of the servo piston through the spool and port K
RI
C1. On the other hand, output pressure Pd1 532
W365P130711
enters the small diameter end of the servo pis-
ton. As a result of the area difference, the ser- Fig. 4-35
E
vo piston moves in direction K and the inclina- AM
tion is reduced, and the flow is also reduced. Psv A
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 Pz
N
spool move to its original position. As a result,

TI
the opening portion between the spool and the P2

valve block is slowly closed. The servo pis-
LA
completely closed.
Pd1
a3
NY
B
W365P130712
SA
Fig. 4-36

Power control (for emergency)

● As shown in the illustration, when load
pressure increases, pump inclination is
reduced to prevent the overloading of the
Output flow Q
prime mover.
● The action of power control is the same as
that of the flow control. The following is a
brief description.
C A
RI
W365P130713
Fig. 4-37
E
AM
N
TI
LA
NY
SA

Action against overloading

When the self pump output pressure Pd1 in- (For emergency) 876 625
creases, the output pressure Pd1 is acted onto 897 N 612 626
R
the ladder portion of the offset piston (621) , Port C1 connected with
head end of servo piston
and as a result, the offset rod (623) moves in
direction M until the output pressure Pd1 bal- 652
ances the elastic forces of outer spring (625)
and inner spring (626). The movement of the 6
offset rod is transmitted to the lever (1) (612) P M 875
A
via pin (875) and rotate in the arrow direction 623
621
with N as the pivot. Then, the movement of
C
611
lever (1) is transmitted to feedback rod (611)
via pin (897) and rotates in the same arrow O
RI
Q
direction as N with O as the pivot. Along with
532
this, spool (652) which is connected to the W365P130714
feedback rod moves in direction P. If the spool
E
Fig. 4-38
moves in direction P, output pressure Pd1 AM
enters the large diameter end of the servo pis-
ton through the spool and port C1. However, Psv A
output pressure Pd1 enters the small diam-
eter end of the servo piston, and as a result
of the area difference, the servo piston moves
N
in direction Q. The inclination is reduced as a

TI
result and the flow is also reduced. Since the

feedback rod, the servo piston and the spool is P2
a whole unit, when the servo piston is moving
LA
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 Pd1
valve block is slowly closed. The servo pis-
NY
a3
completely closed. B
SA
W365P130715
Fig. 4-39

Action of flow recovery

When the self pump output pressure Pd1 (For emergency) 876 625
drops, elastic force offset rod (623) of outer 897 T 612 626
X S
spring (625) and inner spring (626) moves in Port C1 connected with
head end of servo piston
direction S to a point where the elastic force of
the outer spring and the inner spring balances 652
the output pressure Pd1. The movement of
the offset rod (623) is transmitted to lever (1)
(612) via pin (875) and rotates in the arrow V J 875
A
direction with T as the pivot. Then, the move- 621 623
ment of lever (1) is transmitted to feedback 611
C
rod (611) via pin (897) and rotates in the same
arrow direction as T with U as the pivot. Along U
RI
W
with this, spool (652) which is connected to
the feedback rod moves in direction V. If the 532 W365P130716
spool is moving in direction V, port C1 is con- Fig. 4-40
E
nected with the tank port, and the pressure AM
inside the large diameter end of the servo pis-
ton is relieved as a result. Servo piston (532) Psv A
moves in direction W through the output pres-
sure Pd1 of the small diameter end. The flow
is increased in this way. Since the feedback
N
rod, the servo piston and the spool is a whole

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

the feedback rod will rotate with X as the pivot. P2
This allows the spool to move to its original
LA
position. Through this movement, the opening

portion between the spool and the valve block
is slowly closed. The servo piston stops mov-
ing when the opening portion is completely Pd1
closed.
NY
a3
B
W365P130717
SA
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.

Power shift control (power control reduc-

tion)
● As shown in the right diagram, the power
Output flow Q
of the pump can be set freely through pow-
er shift pressure Pf.
● If the power shift pressure Pf is increased,
compensating rod (623) will be pushed to
the right side via pin (898) and the offset
piston (621). Through the same action as
A
described in the power control overload-
ing prevention, the power set value can be
C
reduced by reducing pump inclination. On Output pressure (Pd1)
RI
the contrary, the power set value can be ZX335-1002029
increased by reducing the power shift pres-
Fig. 4-42
sure Pf.
E
● When the pump is under normal condition, AM
the power shift pressure Pf is 0 MPa. In an
emergency, the power shift pressure Pf is
4.9 MPa.
N
Annexed Table: Regulator adjusting values

TI
Model of regulator KR3K-9T06-V

RPM (min-1) 2100
LA
Adjusting screw (954) screw-in (rotation) +1/4

Max flow regulation
Delivery change (l/min-1) 6
Min flow regulation
Delivery change (l/min-1) +4.8
NY

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

4.5 Hydraulic system, Part 2

4.5.1 Main control valve
4.5.1.1 Overview
XBtr (PTb)
XBp2 Px
XBa1 XBtL
XBs
PaL,Dra
Pns XAb1
CCk
A
Dr4 BbR
XAb2 XBc
(P3) (P4) Dr2
C
+
BcR
(XBo)
BoR XAa2
RI
Pna1,Dr3 BaR
Dr3
Rs1
Pna1
CCo
XAa1
(R4) Rs2
E
XAa1 AM (R2) XBp1
XBp1
A向
CT2 CP2 Pns Btr MR (PTa) XAtr BtL CP1 CT1 CMR1 CMR2 AtL
As Atr Dr4 Py Bb
Bs (ROD)
N
ে㸠䍄 XAtL XAs Ⳉ㒓㸠䍄

(PTa)
XAtr XBtr (PTb)
Drb
TI
LCs
XAs ಲ䕀
XBs P2
Pns XBtL Ꮊ㸠䍄 XAtL
PbL Dr4 Ab
CCb LCb2 XBb2
XBb1 LCb PbL,Drb
(HEAD)
XBb2
ࡼ㞖2
XAb2 Hvb AbR XAb1 XBb1
A (XAo) ࡼ㞖1
(Bo) AcR AoR LCk XAc PAcs
LA
LCo
(XAo) OPTION
(XBo) XBc
(Ao) Dr3 Dr1 Dra Bc
䫆᭫
Ac
Dr3 (HEAD) (ROD)
Dra
᭫ᴚ1 ࡼ㞖2
XBa1 XAa1 Pna1 XAa2 XBa2
PaL
ARC XBa2 PaL P1 CUT P2 CUT

XBp2
XBa1
XBp1
HVa XBp2 AaR XBp1 LCAT2
Ba1
NY
Aa (HEAD) (Ba2) N2
(ROD) LCa Pra1 R1 N1
(HEAD) LCAP2
SA
(PTb) XBtr PG
R3
P2
Pns,Dr4
P1
PH
(PTa) XAtr
W365V130701
Fig. 4-43

P1 : Pump port (P1 side) PAcs : Pilot port, bucket (DIG) travel limit
P2 : Pump port (P2 side) Pna1 : Pilot port, arm 1 logic control valve
Aa : Rod end port, arm cylinder (OUT) Pns : Pilot port, swing logic control valve
Ba1 : Head end port, arm cylinder (IN) PG : Pilot pressure source port
(Ba2) : Head end port, arm cylinder (IN) PH : Pilot pressure source port
Ab : Head end port, boom cylinder (UP) Pz : Pilot pressure for boosting main relief valve
Bb : Rod end port, boom cylinder (DOWN) PaL : Pilot port, lock valve (arm rod end )
Ac : Rod end port, bucket cylinder (DUMP) PbL : Pilot port, lock valve (boom head end)
A
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
C
Btr : Motor port, right travel Drl : Oil drain port
RI
AtL : Motor port, left travel Dr2 : Oil drain port
BtL : Motor port, left travel Dr3 : Oil drain port
E
As : Motor port, swing Dr4 : Oil drain port
Bs : Motor port, swing Dra
AM : Oil drain port
XAtr : Pilot port, right travel Drb : Oil drain port
XBtr : Pilot port, right travel R1 : Oil return port
XAtL : Pilot port, left travel (R2) : Oil return port
N
XBtL : Pilot port, left travel R3 : Oil return port

XAs : Pilot port, swing Rs1 : Oil refi lling port
TI
XBs : Pilot port, swing Rs2 : Oil refi lling port

XBb1 : Pilot port, boom 1 (DOWN) (Ao) : Backup port
LA
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)
NY
XAa1 : Pilot port, arm 1 (OUT) (PTb)

XBa2 : Pilot port, arm 2 (IN) (N1)
SA
XAa2 : Pilot port, arm 2 (OUT) (N2)

XAc : Pilot port, bucket (DUMP) (P3)
XBc : Pilot port, bucket (DIG) (P4)
XBp1 : Pilot port, bypass stop valve spool (P1 (R4)
side)
XBp2 : Pilot port, bypass stop valve spool (P2
side)

4.5.1.2 Main valve structure

B A XBp2
XBa1
N
MR M PaL,Dra
Right travel
Straight travel Py
971×6
Pz
101
C Pns C
Left travel Swing
N 273×4
C
PbL Drb
D 252 Dr4
D +
102 (P3)
A
CCk
(P4)
Boom 1 P P Boom 2
991
C
AbR
Rs1
E 992×2
Hvb
AoR
E CCo
RI
Bucket Backup
Rs2
F AcR Q F
Dr3
Dra
Dr1
211 (R4)
Arm 2 Arm 1
E
Pna1
PaL
G G M
AaR Arm regeneration stop AM
P2 stop
252
H XBp2
Q H XAa1
103 XBp1
A 351 152 168 Direction J
B
167
Dra
N
PG
151
J 541
PaL
TI
542
554 167
151
(PTb) XBtr 166 151
167
971×6 543 Q-Q
LA
151
L-L 167
R3
L PG L 515
521
P2
551
CCk
NY
P1 561
169
153
CCo
551
SA
A 561
167 151 521
PH
515
PbL Drb
MR
M-M
Pz
(PTa) XAtr
P-P
N-N
W365V130704
Fig. 4-44

351 152 168 169 153
PH P2 PG
XAtr XBtr
271×2 271×2
XAs XBs
271×2 271×2
A
XBb2 XAb2
C
271×2 271×2
(XAo) (XBo)
RI
341
271×2 168
XBa1 XAa1
E
271×2 271×2
AM (R2)
(P4) Rs1 Rs2

153 169
A-A
N
R3 P1
TI
271×2 271×2
(PTb) (PTa)
271×2 271×2
LA
XBtL XAtL
271×2 271×2
XAb1 XBb1
NY
271×2 271×2
XBc
271×2 271×2
SA
XAa2 XBa2
272×2 272×2
XBp1 XBp2
162
162
561 551 561 551 163
B-B
W365V130705
Fig. 4-45

153 201
169 336
201 332
336 373
332 Straight travel Right travel
337
372 （Pta） 332
337 XAtr
261
332
261 MR
601
308
Py
512 301
522
511
A
552
521
562 CMR2 Atr
551
C
512
522
CMR1 CT2
RI
552 561
562 CT1 CP2 561
561 551
551 521
Btr 511
E
521
511
263
AM Px
203
169 (PTb) XBtr 263
153 203
Section C-C
N
201 201
336 336
TI
332 Left travel Swing 332

373 371
337 337
XAtL XAs
332 332
261 261
LA
301 166 305

166 162
165
163
NY
511 AtL As
521
LCs
CP1 Pns
SA
551
561 256
165 Bs
BtL 254
161
166
263 XBtL XBs 263
203 203
Section D-D
W365V130705
Fig. 4-46

201 201
336 336
332 332
373 Boom 1 Boom 2 371
337 337
332 XBb1 XBb2 332
261 602
AbR 261
553
561 307
523 Hvb
513 165
163
Ab
303 CCb
A
551
511
561
C
521
LCb 561
Lcb2
551
RI
561 551
Bb 521
511
E
602
AM Dr2
BbR XAb1 XAb2

263 263
203 Section E-E 203
153
N
555 169
563
201
204
TI
342 336
Bucket Backup 332
336 371
332 XBa2
337
371 (XAo) 332
PAcs
337 261
LA
332 XAc 309

261
AcR AoR 605
602 166
304
162
164 275×4
NY
165
264
163 Ac (Ao)
213
511
521 511
521
SA
LCk LCo
551 551
561 561
264
164 （Bo）
Bc 213
161
275×4
166 605
602 BoR
BcR XBc (XBo) 263
263 203
203 Section F-F 169
153 W365V130706
Fig. 4-47

201 201
336 336
332 332
375 Arm 2 Arm 1 371
337 337
332 XBa2 XBa1 332
261 261
306
302
Dra
Dr1 167
511 151
521 561
561 553
A
551 Hv6
523
276×4 LCAT2 513
C
LCa
285
266 Pna1
RI
214
531 255
522 Ba1 253
514 Ba2
E
153
169
275×4
214
264
AM
261
602 BaR XAa2
263 205
203
XAa1
152
N
168 Section G-G

202
TI
333 P2 stop
331 Arm regeneration stop
324 XBp2
323 257
334 602
331
LA
262
551 AaR
561
169
153
NY
(N2) CCk Aa
310
310
SA
CCo
R1
(N1)
153
169
561
551 (R2)
262
331
267 215 277×4
334
323
324
331 XBp1
333 Section H-H
P1 stop W365V130707
202
Fig. 4-48

Torque Torque
No. Part name Qty No. Part name Qty
（N.m）（N.m）
101 Valve body A 1 305 Swing spool 1
102 Valve body B 1 306 Spool, arm 2 1
103 Valve body C 1 307 Spool, boom 2 1
Spool AS, straight
151 Oil plug 6 13~17 308 1
travel
152 Oil plug 2 34~39 309 Backup 1
153 Oil plug 10 69~78 310 Spool, bypass stop 2
161 O-ring seal 4 323 Spring 2
163 O-ring seal 9 331 Spring seat 4
A
C
165 O-ring seal 4 333 Bolt with washer 2 16~18
166 O-ring seal 12 334 Stopper 2
RI
167 O-ring seal 6 336 Bolt with washer 10 37~41
168 O-ring seal 3 337 Stopper 10
169 O-ring seal 10 341 Oil plug 1 34~39
201 Spring cap 9 342 Piston 1
E
202 Spring cap 2 351 节流塞（φ0.7） 3 7.8~9.8
203 Spool cap 9 371
AM Spring 8
204 Spring cap 1 372 Spring 1
205 Spool cap 1 375 Spring 1
211 Plate 1 511 Cone valve 10
213 Flange 2 512 Cone valve 2
214 Check valve plate 1 513 Cone valve 2
N
Pipeless opening cover

275 1 514 Cone valve 1
plate
TI
Pipeless opening cover

216 1 515 Cone valve 2
plate
252 Lock valve selector GP 2 9.8~14 521 Spring 12
Logic valve component,
LA
253 1 522 Spring 3

arm 1
Logic valve component,
254 1 523 Spring 2
swing
255 Logic control valve 2 52~62 531 Spring seat 1
Stop valve GP, arm
257 1 120~140 541 Steel ball 1
regeneration
NY

SA

271 Bolt, socket head 40 52~62 561 O-ring seal 19
275 Bolt, socket head 12 140~180 601 Main relief valve 1 120~140
276 Bolt, socket head 4 25~34 602 Port relief valve 6 120~140
277 Bolt, socket head 4 83~110 605 Port relief valve 2 120~140
301 Travel spool 2 971 Bolt, socket head 12 390~470
302 Spool GP, arm 1 1 991 Nameplate 1
303 Spool GP, boom 1 1 992 Rivet 2
304 Bucket spool 1

4.5.2 Hydraulic circuit (With bucket confluence function)
Straight travel Travel (R)
C A
Travel (L)
RI
Swing
E
Boom 1 AM Boom 2
N
TI
Bucket Backup
LA
Arm 2
NY
Arm 1
SA
Bypass stop
W365V130703
Fig. 4-49

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).
A
● 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
C
the neutral bypass (4) (function of neutral M-shaped spool) of each spool in right travel (301),
RI
swing (305), boom 2 (307), backup (309) and arm 1 (302).
E
AM
N
TI
LA
NY
SA

(1) R3 P1
(2)
(PTb) (PTa)
XBtL XAtL
A
XAb1 XBb1
C
RI
XBc
E
XAa2 XBa2
AM
XBp1 XBp2
N
(p3)
TI
(3)
PH P2 PG
(4)
LA
XAtr XBtr
XAs XBs
NY
XBb2 XAb2
SA
(XAo) (XBo)
XBa1
(R2)
(p4) Rs1 Rs2

WJV3651305
Fig. 4-50
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.
A
● Likewise, when pressure is present in pilot port XBtr used for right travel spool (301), the neu-
C
tral bypass (2) at the side of arm 1 closes. The working oil fed from (rear) hydraulic pump is
delivered through port Btr to the right travel motor.
RI
● 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.
E
● When operating travel in the opposite side (pressurizing the pilot ports XAtr and XAtL), the
above principle also applies. AM
N
TI
XAtL XBtL
LA
NY
AtL BtL
SA
Travel motor
WJV3651306
Fig. 4-51

3) Arm
Arm-out operation
(Pilot circuit)
● When switched to the arm 2 spool (302), the side oil passage closes and the pressure in port
Px (work equipment signal port) rises.
(Main circuit)
● When performing the arm-out operation, the pilot oil is fed to port XAa1 and port XAa2. When
A
pilot oil is delivered to the two sides of port XAa1 and port XAa2, arm 1 spool and arm 2 spool
are switched to the left, as shown in Fig. 4-52. As a result, the working oil from port P2 is in-
C
troduced into the neutral bypass (4) via the main passage (3). The neutral bypass is cut off
RI
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 pas-
sage. The oil from arm 1 spool (302) is then delivered to the rod end (R) of arm cylinder.
E
● On the other hand, the working oil coming from port P1 is guided to the neutral bypass (2)
AM
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 conflu-
ence with oil from port Aa in the passage of neutral bypass (306) and is fed to the rod end (R)
N
of the arm cylinder.

TI
● 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.
LA
NY
SA

511 514
(Ba2)
LCAT2
BaR
Dr1
A
XBa2
XAa2
C
RI
XAa1
E
XBa1
AM
Dra
N
TI
LCa Ba1
Aa
LA
253
Pna1
NY
SA
R H
WJV3651307
Fig. 4-52

Arm-in operation
(Pilot circuit)
● When switched to the arm 1 spool (302), the side oil passage closes and the pressure in port
Px (work equipment signal port) rises. Pressurized oil is fed to the port PaL at the same time.
Relief signal is sent to the lock valve selector GP (252).
(Main circuit)
● When performing the arm-in operation, pilot oil is fed to ports XBa1 and XBa2. When pilot oil
is delivered to the two sides of port XBa1 and port XBa2, arm 1 spool and arm 2 spool are
A
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
C
1 spool (302). Therefore, the working oil in the parallel passage pushes open the cone valve
RI
(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.
E
● On the one hand, the working oil from port P1 is guided to the neutral bypass (2) via the main
AM
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).
N
● On the other hand, the oil returning from the arm cylinder rod end (R) and the working oil
TI
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 con-
LA
fluence in the peripheral holes with oil from port BaI.

● If the pressure at the arm cylinder head end and in the U passage rises, arm regeneration
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
NY
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
SA
tank via tank ports R1 and R3.

● Light load
(Ba2)
LCAT2
BaR
Dr1
C A
XBa2 XAa2
RI
(302-317)
(a)
E
XBa1 XAa1
AM
(b)
N
Dra
TI
Aa LCa Ba1
LA
Pna1
NY
SA
Arm dead weight R H
WJV3651308
Fig. 4-53

● When pressure in arm cylinder head end (H) rises
(Ba2)
LCAT2
BaR
A
Dr1
C
XBa2
XAa2
RI
(a)
(302-317)
E
(c)
XBa1 AM XAa1
N
Dra
TI
LCa Ba1
LA
Aa
Pna1
NY
(257-103)
SA
R H
WJV3651309
Fig. 4-54

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
(Main circuit)
● When boom-up operation is performed, the pilot oil is fed to port XAb1 and boom 1 spool
A
(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
C
1 spool (303). In this way, the working oil in the parallel passage pushes open the cone valve
RI
(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.
E
● At the same time, the pilot oil is also fed to port XAb2 and boom 2 spool (307) moves to the
AM
left as shown in Fig. 4-55. The working oil from P2 flows the parallel passage. As the switch-
ing boom 2 spool (307) cuts off the neutral bypass, the working in the parallel passage flows
into boom 2 spool (307) via the U passage. The oil then pushes open the cone valve (511) of
the check valve, comes into confluence with the oil from port Ab, and is fed to the boom cylin-
der head end (H). (This is called the boom confluence function.)
N
● On the other hand, the oil flows to the periphery of boom 1 spool (303) via port Bb from oil re-
TI
turn side of the boom cylinder rod end (R) and goes back to the working oil tank via the ports
R1 and R3.
LA
NY
SA

H R
C A
RI
513 511
LCb
E
Ab Bb
AM
BaR
N
TI
XBb1
XAb1
LA
XBb2
NY
XAb2
Dr2
SA
AbR
511 511
WJV3651310
Fig. 4-55

Boom-down operation
(Pilot circuit)
● When switched to the boom 1 spool (303), the side passage is closed and the pressure in port
Px (work equipment signal port) rises. Pressurized oil is fed to the port PbL at the same time.
Relief signal is sent to the lock valve selector GP (252).
(Main circuit)
● When boom-down operation is performed, the pilot oil is fed to port XBb1 and boom 1 spool
(303) moves to the right as shown in Fig. 4-56. The working oil from port P1 is introduced to
A
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
C
valve (511) of the check valve, and flows to the boom 1 spool (303) via the U passage. It then
RI
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)
E
and periphery of boom 1 spool (303).
AM
● The pressure of return oil rises due to the dead weight of boom. To maintain sufficient pres-
sure, 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
N
of spool via the hole (a) partially goes back to the oil tank via the hole (b).
TI
H R
LA
513 511
LCb
Ab Bb
NY
SA
BbR
XBb1 XAb1
(b) (a) (303-317)

WJV3651311
Fig. 4-56

5) Bucket
Bucket-dig operation
(Pilot circuit)
● When switched to the bucket spool (304), the side passage is closed and the pressure in port
Px (work equipment signal port) rises. The pressure oil is fed to port XBp2 at the same time.
(Main circuit)
● When bucket-dig operation is performed, the pilot oil is fed to the port XBc and the bucket
A
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
C
bucket spool (304), the working oil in the parallel passage pushes open the cone valve (511)
RI
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
E
goes back to the oil tank via the ports R1 and R3 from the periphery of spool.
AM
● 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.
N
TI
R H
LA
511
LCk
AC Bc
NY
AcR BcR
SA
PAcs XAc
XBc
Confluence WJV3651312
Fig. 4-57

Bucket-dump operation
(Pilot circuit)
● When switched to the bucket spool (304), the side passage is closed and the pressure in port
Px (work equipment signal port) rises. The pilot oil is also fed to the port XBp2 at the same
time.
(Main circuit)
● When bucket-dump operation is performed, the pilot oil is fed to the port XAc and bucket
spool (304) moves to the right as shown in Fig. 4-58. The working oil from port P1 is led to the
A
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)
C
of the check valve and flows to the bucket spool (304) via the U passage. It then flows to the
RI
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
E
R2.
AM
R H
N
511
TI
LCk
Ac Bc
LA
AcR
XAc BcR
PAcs
NY
XBc
SA
Confluence
WJV3651313
Fig. 4-58
Bucket confluence
● When bucket-dig or -dump operation is performed, the pilot oil is fed to the port XBp2 and the
neutral bypass stop valve spool (310) is switched. Working oil from port P2 is led to the neu-
tral bypass (4) via the main passage (3). The neutral bypass is cut off by switching neutral by-
pass valve spool (310). Therefore, working oil pushes open the check valve (515) and comes
into confluence with bucket spool (304) via the internal passage and the U passage.

6) Swing
When swing operation performed separately

(Pilot circuit)
● When switched to the swing spool (305), the side passage is closed and the pressure in the
port Px (work equipment signal port) rises.
(Main circuit)
● When swing is operated separately, the pilot oil is fed to the port XAs (or XBs) and swing
A
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
C
in the parallel passage pushes open the logic cone valve (254-101) of the swing logic com-
RI
ponent 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
E
flows into tank ports R1 and R2 from the periphery of spool and goes back to the working oil
tank.
AM
Swing motor
N
TI
Pns
LA
As LCs Bs
NY
(254-101)
SA
XAs
XBs
WJV3651314
Fig. 4-59

7) Priority function
● This function enables the working oil from port P to be sufficiently allocated to the work equip-
ment under higher load in order to improve the operability when the arm-in operation is per-
formed along with swinging operation.
● The following shows the priority of swinging operation relative to the arm-in operation.
(Main circuit)
● When pressure oil is applied to the port Pna1 of the logic control valve (255), the piston (255-
356) and spool (253-107) move upward. The lifting distance of cone valve (253-101) is lim-
A
ited.
C
● In this way, the passage from the parallel passage to the U passage is throttle. As a result, oil
from the arm 1 spool has the priority to go to the swing spool, giving the priority to the boom-
RI
up operation.
E
AM
XBa1
XAa1
N
TI
LA
Aa LCa Ba1
(253-101)
NY
(253-107)
(255)
Pna1
(255-356
SA
WJV3651315
Fig. 4-60

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
(Main circuit)
A
● When the backup is operated, the pilot oil is fed to the port XAo (or XBo) and the backup
C
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
RI
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).
E
● On the other hand, return oil from the attachment flows in via port Bo (or port Ao). Then, it
AM
flows into tank ports R1 and R2 from the spool periphery and returns to the working oil tank.
H R
N
TI
511
LCo
Ao Bo
LA
BoR
NY
XAo XBo
SA
Confluence WJV3651316
Fig. 4-61
Backup confluence
To achieve backup confluence, pilot oil is also fed to port XBp1 and the bypass stop valve spool
(310) is switched. Working oil from port P1 is introduced into neutral bypass (2) via main passage
(1). Neutral bypass is cut off by switching bypass valve spool (310). Therefore, working oil push-
es open the cone valve (515) of check valve and comes into confluence with backup spool (309)
via the internal passage and the U passage.

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
A
spool (308).
C
(Main circuit)
RI
● 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
E
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. AM
● 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 pre-
N
vented.
TI
P1 R3
LA
P2
NY
(PTa) (PTb)
SA
XAtL XBtL
WJV3651317
Fig. 4-62

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).)
A
Spool in neutral position
C
● When boom 1 spool (303) and boom 2 spool (307) are in a neutral position, the spool (252-511)
RI
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
E
out from hole (b) through the periphery of the lockout valve selector module spool (252-511),
AM
pressing the cone valve (513) against the seat of the valve block via hole (b). By this means,
oil leakage is reduced.
(252-512)
N
TI
Drb (252-511)
(b)
LA
(252-101)
(a)
PbL 513
NY
LCb
Ab Bb
SA
(RH)
BbR
XBb1 XAb1
WJV3651318
Fig. 4-63

Boom-down operation
In boom-down operation the pilot oil is fed to the ports PbL, XBb1 and XBb2. Spool (252-511) in-
side the lockout valve selector module is pushed to the top by the pilot oil as shown in Fig. 4-64.
Due to the movement of spool (252-511) inside the lockout valve selector module, hole (a) is cut
off and working oil from boom cylinder head end (H) does not go to spring chamber (RH). In addi-
tion, oil in the spring chamber (RH) enters the oil leak circuit via the hole (b). In this way, the cone
valve (513) is pushed open by the pressure in boom cylinder head end (H) and the function of the
lockout valve selector module (252) is deactivated.
A
(252-512)
C
RI
Drb
(252-511)
(b)
E
(252-101) AM
(a)
513 511
PbL
N
LCb
Ab Bb
TI
(RH)
LA
BbR
NY
XBb1 XAb1
SA
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.

11) Function of main relief valve

The main relief valve is mounted on the valve block A (101). It has the following functions:
● Working oil fulfils the cavity (a) through the hole in valve post housing (601-101) and valve
post (601-511). The valve post (601-511) is therefore pressed against the housing (601-101).
Reliable sealing has formed as a result.
● When pressure in passage (P) exceeds the preload of spring (601-521), the cone valve (611)
opens. Therefore, the working oil passes through the gap between the housing (601-101) and
valve pocket (601-102) from the periphery of cone valve (601-401) and goes to the low pres-
sure passage (R).
A
● Opening of cone valve (601-401) causes pressure drop in cavity (a). So the valve post (601-
C
511) is opened. In this way, working oil in passage (P) flows to the low pressure passage (R)
RI
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 mo-
E
ment.
AM
(601-101) (601-401) (601-512) (601-102)
N
TI
LA
P
NY
R
SA
(a)
(601-511) (601-302)
Pz
WJV3651320
Fig. 4-65

12) Function of port relief valve

The port relief valve, mounted between the oil tank port and low pressure passage, can prevent
cavitation as an oil compensation check valve except working as a port relief valve. Functions of
the valve are given below:
Functioning as a relief valve

● Working oil fulfils into cavity (B) via the hole (A) on plunger (301). Valve post (511) is pressed
against valve seat (541), and valve seat (541) is pressed onto the seat of the valve block,
forming a reliable sealing.
A
(A) (B) 541
C
E RI
P
AM
R
N
WJV3651321
TI
301 511
Fig. 4-66
LA
● 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).
NY
(C)
SA
621
611 WJV3651322
Fig. 4-67

● 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)
C A
P
RI
R
E
511
AM 611
WJV3651323
Fig. 4-68
N
Functioning as oil complement check valve against cavitation

TI
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
LA
valve seat (541). Cavitation is prevented as a result.

NY
SA
541
WJV3651324
Fig. 4-69

4.6 Hydraulic System, Part 3

4.6.1 Swing motor
Type: M5X180CHB-10A-3NA/265
C A
RI
L
SH PG
E
PB
B
IP
AM
PA A
N
1
TI
M DB
LA
2
NY
ZX215-1002081
Fig. 4-70
SA
A: Main oil port Specifications

B: Main oil port
M: Makeup port Model M5X180CHB-10A-3NA/265
PA: Pressure detection port Theoretical dis-
180.1 cm3/rev
placement
PB: Pressure detection port
Safety valve
DB: Lubricant port 26.0 MPa
press. setting
PG: Brake release port Max swing speed 1470 rpm
SH: Brake command port Brake release
2.7-4.9 MPa
L: Level stick pressure
IP: Gear oil feed port
(1) Safety valve
(2) Anti-swing valve

7
6
C A
RI
A-A
E
A
AM
8 9
5
A
N
4
TI
10
LA
11
3
12
2
NY
13
SA
1
ZX215-1002082
Fig. 4-71
(1) Spacer (8) Oil distributor

(2) Housing (9) Cylinder barrel
(3) Disc (10) Brake piston
(4) Brake spring (11) Plate
(5) Shell (12) Piston
(6) Spring (13) Drive shaft
(7) Check valve

4.6.2 Swing holding brake

● Port PG is directly connected with the pilot gear pump and it is always under a pressure of
3.9MPa.
M
Pump a
1
A
Main
valve 7
PX
C
PG
RI
6
SH
E
AM ZX215-1002083
Fig. 4-72
● Port SH is in connection with port (PX) of the main control valve. In case of any operation (ex-
N
cept travel) is performed by the main control valve, Port (PX) will be put under pressure. This
TI
pressure establishes connection between PG and chamber (a) below piston (7). The pres-
surized oil pushes the brake piston upward to compress spring (1) and separate disc (5) from
plate (6). The brake is released.
LA
M
NY
Pump a
1
Main
valve 7
PX
SA
PG
6
SH
ZX215-1002084
Fig. 4-73
● Otherwise, without pressure acting upon the port (PX), the connection between (PG) and
chamber (a) below piston (7) is blocked. Brake spring (1) pushes the brake piston to press
disc (5) against plate (6). The brake is engaged.

4.6.3 Relief valve section
Structure
● The relief valve section consists of relief valves (1) and (2) and check valves (3) and (4).
Function
● When the machine is in the swing holding mode, control valve (5) closes the motor outlet cir-
cuit, but the motor rotation is continued due to inertial force. The motor output is, therefore,
abnormally increased, which could damage the motor.
A
● In order to prevent the motor from being damaged, the relief valve relieves the abnormally
C
high pressure oil to port (M) from the outlet side (high-pressure side) of the motor.
RI
Operating principle From oil port M
1 2
1. When starting swing (suppose pressurized
E
oil is delivered to port A)
● When the swing control lever is set to the
AM
right- swing, pressurized oil from the pump
is delivered to port (A) via control valve (5).
● The pressure at port (A) rises, the starting
N
torque is generated in the motor, and the

motor starts to rotate. 4
TI
3
● The pressurized oil from the outlet port of
the motor passes from port (B) through the C
LA
control valve (5) and returns to the tank.

A B
5
ZX215-1002085
NY
Fig. 4-74
SA

2. When swing is stopped From oil port M

1 2
● When the swing control lever is set neutral,
the supply of pressurized oil from the pump
to port (A) is stopped.
● The pressurized oil from the motor outlet
can't return to the tank since the returning
circuit to the tank is closed from control
valve (5). Thus, the pressure on port (B)
increases. 4
A
3
● Swing resistance is generated on the mo-
C
tor and hence the brake starts working.
C
RI
● Pressurized oil will be relieved when the
A B
pressure on port (B) rises to the set pres-
sure of relief valve (2).
5
E
ZX215-1002086
● A high braking torque acts on the motor,
thereby stopping the motor.
AM
Fig. 4-75
● 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).
N
● The above prevents the formation of cavi-

TI
tation on port (B).

LA
NY
SA

4.6.4 Anti-jerk valve
4.6.4.1 Operation diagram

A T1
(1) Valve body
(2) Spool (side A)
(3) Spring (side A)
(4) Plug
(5) Spool (side B)
(6) Spring (side B)
A
T2 B (7) Plug
C
1 2
3 4
E RI
7 6 5
AM
Swing
motor T
B A
N
Swing Control Valve

TI
ZX215-1002087
Fig. 4-76
LA
4.6.4.2 Effect illustration

: With antiswing valve
：Without antiswing valve

Reversing pressure
NY
Pressure MA
Suppressing pressure
SA
Reversing pressure
Pressure MB
First reversing
Second reversing
Motor speed
Start Brake Reverse
Time ZX215-1002088
Fig. 4-77

Outline
A
● The inertia of the swing body, the counter- T
action and rigidity of the mechanical sys- c e D4 a D3
tem, or the compressibility of the hydraulic
oil can cause shaking of machine during
swing operation. The anti-jerk valve is able
to reduce such impact. It is effective in pre-
venting collapsing of load when the swing
is stopped and in reducing the cycle time
A
(by better positioning performance and
D1 d 㔎ষ D2 % b f
quicker movement for next operation).
C
7
ZX215-1002089
RI
Fig. 4-78
E
Operation
AM $
1. When braking pressure is generated at port T
(B) F H ' D '
● Pressure (MB) is conducted to chamber (d)

via the notch. The pressure compresses
N
spring (6) by use of the difference in areas

of circles (D1 > D2) of spool (5) and moves
TI
the spring (6) to the left side. Port (B) and

chamber (e) will be interconnected. Since
pressure (A) is lower than the set pressure ' G 㔎ষ ' E I
LA
%
of spring (3), spool (2) does not move and
T
the pressurized oil is stopped by spool (2). ZX215-1002090
Thus the braking force is ensured.
Fig. 4-79
NY
2. When motor is stopped

A
● The motor rotation is reversed by the clos- T
SA
ing pressure generated at port (B). (1st a 2 3
reversing) Reversing pressure is gener-

ated on port (A) under the above condition.
Pressure (A) is conducted to chamber (a),
and spool (2) moves spring (3) to the right
side, and A and B is interconnected. At this
time, b is interconnected with f via the ori-
fice on spool (5), and reversing pressure
5 d B b f
on port A is bypassed to port T in order to
T
prevent second reversing.
ZX215-1002091
Fig. 4-80

4.6.5 Central Swivel Joint
12
11
9
10
8 15 E
A
E
C
7
D D
RI
C C
E
B
B
6
A
AM A
5
4
N
3 13，14
2 1
TI
LA
NY
W365R130401
Fig. 4-81
SA
(1) Bolt (9) O-ring

(2) O-ring (10) Swivel shaft
(3) Cap (11) Rotor
(4) O-ring (12) Plug
(5) Washer (13) Bolt, socket-head
(6) Collar (14) Flat washer
(7) Rotary seal (CSI) (15) Dust boot
(8) Housing

4.6.6 Travel motor
Type: MAG-170VP-3800E
View of motor before installation
Z Motor positioning cut

Φ200H7
Bre X
A
Y
C
B
T
RI
S
E
Hexagon bolt
2-M20×40
Torque 358Nm
AM Bolt hole for
motor installation
Oil inlet of brake 2-M20
M12×1.5 Oil inlet of brake
Y向
Z向 Direction B
N
X
B
TI
Bre
Oil inlet, level
M18×1.5
A
LA
MB
MA
S
Drain port
M18×1.5
W365T130401
NY
Fig. 4-82
A, B: Working oil port

SA
T: Oil drain port

MA, MB: Test port
S: Oil compensation port
X: Control pressure port
Bre: Oil port for releasing external brake

Table 1 - Motor Specifications
Item Unit Specifications

Max input torque N·m 546
Max input speed r/min 4788
Max output torque N·m 69309
Max output speed r/min 37.7
Basic braking torque (without
N·m 730
A
back pressure)
Starting pressure bar 18
C
Max withstanding pressure bar 50
RI
Oil refilling capacity L 8.5
Speed ratio - 126.94
Weight kg 400
E
Brake disc AM Disc type brake
Lubricant oil 220（40℃）industrial application
N
TI
LA
NY
SA

4.6.7 Reducer
Type: GFT80
105 15 3 20 5 21 6 19 48 47 8 12 13 14 13 18 11 16 53 55 59 54 58 89 91 93 66 90 94 67 92 200 199
C A
E RI
AM
N
TI
38 37 38 35 36 35
LA
NY
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
SA
Fig. 4-83

No. Code Description Qty No. Code Description Qty
E001 R988011946 Support shaft 1 E048 R913006477 Bolt, hexagon 24
E003 R988012090 Drive shaft 1 E049 R988010958 Gear ring 1
E004 R988011553 Planetary carrier 1 E051 R988011457 End cover 1
E005 R988012073 Bearing seat 1 E052 R988011597 Sun gear 1
E006 R916452282 Collar 1 E053 R988011951 Planetary carrier 1
E008 R916452408 Collar 1 E054 R988011483 Planetary gear 3

Cylindrical roller
E011 R988011587 Planetary gear 5 E055 R988012459 3
bearing
A
Cylidrical roller
E012 R916411696 10 E058 2916650023 Collar 3
bearing
C
E013 R988012373 Collar 10 E059 R913003909 Collar 1
RI
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
E
E017 R988011192 Sun gear 1 E070 R916462052 Washer 2
E018 R916452068 Elastic collar 1

AM
E087 R988011630 Sun gear 1
E019 R988011289 Round nut 1 E088 R988012341 Collar 1

Tapered roller
E020 R916412778 1 E089 R988011188 Planetary carrier 1
bearing
Tapered roller E090 R988011840 Planetary gear 3
E021 R916412722 1
N
bearing
Cylindrical roller
E022 R988012516 O-ring 1 E091 R988012458 3
bearing
TI
E023 R913006409 Bolt, hexagon 2 E092 R916452026 Collar 3
E025 R988011598 Piston 1 E093 R916462507 Collar 6

LA

Deep-grooved
E027 R988012320 Collar 2 E099 R988012398 1
ball bearing
Friction disc,
E029 R988012929 6 E103 R988012357 Cylidrical roller 1
outside
NY
Friction disc, E105 R902165278 Motor 1

E030 R988012931 5
inside
E031 R916423354 Spring 18 E199 R988012436 Rivet 4
E200 R909830326 Nameplate 1

SA
E032 R916423355 Spring 18
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

4.6.8 Travel motor (Nabtesco)

Type: GM60VA
Pi
C A
RI
MA
Nabtesco Nabtesco
E
Dr AM MB A
B
26XM20 18XM24
N
TI
FILL
lEVEL
Filling port DRAIN

LA
Drain port
ZX305-1102601
NY
Fig. 4-84
A: Main oil port

SA
B: Main oil port

Am: Pressure detection port
Bm: Pressure detection port
Pi: Two-speed pilot tubing port
Dr: Oil drain port

Item Unit Specifications

Input flow L/min 280
Relief valve pressure setting Mpa 34.3
2
Motor displacement cm /rev 290.7/170.1
Reduction ratio — 40.67
2
Total displacement cm /rev —
Theoretical output torque KN·m 64.3/37.6
Theoretical output speed r·p·m 23.8/40.7
A
Braking torque KN·m 1.17
C
Brake release pressure Mpa 1.54
Auto switching pressure Mpa 26.5
RI
Operating temperature range ℃ -20~90
Total weight kg 399
E
AM
N
TI
LA
NY
SA

4.6.9 Operating principle of the basic components
4.6.9.1 Double-balanced valve
Function:
● When external load makes the plunger motor tend to go faster than the rated rotating speed
of feed flow (hereunder referred to pump effect), this valve controls motor speed and prevents
over-speed of the motor in relation with the feed flow.
● The double-balanced valve and the relief valve constitute the braking circuit. The braking cir-
A
cuit applies braking force onto the swing of plunger motor and stops the motor gradually.
C
● This valve can serve as a shuttle valve for high pressure selection to release the brake under
its own pressure.
RI
● The structure of a standard double-balanced valve is shown below. The following information
describes the operating principle of a standard double-balanced valve.
E
A. When stopped AM
● When the main valve is neutralized (motor stopped), port M1 and port M2 are shut off by
spool (1) and check valve (2) since no pressure is generated at port P1 and port P2. The mo-
tor is not rotating.
N
TI
8-1
8
LA
8-2
Oil circuit B
Oil circuit C2
Oil circuit C1
NY
M1 M2
Orifice D3
Orifice D1
Damper chamber A2
SA
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber1
P1 P2
6-1 6-2
7-1 7-2
5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002094
Fig. 4-85

B. When motor is started

● When the hydraulic oil from the main pump enters port P1 of the double-balanced valve,
spring (3) is pushed to the left by check valve (2-1), opening circuit C1. The hydraulic oil en-
ters the plunger motor via port M, trying to make the motor rotating. At the same time, return
oil from the plunger motor enters the counterbalance valve via port M2, but it is stopped by
check valve (2-2). The output pressure of the main pump increases as a result, and the hy-
draulic oil works on the inside of spring chamber (1) and damper chamber (A1) via orifice (4-1)
and check valve (5-1). The force generated in this way pushes spring (7-2) on the other side
and moves plunger (1) to the right. At this time, return oil from port M2 passes through circuit
A
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.
C
E RI
8-1
8
AM
8-2
Oil circuit B
N
Oil circuit C2
Oil circuit C1
M1 M2
TI
Orifice D3
Orifice D1
Damper chamber A2
LA
Damper chamberA1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
P1 P2
6-2
NY
6-1
7-1 7-2
SA
5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002095
Fig. 4-86

C. Counterbalance function
● When the engine runs at an excessively high speed because of external force applied on it,
the motor may lose control. At this time, port P1 serves as the inlet side, and the pressure
drops. Pressure in spring chamber (1) and damper chamber A1 also drop. As a result, plunger
(1) moves to the left under the force of spring (7-2), closing circuit B. Circuit at the suction
side is also closed at the same time when the circuit at return side is closed. When circuit B is
closed, pressure at port P1 rises due to hydraulic oil from the main pump, moving plunger (1)
to the right again. In this way, when external load generates pump effect, slight movement of
plunger (1) keep circuit B open. The rotation speed of the motor keeps in line with fuel supply
A
of the main pump, and the motor will not lose control because of the vacuum in the hydraulic
system.
C
E RI
AM
N
TI
LA
NY
SA

D. Braking of motor
● The double-balanced valve and the relief valve forms the braking circuit.
● When the main valve is in neutral position, hydraulic oil from the main pump is cut off, and
pressure at port P1 and P2 is the same. As a result, plunger (1) moves to the neutral position,
and the opening area of circuit B decreases.
● At the same time, because of the inertia of external force, the motor does not stop rotating
(pump effect), and pressure at port M2 rises and serves as the braking force of motor rotation.
● When the pressure at port M2 reaches the set pressure of relief valve (8), cone valve (8-1)
A
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
C
vacuum at port M1 is avoided.
E RI
8-1 AM
8
8-2
Oil circuit B
N
Oil circuit C2
TI
Oil circuit C1 M2
M1
Orifice D3
Orifice D1
Damper chamber A2
LA
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
NY
P1 P2
6-1 6-2
7-1
SA
7-2
5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002096
Fig. 4-87

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.
A
● Hydraulic oil in travel braking cylinder chamber E is conducted to the drain passage of motor
housing, and travel brake is applied.
C
RI
1
Passage D
E
AM Passage D
Orifice
Passage F
Passage F
Passage D Passage G
Passage G Cylinder chamber E
N
TI
ZX215-1002097
Fig. 4-88
LA
1
Passage D
NY
Passage D
SA
Orifice
Passage F
Passage F
Passage D Passage G
Passage G Cylinder chamber E
ZX215-1002098
Fig. 4-89

4.6.9.2 Operation of parking brake
1) When starting travel

● As the travel lever is operated, pressurized
oil from the pump activates back pressure
valve spool (10), opens the parking brake 10
circuit, and flows to chamber A of brake
piston (12). Pressurized oil overcomes the
force of spring (11) and pushes piston (12)
A
toward the left.
C
● Since the pushing force to plate (13) and
RI
disc (14) disappears, plate (13) is sepa-
Travel control valve
rated from disc (14) and the brake is re-
leased.
E
A M
AM 11 14 13 12 22
ZX215-1002099
Fig. 4-90
2) When travel is stopped

N
● As the travel lever is placed in neutral,

TI
back pressure valve spool (10) returns to

the neutral position and closes the parking 10
brake circuit. T
LA
● he pressurized oil in chamber (A) of brake

piston (12) passes through the orifice of
the brake piston and is drained to the mo-
tor casing. Brake piston (12) is pushed to
NY
the right by spring (11).

● Plate (13) and disc (14) are pushed against
each other, and the brake is applied. As
SA
brake piston (12) returns, a time delay is A M

11 14 13 12 22
formed by making the pressurized oil pass ZX215-1002100
through a throttle valve in the slow return
valve (22). This time delay ensures an ac- Fig. 4-91
tive brake after the machine is stopped.

4.6.9.3 Operation of braking valve

PA PB
● The brake valve consists of a suction safe-
ty valve (8A) and a counterbalance valve
8A
(18). As shown in the illustration on the
right, functions and operations of respec-
tive components are described below.
18
C A
RI
MA MB
ZX215-1002101
Fig. 4-92
E
1. Counterbalance valve and check valve
AM Travel control valve
PA PB
Function 8B
● When traveling downhill, the weight of the 8A

N
machine tends to make the travel speed

faster than the motor speed. If the machine
TI
travels with the engine at low speed, the

motor may rotate at zero load, resulting
in runaway and inviting a very dangerous
LA
situation. These valves are used to avoid

such a situation by controlling the machine
19 MA MB
to travel according to the engine speed
(pump flow).
ZX215-1002102
NY
Fig. 4-93
Operation when pressurized oil is supplied
SA
● 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.

● The pressurized oil on the supply side

flows to chamber (S1) via orifice (E1) and Travel control valve
orifice (E2) of the spool (19). As the pres- PA PB

sure in chamber (S1) goes above the spool
shift pressure, spool (19) is pushed toward
the right. Port (MB) and port (PB) are con-
nected, the motor outlet port side opens
and the motor starts rotating, as shown in
the right illustration. S1
A
19
C
MA MB
RI
E1 E2 ZX215-1002103
Fig. 4-94
E
Brake operation in downhill travel
AM
● If the machine goes out of control while
PA PB
travelling downhill, the motor will be caused 20
N
to rotate without load to decrease the inlet

side oil pressure. Pressure in chamber (S1)
TI
drops via orifices (E1) and (E2). As the

pressure in chamber (S1) goes below the
spool shift pressure, spool (19) is returned S1
LA
to the left by spring (20) and outlet port (MB)

is throttled. The pressure at the outlet port
side rises, generating rotation resistance 19
on the motor to prevent the machine from
MA MB
losing control. On the other hand, the spool
NY
moves to a position where the pressure on E1 E2 ZX215-1002104

outlet port (MB) can be balanced against
the machine's own weight and the inlet port Fig. 4-95
SA
pressure. Oil flow from the outlet circuit is

reduced to ensure the travel speed corre-
sponded to the pump delivery, as shown in
the right illustration.

2. Safety valve
Function
● When the machine travel is stopped (or it
is travelling downhill), the double-balanced
valve closes the inlet and outlet circuits of
the motor. Since the motor is rotated by
inertial force, pressure in the motor outlet
port side is abnormally increased, poten-
A
tially resulting in damages on the motor
and piping. The safety valve relieves this
C
abnormal pressure to the inlet port side of
RI
the motor in order to prevent damages to
the equipment.
E
Operation
1) When travel is stopped (or when travelling
downhill or swinging to the right)
AM Travel control valve
PA PB
20
● Reduction of the pressure at motor inlet
(PA) decreases the pressure in chamber
N
(S1). When it drops beyond the spool shift

pressure, the spool is returned to the left
TI
by spring (20), throttling the oil outlet pas- S1

sage (B1). At this time, the motor continues
rotating due to its inertial force, thus pres-
LA
sure on the outlet port (MB) is increased,

as shown in the right illustration. MA MB
A1 B1 ZX215-1002105
NY
Fig. 4-96
● When the pressure rises above the set

SA
pressure of the suction safety valve (8A),

the spool opens. The pressurized oil pass-
es through notch (A1) of the counterbal-
ance valve spool (19) into chamber (MA) of
the circuit at the opposite side, as shown in
Spool MB MA
ZX215-1002107
Fig. 4-97

2) When starting travel (or traveling normally)

● As the travel control lever is operated, the
PA PB 8B
pressurized oil from the pump moves the
counterbalance valve spool (19) toward
right. In this case, the passage to the suc- 8A
tion safety valve functions as a circuit
which passes through notch (B2) of spool
(19), producing large differential pressure. S1
The pump pressure rises, providing a large
A
tractional force to the valve, as shown in
19
C
MA MB
RI
E1 B2
ZX215-1002106
Fig. 4-98
E
3. Overload relief valve
● The structure of the relief valve is shown
AM
in the right figure. This valve is an area-
differential and direct-acting relief valve. It
has impact damping function during start-
N
ing and braking.

TI
LA
ZX365-1304108
Fig. 4-99
NY
A. Operating principle and function

● When the main control valve makes the
motor to start or brake, front pressure of
SA
2-9-2 2-9-5
cone valve (2-9-2) rises above the set pres-
sure and the force of spring (2-9-5), and
moves cone valve (2-9-2) to the right and
off the valve seat (2-9-3). Pressurized oil in
the front of cone valve (2-9-2) is bypassed
to the low pressure side. The impact due
to inertia energy at the high pressure side
2-9-3
is put under control and vacuum is pre-
vented from occurring at the low pressure
ZX365-1304109
side through bypassing pressurized oil to
the low pressure side. Fig. 4-100

B. Damping function
● When the relief valve begins to function, 2-9-2 Area S2 2-9-5
damping piston (2-9-9) moves to the left.
As a result, low pressure is maintained in
spring chamber D. At this time, the loaded
area of cone valve (2-9-2) is S1, and gen-
erally it is much larger than the set loaded
area S1-S2 of the relief valve. So, when
damping piston (2-9-9) is moving, the func-
2-9-3 Area S1 2-9-9 Spring chamber D
A
tional pressure of relief valve is maintained
at 1/3 of normal set pressure in order to
C
ZX365-1304110
absorb the impact at the high pressure
Fig. 4-101
RI
circuit side due to inertial energy. When
the movement of damping piston stops,
pressure in spring chamber D rises. Pres-
E
sure at both side of cone valve (2-9-2) is
the same, and the relief valve is working AM
at normal set pressure. In this way, the re-
lief valve reduces the impact during motor
starting and braking by a two-stage action
to provide excellent performance.
N
TI
LAPressure (P)
NY
SA
O Damping form time (T)

ZX215-1002111
Fig. 4-102

Table 2 Repair standard of motor components
Components Check item Allowable limit Remedy

Grind the boot sliding
surface. Replace the
Roughness 0.8a or surface rough-
1. Boot sliding surface cylinder block assembly
ness, scratch 0.02mm+
if the scratch cannot be
corrected.
1-4-2 Plunger Roughness 1.2a or surface rough-
assembly 2. Plunger outer diameter
ness, scratch 0.02mm+
3. Plunger outer diameter
A
Replace the cylinder
and cylinder block inner Clearance 0.060. block assembly.
C
diameter
4. Boot head clearance Clearance 0.4.
RI
Grind the boot sliding
1. Valve leaf and sliding sur- Roughness 0.8a or surface rough-
cylinder block assembly
face ness, scratch 0.02mm+.
E
if the scratch cannot be
AM corrected.
Roughness 1.6a or surface rough-
1-4-1 Cylinder 2. Shaft hole inner diameter
ness, scratch 0.02mm+.
block
3. Shaft hole inner diameter
and 4-2 plunger assembly Clearance 0.060. Replace the cylinder
outer diameter block assembly
N
Roller distance below 38.749

4. Spline at shaft joint (measuring pin diameter
TI
φ3.333(V1=2.80)); or damaged
Grind the sliding surface.
1-21 Oil distri- Roughness 0.8a, scratch 0.02mm+ Replace the valve sheet
LA
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
NY
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.
SA
1-5 Swash
Roughness 1.6a.
plate 2. Hole for assembling steel
ball Scratch on spherical surface
0.02mm+ or surface roughness Replace the swash plate.
3. Hole for assembling steel
Ball depth 14.5
ball


1. Oil seal sliding portion outer Roughness 1.6a, rough surface, or Replace the swash
diameter scratch 0.02mm+ plate.
Stick spans below 47.380 (testing
2. Cylinder block matching
pin diameter φ3.00), or the stick
1-3 Shaft spline
breakage.
Replace the shaft.
Stick spans below 30.498 (testing
3. Drive gear connection pin diameter φ3.33), or the stick
breakage.
1. Dimension Height 38.2
A
1-15 Brake pis- 2. Sliding surface Roughness 2.5a Replace the brake
C
ton piston.
3. Appearance Scratch 0.02mm+ or rough surface
RI
1. Dimension Thickness 3.2
Replace the disc
1-13 Disc plate Deep scratch on sliding surface or
2. Appearance plate.
friction material peeling
E
1-8 Ball bearing 1. Rolling surface Peeling or fracture
AM Replace the ball
Abnormal rotation (noise•uneven bearing.
1-9 Ball bearing 2. Action
rotation)
Grind the sliding
Roughness 1.6a, rough surface, or
1. Boot sliding surface flange plate parts if
scratch 0.02mm+
N
the scratch cannot

1-7 Plunger as- be corrected
TI
sembly Roughness 1.2a, rough surface,

scratch 0.02mm+
3. Plunger outer diameter and Replace the flange
Gap 0.040. plate parts.
LA
flange part inner diameter

4. Boot head clearance Clearance 1.0
Roughness 0.8 a, scratch 0.02mm+
1-2-2 Plunger or rough surface Replace the valve
assembly 2. Plunger outer diameter and sheet.
Clearance 0.060.
NY
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
SA
Clearance 0.060
and plunger outer diameter
3. Valve spool assembly instal- Roughness 0.8 a, scratch 0.02mm+
1-2-1 Valve lation hole or rough surface Replace the valve
sheet sheet and the parts.
4. Spool valve sheet inner di-
ameter and valve spool outer Clearance 0.060.
diameter
5. Movable plunger sliding part Scratch 0.02mm+ or surface rough-
and seat of the relief valve ness

C A
E RI
AM
N
TI
LA
NY
SA


1. Valve spool out diam- Roughness 0.8 a, scratch 0.02mm+
eter or surface roughness
1-2-9 Spool as- Replace valve sheet
2. Valve spool outer diam-
sembly and parts
eter and valve sheet inner Clearance 0.060.
diameter
1-2-7-9 Movable 1. Sliding portion of valve Scratch 0.02mm+ or surface rough-
plunger sheet and valve seat ness
Replace relief valve
1. Sling portion of the
Scratch 0.02mm+ or surface rough- assembly
1-2-7-1 Case movable piston (outer
ness
A
diameter)
1. Dimension Free length 61.0
C
1-4-7 Spring
2. Appearance Deformation and surface damage
RI
1-18 Spring
E
1-20 Spring
AM
1-2-4 Spring
1-2-10 Spring
N

Replace o-ring and oil
O-ring and oil seal When removed
TI
seal
LA
NY
SA

4.6.10 Control system

8
9
7
C A
RI
6
E
4 1 2 AM
5 10
9 7
5 6
3
4 12
11
N
10
8
TI
13
3 11
LA
2
NY
12
1
SA
ZX365-1304112
Fig. 4-103

(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
A
(10) Solenoid valve
C
(11) Control lever (left work equipment)
(12) Relay
RI
Control lever positions
E
HOLD
1
AM
2 Boom UP
3 Boom DOWN
4 Bucket DUMP
N
5 Bucket DIG
TI
6 HOLD
7 Arm IN
LA
8 Arm OUT
9 Right swing
10 Left swing
NY
11 Neutral
12 Travel BACKWARD
SA
13 Travel FORWARD

4.6.11 Manual pilot valve
P3
P2
A
T
P
2
3
A
P
1
4
C
RI
P4 P1
E
A
64~73.5Nm
AM
19~22Nm
N
TI
LA
NY
SA
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

6
7
A
8
C
E RI
4
AM
9
3
N
TI
10
2
LA
1
NY
A-A ZX215-1002114
SA
Fig. 4-105
(1) Plunger (6) Nut (for control lever connection)

(2) Adjusting spring (7) Connector
(3) Center spring (8) Plate
(4) Piston (9) Retainer
(5) Disc (10) Valve body

Operation
1. When in neutral
● Ports (A) and (B) of the control valve and
ports (P1) and (P2) of the pilot valve are D
connected to drain chamber (D) via orifice
(f) in plunger (1). f
2. During fine control (Neutral to fine control) 1 T
A
● When piston (4) is pushed by disc (5),
retainer (9) is pushed, plunger (1) is also P
C
pushed by adjusting spring (2), and moves
RI
down.
● When orifice (f) is shut off from drain cham- Pilot
ber (D), it is almost simultaneously inter- pump P1 P2
E
connected to pump pressure chamber (PP).
Pilot pressurized oil of the control pump is AM
led to port (A) from port (P1) via orifice (f).
A M M B
When the pressure at port (P1) becomes Control valve
higher, plunger (1) is pushed back and ZX365-1304115
orifice (f) is shut off from pump pressure
Fig. 4-106
N
chamber (PP). At almost the same time, it

is connected to drain chamber (D) to re-
TI
lease the pressure at port (P1). As a result,

plunger (1) moves up and down until the
force of adjusting spring (2) is balanced
LA
with the pressure at port (P1).

● The relationship of the position of plunger D
(1) and body (10) [orifice (f) is in the middle
between drain chamber (D) and pump f
NY
pressure chamber (PP)] does not change

until retainer (9) contacts plunger (1). Ad- 1 T
justing spring (2) contracts in proportion
SA
to the stroke of the control lever. Pressure P

at port (P1) also rises in proportion to the
stroke of the control lever. In this way, the
control valve plunger moves to a position
where the pressure of chamber (A) (same Pilot
P1 P2
pump
as pressure at port (P1)) and the force of
the return spring of the control valve plung-
er are balanced.
A M M B
Control valve
ZX365-1304116
Fig. 4-107

3. Fine control (When control lever returns)

● When disc (5) starts to return, plunger (1)
is pushed up by the force of center spring
(3) and the pressure at port (P1).
● Because of this, orifice (f) is connected to D
drain chamber (D), and the pressurized oil
f
at port (P1) is released.
● If the pressure of port (P1) is lowered ex- 1 T
cessively, plunger (1) is pushed down by
A
adjusting spring (2). P
C
● Orifice (f) is shut off from drain chamber
RI
(D), and it is almost simultaneously in-
f1
terconnected to pump pressure chamber
(PP). Pump pressure is supplied until the Pilot
pump P1 P2
E
pressure at port (P1) recovers to the level PP
equivalent to the lever position. AM
● When the plunger of the control valve re-
A M M B
turns, the oil in drain chamber (D) flows in Control valve
from orifice (f) in the valve on the side that ZX365-1304117
is not working. The oil passes through port
Fig. 4-108
N
(P2) and enters chamber (B) to replenish

TI
the chamber with pressurized oil.

LA
4. At full stroke
● Disc (5) pushes down piston (4), and re-
D
tainer (9) pushes down plunger (1).
● Orifice (f) is shut off from drain chamber (D), f
NY
and is interconnected to pump pressure

chamber (PP). 1 T
● Therefore, the pilot pressure oil from

SA
P
the self pressure reducing valve passes
through orifice (f) and flows to chamber
(A) from port (P1) to push the control valve
f1
plunger.
Pilot
pump P1 P2
● The oil returning from chamber (B) passes PP
from port (P2) through orifice (f) and flows
to drain chamber (D).
A M M B
Control valve
ZX215-1002118
Fig. 4-109

4.6.12 Travel pilot valve
C A
T
RI
P
P
E
AM
P5 A
P6
P5
P2 P1
N
TI
LA
2 1
4 3
NY
SA
P4 P3
ZX215-1002119
Fig. 4-110
P: From pilot pump P4: R.H. forward

P1: L.H. reverse P5: Travel signal
P2: L.H. forward P6: Travel signal
P3: R.H. reverse T: To tank

37~30Nm
B
65~45Nm
1 8~6Nm
A
2
C
RI
3
E
5 AM
6
C C
7
B-B
2，4 1，3
N
B
TI
13~11Nm
LA
C-C
NY
8~6Nm
ZX215-1002120
Fig. 4-111
SA
(1) Plate (5) Center spring

(2) Body (6) Adjusting spring
(3) Piston (7) Valve
(4) Collar


1) When in neutral
● Ports (A) and (B) of the control valve and
ports (P1) and (P2) of the pilot valve are D
connected to drain chamber (D) via orifice

f
(f) in spool (1).
T
2) Fine control (Neutral to fine control) P
● When piston (4) is pushed by lever (5), re-
A
1
tainer (9) is pushed, and plunger (1) is also
Pilot pump
pushed by adjusting spring (2), and moves
C
P1 P2
downward.
RI
● When orifice (f) is shut off from drain A B
Control Valve
chamber (D), it is almost simultaneously
interconnected to pump pressure chamber
E
ZX215-1002121
(PP).
Fig. 4-112
AM
● 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
N
orifice (f) is shut off from pump pressure

5
chamber (PP). At almost the same time, it
TI
4
is connected to drain chamber (D) to re-
lease the pressure at port (P1). 9 D
LA
● As a result, plunger (1) moves up and 2

down until the force of adjusting plunger (2) f
T
is balanced with the pressure at port (P1).
P
● The relationship of the position of plunger
NY
(1) and body (10) [orifice (f) is in the middle 1

between drain chamber (D) and pump Pilot pump PP
P1 P2
pressure chamber (PP)] does not change
10
SA
until retainer (9) contacts plunger (1).

A B
Control Valve
● Adjusting spring (2) contracts in proportion
to the stroke of the control lever. ZX215-1002122
● Pressure at port (P1) also rises in propor- Fig. 4-113

tion to the stroke of the control lever.
● In this way, the control valve spool moves
to a position where the pressure of cham-
ber (A) (same as pressure at port (P1)) and
the force of the return spring of the control
valve spool are balanced.

3) Fine control (When control lever returns)

● When lever (5) starts to return, plunger (1)
is pushed up by the force of center spring 5
(3) and pressure at port (P1).
● Because of this, orifice (f) is connected to
3 D
drain chamber (D), and the pressurized oil
2
at port (P1) is released.
f T
● If the pressure of port (P1) is lowered ex-
cessively, plunger (1) is pushed down by P
A
f’
adjusting spring (2).
C
1
● Orifice (f) is shut off from drain chamber (D), Pilot pump PP
RI
and it is almost simultaneously intercon- P1 P2
nected to pump pressure chamber (PP).
A B
● Pump pressure is supplied until the pres- Control Valve
E
sure at port (P1) recovers to the level ZX215-1002123
equivalent to the lever position.
AM
Fig. 4-114
● When the spool of the control valve re-
turns, the oil in drain chamber (D) flows in
from orifice (f) in the valve on the side that
is not working. The oil passes through port
N
(P2) and enters chamber (B) to replenish

TI
the chamber with pressurized oil.
4) At full stroke
LA
● Lever (5) pushes down piston (4), and re-

tainer (9) pushes down plunger (1). 5
4
● Orifice (f) is shut off from drain chamber (D),
NY
and is interconnected to pump pressure D

9
chamber (PP).
● Therefore, the pilot pressure oil from f
SA
T
the self pressure reducing valve passes
P
through orifice (f) and flows to chamber f’
(A) from port (P1) to push the control valve
1
spool. PP
Pilot pump
● The oil returning from chamber (B) passes P1 P2
from port (P2) through orifice (f) and flows
to drain chamber (D). A Control Valve B
ZX215-1002124
Fig. 4-115

4.6.13 Solenoid valve
P2 T A1 A2
2
P1
C A
E RI
3 4 5 6 7 8
AM W365-1304125
Fig. 4-116
(1) Solenoid valve block P1: To pilot fi lter

N
(2) Accumulator P2: To main valve port G

TI
(3) High-speed travel solenoid valve T: To oil tank

(4) Backup valve A1: To swivel joint port X
LA
(5) Backup valve A2: To pilot oil circuit block P

(6) Bucket confl uence solenoid valve
(7) Backup
NY
(8) Pilot pressure solenoid valve

SA

4.6.14 PPC accumulator
(1) Gas plug

1
(2) Shell
(3) Poppet
2
(4) Holder
(5) Bladder
A
(6) Oil port 3
C
RI
4
Specifications
Gas capacity: 300 cc (for PPC)
E
5
AM
6
ZX215-1002126
N
Fig. 4-117
TI
LA
NY
SA

C A
E RI
AM
N
TI
LA
NY
SA

4.6.15 Pilot oil filter
1
K
2
Model
Pressure
Precision
A
3
C
4
E RI
5
AM
6
N
TI
LA
ZX215-1002127
Fig. 4-118
NY
(1) Nameplate Specifications

SA
(2) Head cover Max. delivery: 40 L/min

(3) O-ring Filter fineness: 10 um
(4) Seal ring Operating pressure: 20 Mpa
(5) Filter Max. operating pressure: 40 Mpa
(6) Casing Pressure loss: 0.05 Mpa
Max. allowable pressure difference: 1 Mpa
Specification of inlet/outlet port O-ring: 30×3.1

4.6.16 Hydraulic cylinders
Boom cylinder
2 1 7960N·m 3
C A
56.9±10.7N·m
RI
367N·m
ZX335-1002035
Fig. 4-119
E
Arm cylinder
AM
2 1 22200N·m 3
N
TI
LA
711N·m 96.6±18.2N·m
ZX335-1002036
Fig. 4-120
NY
Bucket cylinder
SA
2 1 3
9550N.m
56.9±10.7N.m
367N.m
ZX335-1002037
Fig. 4-121

4.6.16.2 Lubrication at every 100 service hours

Unit: mm
No. Check Item Criteria Remedy
Cylinder
size Shaft Hole clearance limit
Clearance be- -0.012 +0.222
Boom 100 0.083-0.312 0.412
-0.034 +0.047 Replace the
1 tween piston rod
-0.012 +0.222 bushing.
and bushing Arm 120 0.083-0.312 0.412
-0.047 +0.047
-0.012 +0.258
A
Bucket 100 0.078-0.334 0.434
-0.034 +0.048
C
-0.036 +0.25
Clearance be- Boom 100 0.086-0.321 1.0
-0.071 +0.05
RI
tween piston rod -0.036 +0.25
2 Arm 110 0.086-0.321 1.0
support pin and -0.071 +0.05
bushing -0.036 +0.25
Bucket 90 0.086-0.321 1.0 Replace the
E
-0.071 +0.05
pin or bush-
-0.036 AM+0.25
Clearance be- Boom 90 0.086-0.321 1.0 ing.
-0.071 +0.05
tween cylinder -0.036 +0.25
3 Arm 110 0.086-0.321 1.0
bottom support -0.071 +0.05
pin and bushing -0.036 +0.25
Bucket 90 0.086-0.321 1.0
-0.071 +0.05
N
TI
4.6.16.1 Lubrication at every 500 service hours

Unit: mm
LA
No. Check Item Criteria Remedy

Cylinder
size Shaft Hole clearance limit
Clearance be- -0.012 +0.222
Boom 100 0.083-0.312 0.412
NY
-0.034 +0.047 Replace the

1 tween piston rod
-0.012 +0.222 bushing.
and bushing Arm 120 0.083-0.312 0.412
-0.047 +0.047
SA
-0.012 +0.258
Bucket 100 0.078-0.334 0.434
-0.034 +0.048
-0.036 +0.25
Clearance be- Boom 100 0.086-0.321 1.0
-0.071 +0.05
tween piston rod -0.036 +0.25
2 Arm 110 0.086-0.321 1.0
support pin and -0.071 +0.05
bushing -0.036 +0.25
Bucket 90 0.086-0.321 1.0 Replace the
-0.071 +0.05
pin or bush-
-0.036 +0.25
Clearance be- Boom 90 0.086-0.321 1.0 ing.
-0.071 +0.05
tween cylinder -0.036 +0.25
3 Arm 110 0.086-0.321 1.0
bottom support -0.071 +0.05
pin and bushing -0.036 +0.25
Bucket 90 0.086-0.321 1.0
-0.071 +0.05

4.7 Work Equipment

4.7.1 Component dimensions
A
G
C
RI
A
E
AM
J
,
K
N
TI
LA
H
NY
ZX365-1304500
Fig. 4-122
SA

1 3
D-D G-G J-J

A-A 5
2 4
A
B-B
C
H-H K-K
RI
E-E 6
E
AM
C-C F-F I-I ZX285-1002022
Fig. 4-123
N
TI
Lubrication
Unit：mm
Std. tolerance Clear-
Bushing Lube Std. clear-
LA
No. Item Std. size ance Remedy

material interval 轴孔 ance
limit
Clearance between the pin and
–0.036 +0.063 0.036 ～
1 bushing connecting the boom Copper 500 h Ф110 1.0
–0.071 0 0.134
with swing platform
NY

–0.036 +0.087 0.036 ～
2 bushing connecting the boom Copper 500 h Ф110 1.0
–0.071 0 0.158
with arm
SA
–0.036 +0.054 0.036 ～

3 bushing connecting the arm with Steel 100 h Ф90 1.0
–0.071 0 0.125
rocker
Replace
–0.036 +0.054 0.036 ～
4 bushing connecting the arm with Steel 100 h Ф90 1.0
–0.071 0 0.125
bucket
–0.036 +0.2 0.036 ～
5 bushing connecting the linkage Steel 100 h Ф90 1.0
–0.071 0 0.271
with bucket
–0.036 +0.054 0.036 ～
6 bushing connecting the linkage Steel 100 h Ф90 1.0
–0.071 0 0.125
with rocker

4.7.2 Arm dimensions
19
11
B
12 A A
5
13
A
C D
10
B
6
D
C
14
RI
8
E
AM
N
18
TI
16
LA
17 15
A-A B-B
NY
SA
2
3
D-D
C-C
ZX285-1002501
Fig. 4-124

单位：mm
SY365H-9 SY365BH-9
No.
Standard size Tolerance Standard size Tolerance
+0.087 +0.087
1 φ100 φ100
0 0
+1.5 +1.5
2
131 0 131 0
0 0
3
345 -0.5 316 -0.5
A
-0.036 -0.071
4 φ90 φ110
C
-0.071 -0.036
5 473 ±1 602 ±0.8
RI
6 354 ±1 215 ±0.5
7 989 ±1 976.6 ±0.8
E
8 2914 ±3 2906 ±2
9 3018 ±3 AM 3071 ±2
10 473 ±1 458 ±0.8
11 740 ±0.3 770 ±0.3
12 728 ±0.5 728 ±0.5
N
13 520 ±0.5 513.6 —

14 1,661 — 1570 —
TI
-0.036 -0.036
15 φ90 φ90
-0.071 -0.071
0 +1
LA
16 345 346
-0.5 0
-0.036 -0.03
17 φ90 φ90
-0.071 -0.06
0 0
Arm body
345 -0.5 329 -0.5
NY
18 When bushing
345 — 344 —
is pressed on
Minimum 2,395 — 1,990 —
SA
19 Maximum 4,145 — 3,275 —

4.7.2.1 Bucket dimensions
C A
1
RI
3
E 6
AM
5
N
TI
LA7
NY
SA
9 10
11
12
W365-1304502
Fig. 4-125

Unit：mm
SY365H-9 SY365BH-9
No.
Standard size Tolerance Standard size Tolerance
1 520 ±0.5 567 ±0.5
2 1661 — 1714 —
3 R100 — R130 —
4 R125 — R130 —
5 1478 — 1451 —
A
6 1570 — 1889 —
C
+0.2 +0.2
7 φ90 φ100
RI
0 0
+0.2 +0.2
8 φ90 φ90
0 0
9 36 — 36 —
E
10 34 — AM 36 —
+1 +1
11 346 346
0 0
12 486 — 500 —
N
TI
LA
NY
SA

4.8 Operator Station and Its Attachments

4.8.1 Air conditioner lines
C A
C
RI
C
E
C
C B AM
A
6
N
7 1
TI
LA
2
NY
SA
3
5
4 ZX335-1002042
Fig. 4-126

(1) Air conditioner

(2) Hot water pumping line
(3) Air compressor
(4) Refrigerant line
(5) Condenser
(6) Hot water return line
(7) Duct
A
A: Fresh air
C
B: Recirculated air
RI
C: Warm air / cool air
E
AM
N
TI
LA
NY
SA

4.8.1.1 Layout of A/C components
2
1
3
4
C A
RI
5
E
AM
N
TI
LA
7 6
ZX215-1002138
NY
Fig. 4-127
SA
(1) Sunlight sensor

(2) Control panel
(3) Air conditioning unit
(4) Condenser
(5) Compressor
(6) Fresh air sensor
(7) Recirculated air sensor

4.8.1.2 A/C control panel
1 2 3 4 5
OFF
MODE AUTO
FULL AUTO AIRCONDITION
TEMP
A
A/C
C
RI
6 7 8
W365413093
E
Fig. 4-128 AM
(1) OFF switch Remark:
(2) Fan speed control switch
When auto mode switch (5), fresh air/recircu-
(3) Temperature control switch
lation control (6) and A/C power (8) are turned
N
(4) Air outlet mode switch on, indicator lights above these switches will
(5) Auto mode switch light up.
TI
(6) Fresh air/recirculation control

(7) LCD display
(8) A/C power
LA
NY
SA

ZX215-1002140
A C SW
1.25R
RI
7
FURM B G1 G2 ACC M ST
3
FL1
3 8
H
FUCD 20A FUM OFF
60A 15A 8
1.25R 5A ACC
2 13 ON
2
CMB RLCD
E 8
RLCC
8
RLBM
START MRF
AM 9 10
13 15
RLCC RLCD RLBM
13
M
GND
REC
FFE
1
Vz
2RL 1.25RL
Pt
10 1.25L 15
16 16 19 25 24 22 26 25
1
D MR
FLZ
MCD SPCD M 200W
RLSF 5 2 40A
M 11
1.256 10 2G 13 +B 16 19 25 24 26
5
80W 6 16 19 22 23 1
10 BLCM
N

10
5
1
SW 4 3
6 RLCH ACM
BAT BLC 2
ACC 7
7
D1
RCD RLCH RLCH
9
ECC
1
TI
12 12
G
8
12
28 15
14
14
17
THAM THW THI THF
18
12
20
13 3
22 21
16
SSD
27 4
15 23
21
27 28
20
29
2 24
30
25
31 32
9 38
32
26
34 35
10
G
4
4
4
02 02 02
03
40W
15 15 15
LA 15
22
4.8.1.3 Diagram of electrical circuit
CMB D2 30 31 22 32 15 33 34 35 35 22
1.25B
1.25B
3
SPHL
CM
0.85B
0.50
02 02
M M M
2B
06 0.5B
2B 2B
NY
Structure and Functions
01 02
06
03
MAM MV1 MV2
SA
Fig. 4-129
4-134
Diameter/Color Diameter/Color
Wire No. Wire Color Wire No. Wire Color
Code Code
B Black 0.5VW Violet+white
Br(R) Brown 0.5YB Yellow+black
0.85W White 0.5WO White+orange
RL Red+blue 0.5PB Pink+black
G Green 0.5VR Violet+red
0.5BL Black+blue 0.5BG Black+green
A
0.5R Red+blue 0.5WY White+yellow
0.5Y Yellow 0.5WR White+red
C
0.5BR Black+red 0.5BrW Brown+white
RI
0.5BrY Brown+yellow 0.5GO Green+orange
0.5BY Black+yellow 0.5Sb Sky blue
E
0.5GW Green+white 0.5OW Orange+white
0.5LO Blue+orange AM 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
N
0.5LgR Light green+red

TI
Code Name Code Name Code Name

LA
Condenser high speed

ACM A/C amplifier FUCD Condenser fuse RLCH
relay
BAT Battery FUM A/C main fuse RLSF Protective relay
BLC Speed regulating resistor G Alternator SSD Sunlight sensor
NY
Condenser pressure
CMB Battery relay MAM A/M servo motor SPCD
switch
D Diode MB Blower motor SPHL Hi\Lo pressure switch
SA
D1 Diode 1 MCD Condenser motor SW Switcher

Fresh/recirculated air Recirculated air therm-
D2 Diode 2 MRF THAM
servo motor istor
ECC Compressor clutch MV1 Air outlet servo motor THF Anti-frosting thermistor
Recirculated air therm-
FL1 Fuse MV2 FRONT outlet servo motor THI
istor
FL2 Fuse RCD Condenser resistor THW Water temp thermistor
FUBM Blower fuse RLBM Blower main relay
RLCC Compressor relay RLCD Condenser relay

Refrigeration cycle diagram
Expansion valve
Cool air
Lo temp\Lo press\Liquid (Mist)

Evaporator
Lo temp\Lo press\Gas
A Hi temp\Hi press\Liquid
Cooling fan
C
Blower motor
RI
Air in cab
Out side fresh air
Hi-temp hi-pres gas
E
Lo-pres. Hi-pres. AM
side side
Reservoir
Compressor
N
Warm air
Lo-pressure part Hi-pressure part
TI
ZX215-1002141
Fig. 4-130
LA
Heating cycle diagram
Water tank radiator Water valve switch

NY
Water pump Warm air

SA
Engine
Blower motor
Air in cab
Low temp water

High temp water
ZX215-1002142
Fig. 4-131

4.8.1.5 Compressor
3 4
1 2
16
A
15
C
RI
14
E
AM 5
13
N
6
TI
12
11
LA
10 9 8 7
ZX215-1002143
Fig. 4-132
(1) Stator Operating principle
NY
(2) Front radial bearing

Compressor type: 10S15C. This compres-
(3) Thrust bearing
sor has 5 plungers in total with a piston at
(4) Front radial bearing
both sides of each plunger. The rotation of
SA
(5) Rear cylinder head

the swash plate drives the pistons to move
(6) Safety valve back and forth and transforms the refrigerant
(7) Rear cylinder block sucked from the evaporator from low tempera-
(8) Swash plate ture and low pressure gas state to high tem-
(9) Slipper perature and high pressure state.
(10) Front cylinder block
(11) Piston
(12) Front cylinder head
(13) Shaft seal
(14) Main shaft
(15) Boss
(16) Rotor
Process1 Process2
HI press.end pipe LO press.end pipe HI press.end pipe LO press.end pipe
Valve plate
Outlet valve disc
C A
Main shaft and swash plate Intlet valve disc
RI
Process6 Process3
E
AM
N
TI
LA
Process5 Process4

NY
SA
ZX215-1002144
Fig. 4-133

4.8.1.6 Clutch
● The electromagnetic clutch is used to

1
transmit moment of torsion. When the en-
gine is operating, the compressor may not 2
be working. The clutch controls the opera- 3

tion of the compressor only when the air 4
conditioner is under refrigerating mode.
● Operating principle
A
When the A/C power is turned on, the 5
C
clutch coil with an electromagnet gener-
ates a magnetic field and attracts the metal
RI
piece. The stator and rotor of the clutch are 6
engaged and bring the main shaft of the ZX215-1002145
compressor into rotation. Fig. 4-134
E
AM
(1)
(2)
Rotor
Stator coil
(3) Clasp
(4) Ball bearing
(5) Stator
N
(6) Center piece

TI
LA
NY
SA

4.8.1.7 Condenser
1
4
2
C A
RI
5
E
AM ZX215-1002146
Fig. 4-135
N
(1) Condenser core Function

TI
(2) Bracket
● The condenser changes high-temperature,
(3) Bolt with washer
high-pressure gas refrigerant (16Kg/cm²,
(4) Refrigerant inlet
approx. 80 ℃ ) to high-temperature and
LA
(5) Refrigerant outlet high-pressure liquid refrigerant (16Kg/cm²,

below approx. 60℃ ) through radiating.
NY
SA

4.8.1.8 Expansion valve
Operating principle
Evaporator
Refrigerant from the reservoir spurts out via
the orifice, turns into low-temperature, low- 2
pressure liquid (mist) after immediate expan-
sion, and enters the evaporator. 1
C A
RI
3
4 Compressor
E
Reservoir
ZX215-1002147
AM
Fig. 4-136
(1) Spring
(2) Diaphragm
N
(3) Probe
(4) Needle valve
TI
4.8.1.9 Evaporator
LA
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
NY
blower motor and undergoes heat exchange

with the surface of the evaporator. Heat is ab-
sorbed and warm air turns into cool air, which
SA
flows into the cab through the air ducts. Evap-

orator surface absorbs heat → Refrigerant in 2
1
the evaporator absorbs heat → Refrigerant
evaporates . Evaporated refrigerant (gas) is
absorbed by the compressor. ZX215-1002148
Fig. 4-137
(1) Expansion valve

(2) Evaporator

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
C A
4
E RI
AM
N
ZX215-1002149
TI
Fig. 4-138
(1) Inlet
LA
(2) Outlet
(3) Receiver/dehydrator
(4) Desiccant
NY
SA

4.8.1.11 Pressure switch
Function
Pressure
● The pressure switch is installed between
the reservoir and the expansion valve (hi-
1
pressure pipe). It is a combination switch
7
(Hi-Lo pressure combination switch). 2
6
● When pressure is excessively high, the
A
compressor stops.
C
● When pressure is excessively low, the low-
temperature condition disappears.
RI
3
5
E
AM 4
ZX215-1002150
Fig. 4-139
N
(1) O-ring
(2) Mobile contact point
TI
(3) Hood
(4) Plug and fixed contact
(5) Spring
LA
(6) Chamber
(7) Diaphragm
Operating features:
NY
Feature
DIFF
SA
DIFF
High pressure ON
Above 0.02 MPa 0.59±0.2 MPa
OFF
Low pressure 0.196±0.02 MPa 0.196~0.250 MPa 2.94~3.19 MPa
ON
Medium pressure OFF

1.23±0.1 MPa 1.52±0.08 MPa

4.8.1.12 Fresh air sensor
Fresh air temperature sensor is mounted be-

side the condenser or at the fresh air inlet.
Consisting of thermistors, it is used to detect
12
ambient temperature.
Resistance /Kȍ
10
Specification
8
A
Item Specification
6
C
Applicable voltage 4.4~5.6 V
4
Applicable temperature -30~60 ℃
RI
Storage temperature -40~90 ℃ 2
Resistance 1700±85Ω
-10 0 10 20 30 40 AT
E
B Constant 3900±195 K ZX215-1002151
Permissible working cur-

rent
1.6 mA (MAX) Fig. 4-140
AM
N
TI
LA
NY
SA

4.8.2 Refrigerant
1. General property
● High heat absorption and easy liquefaction
● Non-flammable, nonexplosive
● Stable chemical composition and quality
● Non-toxic
A
● Non-corrosive
C
● No hazard to clothing
RI
2. Refrigerant circulation
E
● After evaporation in the evaporator, re- AM
frigerant turns from gas into liquid via the
compressor and the condenser, which fin-
ishes a refrigerant cycle.
N
TI
Compressor LO press. side (inlet): LO temp?LO press.?Gas

Compressor Pressure/Temperature:2Kg/cm²，approx. 8ć
Evaporator
LA
IntakeėDischarge Absorb heatėEmit cold air
Compress HI press. side(outlet): HI temp\HI press.\Gas

NY
Pressure/Temperature:16Kg/cm²ˈapprox. 80ć
Condensor (outlet): LO temp\LO press.\Mist

Pressure/Temperature: 2Kg/cm²ˈapprox. 0~2ć
SA
Condensor (outlet)˖HI temp?HI pressure?Liquid Expansion valve

Condensor Pressure/Tempterature˖16Kg/cm²ˈBelow 60ć
Hi pressureėLo pressure
Via radiating:Gas refri- Hi tempėLo temp
gerantėLiquid refrigerant
LiquidėMist

● Refrigerant cycle principle (pressure - enthalpy diagram)
lgp
Liquefaction completed Refrigerant cyclic curve
Liquefaction starts
Throttling point Condensor
A
Condensing process
Liquid
C
Expansion throttle
RI
Expansion valve Compressing Compressor
process
Evaporating process
E
Evaporator
AM
Gas-liquid mixture
Gasification completed
N
h=u+Apv(kJ/kg)
TI
UInternal energy pPressure VSpecial volume AJoule equivalent

ZX215-1002152
Fig. 4-141
LA
NY
SA

3. Feeding of refrigerant
● Filling method and volume:
1) Refrigerant: HFC-134a
2) Feeding volume: 900±50 g (for refer-
ence)
3) Feeding method: Feeding of liquid re-
frigerant from the low-pressure end is
not allowed. If feeding operation fails,
A
discharge the refrigerant that has been
fed before re-feeding.
C
RI
ZX215-1002153
● Inspect the state of the refrigerant in the
Fig. 4-142
A/C circulation system through the sight
E
glass:
1) Correct feeding: Foam is hardly ob-
served when the refrigerant is flowing.
AM Sight glass
When engine speed increases from
idling to 1500 rpm, foam disappears
and the refrigerant turns clear.
N
2) Over-feeding: No foam can be ob-

TI
served when refrigerant is flowing. Proper filling
3) Under-feeding: Foam is always ob-

served when refrigerant is flowing.
LA
4. Evacuation Inadequate filling

ZX215-1002154
● Reason of evacuation
NY
Fig. 4-143
No moisture shall be mixed inside the air
conditioning unit. Refrigerant (R134a) is
SA
soluble in water. Very small amount of

moisture in the unit can cause the orifice of
the expansion valve to ice up, or cause the
valve of the compressor to rust. To avoid
such problems, moisture in the system
shall be removed before refrigerant is fed.
To reduce the residual moisture in the sys-
tem to the minimum, moisture in the sys-
tem can evaporate through evacuating. No
better means is available so far.

● Evacuating steps
1) Connection of manifold pressure Valve
Lo-pres.gauge
LO HI
above 750mmHg LO HI
gauge: Lo-pres. ON ON OFFOFF
gauge
a) Close the high-pressure valve (HI) Hi-pres. gauge
and low-pressure valve (LO) of the
manifold pressure gauge.
Lo-pres. valve (ON) Hi-pres. valve(ON)
b) Connect the air hose (red, blue) Green
to the auxiliary valve of the Red D
compressor.
A
Blue
Red hose——High pressure side S
C
(Mark D)
RI
Blue hose——Low pressure side Vacuum pump (running)
Compressor
(Mark S) ZX215-1002155
★ Connect the end of the air hose Fig. 4-144
E
with a L to the auxiliary valve of the AM
compressor. If connected inverse-
ly, the valve will not open. Besides,
do not inversely connect the high-
pressure end and the low-pressure
end.
N
c) Connect the middle hose (green) to

TI
the vacuum pump.

2) Evacuating
LA
a) Open the high-pressure valve (HI)

and low-pressure valve (LO) on the
manifold pressure gauge.
b) Turn on the vacuum pump and
NY
evacuate for about 15 minutes.

c) When negative pressure reading
on the gauge (degree of vacuum)
SA
reaches above 750 mmHg, turn off

the vacuum pump and close the Hi-
pressure valve and the Lo-pressure
valve on the gauge.

3) Air - proof check

Valve
a) Keep the Hi- and Lo-pressure valve Lo Hi Left at least
Lo-press gauge
OFFOFF for 5 minutes
of the manifold pressure gauge backs to zero.
Lo-press gauge
under closed state for more than 5
minutes, and make sure the pointer
on the gauge does not return to
zero.
Pointer backs
to zero.
b) If the pointer returns to near zero, Tighten the connector
a leakage is available somewhere. ZX215-1002156
A
Check and adjust the pipe joint. Fig. 4-145
Tighten the joint and conduct an-
C
other evacuating operation until no
RI
leakage is detected.
4) Leak check
Valve
a) Connect the air hose (green) that is Lo Hi
E
OFF OFF
previously connected to the vacuum AM
pump to the fluorine cylinder.
b) Connect the other end of the hose Vent valve
(green) to the pressure gauge. Release air
Open the valve
Open the valve of the cylinder and
N
press the vent valve of the pres-

sure gauge. (Do not press the valve
TI
with naked hand to avoid frostbite Blue

Air hose (green) R134a
caused by refrigerant). Release the Red
air in the hose with the pressure of
LA
To compressor Fluorine cylinder

the refrigerant. (Release the vent
ZX215-1002157
valve when you hear a squeezing
sound). Fig. 4-146
c) Add refrigerant until pressure read-

NY
ing on the Lo-pressure gauge is Lo-pres. gauge

reads1kg
1kgf/cm2. Hi-pressure valve of the Valve
gauge is open at this time. Close Lo Hi 1kg/cm2 Lo Hi
SA
Lo-pres. gauge OFF ON OFFOFF

the Hi-pressure valve when feeding reads1kg/cm2
is finished.
d) Use a leak detector to check if
Lo-pres.valve (OFF) Open Hi-pres.valve
leakage is present in the cooling Cylinder valve (ON)
system. D
e) Make necessary repairs (tightening)
S
if leakage is observed. R134a
Compressor
Fluorine cylinder
ZX215-1002158
Fig. 4-147

5. Refrigerant filling operation

● When evacuation is finished, fill refrigerant
into the cooling system as per the following
instruction:
Fill refrigerant kg/cm2
Performance testing
Air-proofness check
Evacuation starts
Evacuation ends
Air leak check

Fill refrigerant
Air leak check
A
75cm-Hg or more
Wait 5 min.
C
More than 15 min. Pres. gauge
normal
RI
Pres. gauge
Tighten pipe joint abnormal (1) Compressor stopped, fill at hi pressure end
Repair any leak. (2)Compressor running, add at lo pressure end
E
AM
● Fill from the hi-pressure side Valve
Lo Hi
1) Remove the air hose (green) of the OFFOFF
(Note)
manifold pressure gauge from the vac-
N
Refrigerant is released
uum pump and connect it to the fluorine when squeaking is heard.
cylinder.
TI
Vent valve
2) Open the valve of the cylinder and
press the vent valve on the pressure Open the valve
Loosen
LA
gauge. Use the pressure of the refriger- this nut

ant to release the air in the hose.
Release the vent valve when you hear Blue
Air hose (green) R134a
a squeezing sound. Do not press the Red
NY
vent valve with naked hand to avoid

To compressor Fluorine cylinder
frostbite.
ZX215-1002159
Fig. 4-148
SA

3) With the engine stopped, open the

high-pressure valve on the manifold
pressure gauge and the fluorine cylin- Valve
Filling one cylinder
Lo Hi (about 600g) Lo Hi
der valve and fill in one and a half cylin- OFF ON OFF OFF
der of fluorine (approximate 600g). (Never)

·Run the compressor
Do not run the compressor at this ·Open the low-press valve
moment. Once the compressor is Lo press valve (OFF) Open the high-press valve
started, the refrigerant could flow Fluorine cylinder
valve (ON)
back, causing the fluorine cylinder D
A
and hose to burst.
S
C
Operating the compressor without R134a
refrigerant will burn the compressor.
RI
Never run the compressor without ZX215-1002160
refrigerant.
Fig. 4-149
Do not open the low-pressure valve
E
on the manifold pressure gauge (liq- AM
uid compression will occur, causing
damage tot he compressor).
4) Close the high-pressure valve on mani-
fold pressure gauge and the fluorine
N
cylinder valve.
TI
● Fill from lo-pressure side (additional fill-

LA
ing) Hi-press valve (OFF) ON

Manifold
Press gauge
1) Confirm the hi-pressure valve of the
manifold pressure gauge is closed.
H I
NY
2) Start the engine and open the cab door.

(Note) Engine started
3) Turn on the air conditioner, and set Opening the high-pressure valve
can cause the fluorine cylinder
Temperature control switch to mini- to explode, resulting in serious
1300~1500rpm
SA
ZX215-1002161
mum. injury
Fig. 4-150
4) Adjust engine speed to 1300 – 1500
rpm.
5) Open the Lo-pressure valve of the
manifold pressure gauge and the valve
of the fluorine cylinder, and fill refriger-
ant into the reservoir until no foam is
observed.

Note:
Manifold pressure gauge reading (for refer-
ence):
High pressure 13~17kg/cm2 (ambient tempera-
ture 30℃ );
Low pressure 1.5~2kg/cm2 (ambient tempera-
ture 30℃ ).
A
6) When refrigerant filling is finished, close
the Lo-pressure valve of the manifold
C
Fill until no foam is not
pressure gauge and the valve of the Valve observed via sight glass
RI
Lo Hi Lo Hi
fluorine cylinder. ON OFF OFFOFF
Lo-pressure gauge
7) Check carefully for air leaks with a leak (1.5~2.5kgf/cm2)
Hi-pressure gauge
(13~17kgf/cm2)
detector.
E
Lo-pressure Hi-pressure valve (close)
valve (open)
Never open the Hi-pressure valve of AM Fluorine cylinder
(Never open it)
the manifold pressure gauge. If it is valve (open)

opened, high-pressure gas will coun-
terflow and cause the air hoses and
the fluorine cylinder to explode, result-
Compressor
ing in serious injury.
N
running
Fluorine cylinder
(never placed upside down)
Do not position the fluorine cylinder ZX215-1002162
TI
upside down (when engine is oper- Fig. 4-151

ating and filling in progress). If the
cylinder is placed upside down, liquid
LA
refrigerant will be sucked directly into

the compressor and cause liquid com- Fill until no foam is seen
via the sight glass
Valve
pression, resulting in damage to the
Lo Hi Lo Hi
compressor valve and the gaskets. ON OFF OFF OFF
NY
Place the cylinder vertically and fill

gas refrigerant.
Lo-pressure
8) When ambient temperature is low valve (open) Hi-pressure valve
SA
Cylinder valve (close)

When refrigerant filling can not be per- (open)
formed due to low ambient tempera-
ture, place the cylinder in water of less
than 40 ℃ to increase the pressure of
the refrigerant inside the cylinder. Compressor
Warm water less than 40°C running
9) When ambient temperature is high (Do not heat with hot water)
ZX215-1002163
When ambient temperature is very
high, cool the compressor with an elec- Fig. 4-152
trical fan.

● Replace the fluorine cylinder

Handle
When the refrigerant in a cylinder is used
up, replace the cylinder as per the follow-
ing instruction:
1) Close the Hi- and Lo-pressure valves of Air hose port
the manifold pressure gauge. Needle
valve
2) Raise the needle and disc plate of the
cylinder and remove the empty cylin- Gasket
der. Disc plate
A
3) Install a new cylinder onto the cylinder Refrigerant
C
cylinder
valve.
RI
4) Release the air in the hose as per the ZX215-1002164
following instruction:
Fig. 4-153
a) Tighten the valve of the fluorine cyl-
E
inder, and then, loosen it a bit. AM Valve
Lo Hi
b) Open the Lo-pressure valve of the Loosen Close
Close the Lo-pressure valve
manifold pressure gauge a bit. immediately after the refrig-
c) Press the vent valve and allow a lit- erant squeaks.
tle refrigerant to come out. Immedi-

N
ately close the valve of the cylinder

Loosen the valve a bit
TI
and the Lo-pressure valve of the Lo-pressure

manifold pressure gauge. valve
★ Do not press the vent valve with Green

LA
naked hand to avoid frostbite by Blue

R-134a
refrigerant. Red
5) Turn the handle of the cylinder valve to To compressor Refrigerant cylinder

ZX215-1002165
pierce the cylinder and continue filling
NY
operation. Fig. 4-154

SA

6. Troubleshooting with manifold pressure gauge
After the engine has been preheated, read the

pressure value on the gauge under the follow-
ing conditions:
1) Temperature at air inlet: 30 – 35℃
2) Engine speed: 1500 rpm
3) Fan speed: High
A
4) Temperature control: Minimum.
C
5) Air mode: Recirculation
RI
● Refrigerating system under normal condi-
E
tion
Gauge reading:
AM
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/
N
cm²)
TI
LA
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
NY
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
SA
R134a
ZX215-1002167
Fig. 4-155

● Moisture in the refrigerating system

Fault: Intermittent refrigeration to non-refriger-
ation
04 15 2
03 05
4 15 20
3 5
1
06
A
02
6 10 25
2 25
7
1
C
01 07 5 30
8 3
0
-50 8.5 0
RI
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
E
Fig. 4-156
AM ZX215-1002168
Symptom Cause Analysis Remedy

N
● Replace receiver/
● Moisture in the system ● Over-saturation of de-
TI
dehydrator
● When the system is hydrator.
ices up at the expan-
operating, pressure ● Remove the mois-
sion valve causing ● Moisture in the system
at the Lo-pressure ture in the system
LA
temporary stop of ices up at the expan-

end unstable (some- through constant
circulation. When ice sion valve and hinders
times vacuum, pumping.
melts, the system be- the circulation of the
sometimes normal)
comes normal again. refrigerating system. ● Add proper volume
of new refrigerant.
NY
SA

● Insufficient refrigeration
Fault: Insufficient refrigeration.
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
A
7
1
01 07 5 30
C
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
RI
-01 15 -01 35
MPa MPa
E
ZX215-1002169
Fig. 4-157 AM
● Check for air leakage with a leak
N
detector. Make necessary re-

● Pressure at both Hi- and
TI
● Insufficient repairs.

Ho-pressure ends very ● Air leaks
low somewhere frigerant in the ● Add proper amount of refriger-
in the refrig- system ant.
LA
● Foam is continuously ob-

erating sys- ● Leak of refriger-
served via the sight glass ● When connected with the gauge,
tem ant if the reading is near zero, set
● Insufficient refrigeration.
the system under vacuum state
after inspection and repair.
NY
SA

● Defective refrigerant circulation

Fault: insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
A
7
1
01 07 5 30
0 8 3
C
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
RI
MPa MPa
E
ZX215-1002170
Fig. 4-158 AM
● Pressure at both
N
Hi- and Lo-pressure

● Contaminant in the
TI
sides very low ● Blocked reservoir ● Replace reservoir

reservoir hinders the
● Frosting on the pip- flow of refrigerant.
ing between parts
LA
and reservoir
NY
SA

● Refrigerant not circulating

Fault: Non-refrigeration (intermittent refrigera-
tion)
04 15 2
03 05
4 15 20
3 5
1
02 06 25
2 6 10 25
A
7
1
01 07 5 30
C
0 8 3
-50 8.5 0
0 08 -76 35
-76
RI
085 0
-01 15 -01 35
MPa MPa
E
ZX215-1002171
Fig. 4-159 AM
N
● Check the expansion valve

and ERP.
● Vacuum at Lo-pres-
TI
● Moisture or contami-
sure side; pressure ● Blow the contaminant in the
nant in the refrigerant
at Hi-pressure side expansion valve or replace
hinders the flow of
extremely low ● Refrigerant not the expansion valve if nec-
LA
refrigerant.
circulating essary.
● Frosting or conden-
● Air leak at the thermal
sation on the pipes ● Replace the receiver
pipe of the expansion
around the expan-
valve hinders the flow ● Release internal air and
sion valve or receiv-
NY
of refrigerant. add refrigerant. If air leaks

er/dehydrator
from thermal pipe, replace
expansion valve.
SA

● Over-filling of refrigerant or insufficient re-

frigeration of condenser
Fault: Insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
A
7
1
01 07 5 30
C
0 8 3
-50 8.5 0
0 08 35
-76 -76
0
RI
085
-01 15 -01
35
MPa MPa
E
ZX215-1002172
Fig. 4-160 AM
● Clean the condenser
N
● Excessive refrigerant in
● Pressure at both Hi-
● Over-filling of refriger- system → Over-filling of ● Check the working
TI
and Lo-pressure condition of fan mo-

ant in the system. Re- refrigerant
sides very high tor
frigerating performance
● Insufficient refrigeration
● No foam can be ob- inadequate. ● If the two above
LA
of condenser → Ra-
served via the sight items are normal,
● Insufficient refrigeration diator fins of condenser
glass even when check the volume of
of condenser plugged or failure of fan
engine speed drops. refrigerant. Add re-
motor
frigerant as required.
NY
SA

● Air present in refrigerating system

Fault: Poor refrigeration
If refrigerant is added with no evacuation

operation performed, the following gauge
reading will appear:
A
04 15 2
03 05
4 15
C
5 20
3
1
02 06
2 6 10 25
25
RI
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
E
-01 15 -01 35
MPa MPa
AM
ZX215-1002173
Fig. 4-161
N

TI
● Pressure at both Hi- and

Lo-pressure ends very ● Check if compressor
LA
high ● Air enters the refriger- oil is contaminated

● Air enters the re- ant system or inadequate.
● Lo-pressure piping feel-
frigerating system
ing hot ● Insufficient evacuation ● Evacuate and add
● Foam is observed new refrigerant.
NY
through the sight glass

SA

● Improper installation of expansion valve/

thermal pipe defect (wide opening)
Fault: insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
A
7
1
01 07 5 30
C
0 8 3
-50 8.5 0
0 08
-76 -76 35
RI
085 0
-01 15 -01 35
MPa MPa
E
ZX215-1002174
Fig. 4-162
AM
N
● Pressure at both ● Excessive re- ● Check the installation of

● Improper installation of
Hi- and Lo-pressure frigerant in Lo- thermal piping
TI
thermal pipe/defective
ends very high pressure piping
thermal pipe (exces- ● If thermal piping is normal,
● Frosting or conden- sively wide opening) ● Expansion check the expansion valve.
LA
sation on Lo-pres- valve opening Replace expansion valve if

sure piping too wide found defective.
NY
SA

● Compressing error
Fault: No refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1 5
01 07
A
30
0 8 3
-50 8.5 0
0 08 -76 35
C
-76
085 0
-01 15 - 01 35
MPa MPa
RI
ZX215-1002175
E
Fig. 4-163
AM
● Compressing fault;
● Pressure at Lo-pressure
N
side very high ● Leaking or damaged

● Compressor internal ● Repair or replace
valve, or missing
TI
● Pressure at Hi-pressure leakage compressor

parts
side very low
LA
NY
SA

4.8.2.1 Compressor oil
Oil shall be added into the A/C system for lubrication. Compressor oil is solved in the refrigerant
and circulates in the system. When the air conditioning system is shut down, compressor oil will
stay inside the components. If no compressor oil is added into the system when replacing com-
ponents, inadequate lubrication will result. Add compressor oil according to the chart below:
Replaced component
A
Compressor Condenser Evaporator
C
Volume (CC) See "NOTICE" below 40 40
RI
ND8# (10P, 10PA, 10S series compressor)
Compressor oil grade
ND9# (TV series compressor)
E
NOTICE
AM
● 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.
N
● 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 abnor-
TI
mal compressor.
● Keep the pipe connectors and O-ring seals free from contamination when disassem-
LA
bling the compressor.

NY
SA

4.9 Engine Control
4 5
Z
3
C A
1
E RI
AM
2
9
6 7 8
N
TI
LA
Z
W365-1304503
Fig. 4-164
NY
(1) Battery relay Outline

(2) Battery
● The engine is only started and stopped
(3) Start switch with the start witch (3).
SA
(4) Fuel control dial

(5) Start motor
● The engine controller (6) receives the sig-
nal from the fuel control dial (4) and trans-
(6) Controller
mits the drive signal to the throttle motor (8)
(7) Fuel injection pump
to control the governor lever angle of fuel
(8) Throttle motor
injection pump (7) in order to regulate en-
(9) Shutdown device
gine speed.
● When the start switch (3) is turned to the
OFF position, the shutdown device (9)
closes the injection nozzle of the fuel injec-
tion pump to cut off the engine fuel supply.
Then, the engine stops.

4.9.1 System operation
4.9.1.1 Engine starting (Power supply)
Fuel control dial Engine Start switch

Start motor Safety relay
● When the start switch is turned to the B s

Lo s
Hi Hi (Start signal) R E C
Governor E
motor
START position, the starting signal is sent Lo M

L
B E
B BR C
Throttle OFF
to the start motor. Then, the start motor Throttle ON P Alternator
(Potentiometer signal)
(Start signal)
starts the engine.
(Driving signal)
Shutdown Battery relay
device
Pilot switch
Start
When it happens, the engine controller de- Shutdown

relay
relay
tects the signal voltage sent from the fuel
A
Shutdown
delay relay
Monitor - controller
(Regulating signal)
control dial and sets the engine speed to (Start switch ON siganl)
C
ZX335-1002044
the speed set by the fuel control dial.
Fig. 4-165
E RI
4.9.1.2 Engine speed control (Power supply)
Fuel control dial Engine Start switch

● The fuel control dial sends to the controller

a signal voltage corresponding to its angle.
AMHi Hi
Lo
Governor
motor
L
BE
s
E
(Start signal)
B
R E C
s
B BR C
Lo Throttle OFF M
P Alternator
According to the signal voltage, the control-
Throttle ON
(Potentiometer signal)
(Start signal)
(Driving signal)
ler sends a driving signal to throttle motor Shutdown
device
Battery relay Pilot switch
in order to control the fuel injection pump,

Start
N
Shutdown relay
relay
hence controlling the engine speed.

Shutdown
delay relay
Monitor - controller
TI
(Regulating signal)
(Start switch ON siganl)
ZX335-1002045
Fig. 4-166
LA
4.9.1.3 Engine shutdown (Power supply)

Engine Start switch
● When the start switch is turned to the Hi

Lo
Governor
s
E
(Start signal)
B
R E C
s
motor
STOP position, the shutdown controller L
NY
B BR C
B E
Throttle OFF
controls the shutdown device to stop fuel Throttle ON Alternator

(Start signal)
supply to the fuel feed pump. The engine Shutdown Battery relay
device Pilot switch
is then stopped. Start
SA
relay
Shutdown
relay
Shutdown
Monitor - controller delay relay
(Start switch ON siganl)

ZX335-1002046
Fig. 4-167

4.9.2 System components
4.9.2.1 Fuel control dial
140°
9×10°
1
Gear position 1
Gear position 10
25°
A
2
C
3 Leftmost position Rightmost position
RI
4
E
5 AM
N
TI
6 1 Yellow
5V
LA
2 Blue
VR
2
1 3
Red
3 0V
NY
ZX215-1002180
SA
Fig. 4-168
(1) Knob
(2) Dial
(3) Spring
(4) Ball
(5) Potentiometer
(6) Plug

Function
● Turning of the fuel control dial changes the
resistance of the sliding rheostat inside （%）
the dial and the voltage signal collected by 100
Dial angle
the controller. The controller calculates the
collected signals and drives the governor
motor via signal output and controls the in-
jection of the fuel pump so that the engine
can run at an optimal speed.
A
● When throttle voltage is beyond the area, 0 0.25 1.72 4.49 4.75 5（V）
Voltage (V)
the controller sends out alarm code and
C
ZX215-1002181
the engine runs at low idle. The area under
RI
the sloping line is the abnormality detection Fig. 4-169
area.
E
Remark:
The leftmost position is 0%; and the rightmost
position is 100%.
AM
N
TI
LA
NY
SA

4.9.2.2 Controller
SEHC-281A (Huaxing)
C A
E RI
AM
N
TI
J1-2（40 pins）
J1-1（81 pins） WT365-1304001
LA
Fig. 4-170
Controller ports
NY
SA
........
........ ...................
...................
........
........ ...................
...................
J1-2 J1-1 W365K-1304002
Fig. 4-171

Controller signal distribution
J1-1 J1-2
No. Signal name I/O No. Signal name I/O
1 Power ground 82 High/low speed shift valve
2 Power ground 88 Front pump proportional valve
3 Power ground 89 Rear pump proportional valve
4 Power（24V） Input 98 Bucket confluence valve
5 Power（24V） Input 99 Engine start control
11 Fuel level sensor signal Input 100 Shutdown delay signal
13 GPS detecting signal 101 Bucket solenoid valve
A
15 Throttle position signal Input 105 Throttle motor drive signal+
C
23 RX232 113 Throttle motor drive signal-
28 Air filter plugging sensor signal Input 114 Power ground
RI
30 Water temp sensor signal Input 115 Power ground
31 Oil temp sensor signal Input 116 Power ground
34 Fuel control dial signal Input 117 Power ground
38 Engine speed signal 118 Power（24V）
E
39 2RS 119 Power（24V）
40 RS AM120 Power（24V）
41 TX232 121 Power（24V）
42 2nd boost button signal
48 Engine oil pressure signal Input
49 L. travel pressure sensor Input
50 Bucket-dig pressure sensor Input
N
51 Boom-down pressure sensor Input

52 Arm-in pressure sensor Input
TI
Rear pump principal pressure

53 Input
sensor
54 Sensor power ground Input
LA

56 Sensor power Output
58 Monitor CAN low
60 Calibrator CAN high
65 Pilot switch
66 Coolant temp high Input
NY
67 R. travel pressure sensor Input

68 Swing pressure sensor Input
69 Bucket-dump pressure sensor Input
SA
70 Boom-up pressure sensor Input

71 Arm-out pressure sensor Input
Front pump principal pressure
72 Input
sensor
77 Monitor CAN low
78 Calibrator CAN high
79 Engine shutdown signal
80 Engine start signal

4.10 Electrical Control System
4.10.1 Control function
Engine - pump combination control
A
Pump control
C
RI
Valve control
E
AM Dual-speed Travel control
Electrical control system Engine preheat/overheat alarm

N
Low Engine oil pressure alarm

TI
LA
Auto deceleration/acceleration control
Engine speed calibration

NY
Self-diagnostic function
SA

4.10.2 Diagram of machine control system
Battery Battery relay drive

Fuel control dial
Fuse
Start switch Energizing signal Shutdown

delay relay
Power supply
Power supply
Power regulator valve signal 1
Preheating signal
Starting signal
A
Monitor controller Travel speed select signal
integration 11
C
CAN bus Right travel signal
Working mode signal 2
RI
Travel speed select signal Left travel signal
Signal monitoring info 3
Auto deceleration signal
Boom-up signal
Signal monitoring info
4
Boom-down siganl
5
E
Arm-in signal
6
Fuel level signal AM Arm-out signal
Fuel level sensor 7
Bucket-dig signal
8
Bucket-dump signal
9
Swing signal
10
Controller
N
HCU
TI
LA
R pump outlet press signal

12
F pump outlet press signal
13
F pump control signal
Start relay
14
R pump control signal
15
NY
16
Real throttle position
SA
Motor drive signal

Engine speed
feedback signal
PPC lock signal

Starting signal
Engine speed sensor Motor Potentiometer
Engine oil pressure

Eng oil press sensor
Safety relay Coolant temp signal
Eng coolant temp sensor
Battery charge signal
Charge indicator Alternator Engine
Start signal Air filter plugging switch

Start motor
Electric air heater
Preheater relay
Preheat signal W365413081
Fig. 4-172

2 R. travel pressure sensor
3 L. travel pressure sensor
4 Boom-up pressure sensor
5 Boom-down pressure sensor

PPC
6 Arm-in pressure sensor valve
7 Arm-out pressure sensor
8 Bucket-dig pressure sensor
A
Bucket-dump pressure sensor
9
C
10 Swing pressure sensor
RI
Frong pump oil feed device
Work equipment rotating device
E
11 AM
14
15
PPC basic pressure
13
N
12
PPC Rear pump Front pump Two-speed
16 proportional proportional solenoid
TI
lock valve
valve valve valve
LA
Port for each action control valve

Power limit
solenoid valve
Main valve
NY
Swing motor
Servo Servo
F R
SA
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.

4.10.3 Engine-pump combination control
Cab
Pilot valve
A B
Travel Travel MAX
Boom up/down
Arm in/out Bucket dig/dump
Swing
MIN
F1 F2 F3 F4 F5
Fuel control dial
A
Esc Enter
C
MC controller input
RI
H/S/L/B
Pressure
Cancel auto deceleration
sensor
Pilot oil pressure

Shift travel speed
Alarm output
E
AM
N
Main control valve

TI
Engine chamber
LA
Pressure
sensor
Controller
P2
P1
NY
Engine feed
Pump regulation
Pump proportional
pressure reducing
SA
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

Function
● This function allows operator to select a 10
working mode and change the engine pow-

er output according to the kind of job that
the machine is to be engaged. The working
modes include H, S, L and B. A selector
button on the monitor is available for selec-
tion of a working mode.
● Pump controller controls the pump so that
A
7
the pump is able to absorb all torques at

6
engine output point. These torques are
C
1
determined by the pump absorption torque
RI
9
specification, fuel control dial setting and

real engine speed under each mode.
Fig. 4-175
E
Technical specifications AM
H mode H
S
Engine power KW
Speed (rpm) ~1750 1750~1900 1900~2180 L

N
Power(KW) 143 159 174

TI
S mode
Speed (rpm) ~1750 1750~2180

LA
Power(KW) 133 166 Engine speed N

ZX335-1002051
L mode
Fig. 4-176
Speed (rpm) ~1850
NY
Power(KW) 150
H
S
SA
L, B
Pump flow Q
Pump output pressure P

ZX335-1002052
Fig. 4-177

Mode control methods
● Mode H
● H mode matching point: Rated speed
184kW/2180rpm
Engine torque T
● Engine speed decreases when pump load
increases and the pressure rises. In this
case, engine speed will be up to the prox-
A
imity of matching point, allowing pump con-
C
troller to reduce output. On the contrary,
when pump load reduces and the pressure
RI
Engine speed N
decreases, the pump controller will keep
ZX335-1002053
increasing pump output until engine speed
reaches the proximity of matching point. Fig. 4-178
E
AM Engine power KW
N
TI
LA
Engine speed N
ZX335-1002054
Fig. 4-179
NY
SA
Pump flow Q
ZX335-1002055
Fig. 4-180

● Power output percentage corresponding to 10
each mode
Mode H S L B
Power out-
put percent- 95% 90% 80% 80%
age
● The controller maintains the pump suction 7
force along the stable horse power curve 6
A
and controls engine speed through engine- 1
pump combination control.
C
9
RI
Fig. 4-181
E
H
AM S
Engine power KW
L
N
TI
Engine speed N
LA
ZX335-1002051
Fig. 4-182
NY
L, B
SA
Pump flow Q

ZX335-1002052
Fig. 4-183

4.10.4 Pump control function
Engine Pressure sensor Pressure sensor

Main pump
Injection Governor
pump motor F R
M
P Speed
A
Servo Servo
sensor
C
E RI
AM Valve Valve
Fuel control dial
(Control signal)
(Control signal)
Hi
(Engine speed signal)
Lo
N
TI
LA
Controller
Bucket DUMP signal
Boom DOWN signal

NY
Bucket DIG signal
Right travel signal

Left travel signal
Boom UP signal
Arm OUT signal
Arm IN signal
Swing signal
SA
W365413084
Fig. 4-184

Pump 1
delivery
amount
Boom RAISE PPC pressure

Pump 1
delivery
amount
A
Arm IN PPC pressure
C
Pump 1
delivery
RI
amount
Arm OUT PPC pressure

Pump 1
E
delivery Corresponding
amount AM delivery output
MAX
Bucket CURL PPC pressure

Pump 1
delivery
amount
N
TI
Bucket DUMP PPC pressure

Pump 1
delivery
amount
LA
Swing PPC pressure

Pump 1
delivery
amount
NY
L. Travel PPC pressure

SA
ZX215-1002197
Fig. 4-185

Pump 2
delivery
amount
Boom RAISE PPC pressure
Pump 2
delivery
amount
A
Arm IN PPC pressure
C
Pump 2
delivery
RI
amount
Arm OUT PPC pressure
E
Pump 2
delivery Corresponding
amount AM delivery output
MAX
Bucket CURL PPC pressure

Pump 2
delivery
amount
N
TI
Bucket DUMP PPC pressure
Pump 2
delivery
LA
amount
Boom LOWER PPC pressure

Pump 2
delivery
amount
NY
R. Travel PPC pressure

SA
ZX215-1002198
Fig. 4-186
Function charge amount and pilot pressure. During
combined operation, the set discharge amount
Use the work equipment and swing pilot pres-
of each operation shall be added.
sure signal directly as the hydraulic pump dis-
charge control signal. Pilot pressure is applied
on the valve stem and, on the other hand, Operation
is collected by the controller. The controller When the work equipment is operating, the
keeps the discharge amount of the hydraulic controller collects the signal of pilot pressure
pump at the specified value of the correspond- sensor, and determines the control discharge
ing pilot pressure according to the functional amount of pump 1 and pump 2 according to
relation between the set hydraulic pump dis- the pressure signal.
4.10.4.1 Constant power control
Function
● It is mainly used to calculate the theoreti-
cal maximum displacement. The system Q
employs constant power control. Two
Flow
Pump curve P-Q
regulators are interconnected hydraulically, P0
enabling synchronized operation of two PMax
actuators of the same specification at the
A
same time. Change of pump flow is deter-
PMax
C
mined by the sum P ∑ of working pressures
of both hydraulic pumps. So long as it sat- P
RI
isfies 2P0 ≤ P ∑ ≤ 2 PMax, the sum of powers Pressure
of both hydraulic pumps remains constant, ZX215-1002199
exceeding not the power of diesel engine. Fig. 4-187
E
Operation
AM
● When work equipment is working, the con-
troller collects throttle position signal and
gives a constant current in order to control
N
power of pump.
TI
4.10.4.2 ESS control

LA
Function
● Changing of the engine speed due to load change controls the pump power, and engine out-
put can be used more efficiently. (This function can also prevent the engine from losing con-
NY
trol when the machine is operating under harsh conditions (eg. high - altitude area).
Operation
SA
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.

4.10.5 Valve control function
Swing priority Bucket confluence
Main control valve
Engine Pressure sensor Pressure sensor

Main pump
A
Injection Governor
pump motor F R
C
M
RI
P Speed
Servo Servo
sensor
E
AM
(Throttle position feedback signal)
(Motor drive signal)
Valve Valve
N
Fuel control dial

Hi (Control signal)
(Control signal)
TI
(Engine speed signal)
Lo
LA
NY
Controller
A B
CAN bus
SA
Bucket DUMP signal
Boom DOWN signal

Bucket DIG signal
Right travel signal

Left travel signal
Boom UP signal
Arm OUT signal
Arm IN signal
Swing signal
F1 F2 F3 F4 F5
Esc Enter
W365413086
Fig. 4-188
● Bucket fl ow control
● Swing priority control

1) Bucket flow control

Swash plate angle
Function
Control the pump swash plate angle according Max
to the operation of bucket control lever.
Operation
Min Bucket joystick
When the bucket control lever is operated, the pilot pressure
controller collects the signal from the bucket
A
DUMP pressure sensor and bucket CURL ZX215-1002201
pressure sensor, and controls the bucket con-
C
Fig. 4-189
fluence proportional valve.
E RI
Bucket confluence
AM valve current
450mA
Bucket joystick
N
400mA
pilot pressure
TI
ZX305-1002202
Fig. 4-190
LA
2) Swing priority control
Function
NY
● Pressurized oil from pump 1 bypasses bucket 1 valve spool, and flows first to swing motor
valve spool to activate swing first.
SA
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

4.10.6 Dual travel speed control
Travel Motor
A
Regulator Regulator
C
Right travel pressure sensor
RI
Main Control Valve
Left travel pressure sensor
Travel Speed
Solenoid Valve
E
Engine
Injection Governor
AM
Pump Motor F Main Pump R
M
P
N
Servo Servo
TI
(Throttle position
feedback signal)
Fuel Control Dial

LA
Hi
(Control signal)
Lo
(Control signal)
NY
A B
SA
Controller F1
Esc
F2 F3
Enter
F4 F5
(CAN Bus)
W365413085
Fig. 4-191

Function
Travel mode control
Operation
● When travel mode is set to LOW, the angle
travel motor swashplate reaches its maxi-
mum and travel speed is slow.
● When the controller receives signal from
travel pressure sensor under the following
A
condition, it activates the solenoid valve.
C
The solenoid valve delivers pilot oil to the
travel motor swashplate angle control valve
RI
in order to reduce the angle to its minimum
and increase travel speed.
E
Operating condition AM
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
N
track, the pump control pressure on the side

TI
increases to enable fast running of the track.

When the machine is traveling under HIGH
mode, the travel mode cannot be changed
LA
even if work equipment is operated (work

equipment pressure sensor is turned ON).
NY
SA

4.10.7 Engine preheat/overheat alarm
Start switch
Heat
Preheat Relay Main Control Valve
C A
Engine Main Pump
RI
Governor motor
Coolant Temp F R
Sensor
E
M
P
AM Servo Servo
feedback signal)
(Throttle position
N
TI
(Control signal)
(Control signal)
LA
Hi
Lo
NY
SA
A B
Controller
(CAN bus)
F1 F2 F3 F4 F5
Esc Enter
W365413087
Fig. 4-192

1) Engine preheating
Function
● Preheat control
Operation
● The excavator starts preheating when it is powered on.
Operating condition
A
● Low temperature switch is closed; excavator is energized; auto preheating begins at starting.
C
RI
2) Engine overheat alarm
Function
E
● When coolant temperature is high (over 103℃ ) during operation, the monitor displays alarm.
Operation
AM
● 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.
N
TI
Operating condition
● Power on
LA
● Coolant temperature greater than 103℃
3) Alarm - low engine oil pressure
Function
NY
● 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
SA
the monitor. Receiving the alarm message, the alarm indicator lights up.

4.10.8 Auto deceleration/acceleration control
Right Joystick control

Boom Bucket
Engine
DOWN
DUMP
DIG
UP
Engine
throttle
controller
Swing Left Arm
A
Joystick
RIGHT
LEFT
OUT
Control
IN
Fuel Control Dial
C
RI
(Throttle signal)
Left travel Travel Right travel

Control
BWD
FWD
BWD
FWD
Levers
E
A B
AM
Controller
N
F1 F2 F3 F4 F5
CAN Bus
Esc Enter
Control lever signal

TI
ZX225-1002022
Fig. 4-193
LA
Function Speed (rmp)

Set speed
● When all control levers are in the neutral Drop 100 rpm
position, lower engine speed in order to re-

Auto deceleration
duce fuel consumption and noise.
NY
(1400rpm)
● When any control lever is operated, engine 3.2S

0.5S 0.5S
speed will be back to the setting of the fuel 0.2S

Time (s)
SA
Operated
control dial. Control lever
Unoperated Operated
ZX335-1002061
Fig. 4-194
Operation
● Engine speed will drop to the speed of gear position 1 (100 rpm lower than the set speed) 0.2
second after the control levers are placed in the neutral position. The engine will run at low
speed (1400 rpm) after another three (3) seconds. This can reduce void flow of hydraulic sys-
tem and wear of the engine, hence saving energy and reducing noise. When any control lever
is operated to resume the operation, the engine speed will be restored.
● When any control lever is operated during engine deceleration, engine speed will increase im-
mediately to the speed set by the fuel control dial.

4.10.9 Engine speed calibration function
Swing pripority Bucket confluence
Main valve
Pressure sensor Pressure sensor

Engine
Governor Main pump
A
Injection
pump motor F R
C
M
Speed
RI
P Servo Servo
sensor
E
AM
N
Fuel control dial

（Engine speed signal）
（Control signal）
（Control signal）
TI
Hi
Lo
LA
NY
Controller A B
SA
(CAN bus)
Bucket DUMP signal
Boom DOWN signal

Bucket DIG signal
Arm OUT signal
Boom UP signal
R. Travel signal
L. Travel signal
Arm IN signal
Swing signal
F1 F2 F3 F4 F5
Esc Enter
W365413088
Fig. 4-195

Function
Enter the maximum engine speed for each
working mode as a criteria for engine speed
control. Throttle Help Info
Operation
Current Gear N：
1. Auto calibration of engine speed requires
starting the engine. Engine Speed rpm：
2. Call the interface of System Information
A
Gear Position V：
and select Throttle Installation Aid.
C
A. Turn the fuel control dial to position 1. Throttle Position V：
RI
B. Press the key [F4] to start speed cali-
bration process.
s AUTO
rpm
E
C. Turn the fuel control dial after calibra-
n/min
tion. AM XP2051203013
D. Repeat step (2) to finish calibration of Fig. 4-196

speed at all positions.
E. Press the key [F5] or [ESC] to end
calibration.
N
TI
LA
NY
SA

4.10.10 System parts and components
1) Pump pressure sensor
Connector Housing Pressure joint

B
A C
C A
RI
Connection Diagram
E
Terminal No. Signal Name
AMA Power (+5V)
B Ground
C Output
N
W365-1304208
TI
Fig. 4-197
LA
Operation
● The illustration on the right shows the rela- (V)
tionship between the pressure acting upon
the sensor and the output voltage.
NY

Ӵᛳ఼䕧ߎ⬉य़

SA

(MPa)

⊍य़࡯
ZX335-1002067
Fig. 4-198

2) Pilot pressure sensor
Connector Housing Pressure joint

B
A C
C A
Connection Diagram
RI
Terminal No. Signal Name
A Power (+5V)
E
AM B Ground
Output
C
W365-1304208
Fig. 4-199
N
TI
Operation
● The illustration on the right shows the rela- (V)
LA
tionship between the pressure acting upon

the sensor and the output voltage.

Ӵᛳ఼䕧ߎ⬉य़

NY

SA

(MPa)

⊍य़࡯
ZX335-1002067
Fig. 4-200

3) Engine speed sensor
C A
2 1
ZX335-1002070
RI
Fig. 4-201
E
Function
AM
● 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 pro-
duce signal. Always tighten the engine speed sensor to the specific torque.
N
4) Engine oil pressure switch

TI
1
LA
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W365413089
Fig. 4-202
(1) Pressure detector Function

(2) Connector Engine oil pressure switch is mounted on the
delivery pipe of engine oil filter. It detects en-
gine oil pressure and sends generated pres-
sure signal or alarm signal to the controller.

5) Fuel level sensor
1 2 3 4
C A
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ZX215-1002246
Fig. 4-203
E
(1) Float AM
(2) Lever
(3) Shell
(4) Connector
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Function
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Signal from the sensor will be collected by the controller and displayed on the monitor. Resis-
tance output sensors like hydraulic oil temperature sensor, fuel level sensor and coolant tempera-
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ture sensor send signal to the controller. The controller collects, process and calculate voltage
signals and converts it into related information that will be displayed on the monitor.
Specifications
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Electrical parameters:
● Total resistance: 100Ω
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● 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

6) Coolant temperature sensor
C A
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ZX335-1002071
E
Fig. 4-204
Function
AM
The output resistance of engine coolant tem-
perature sensor changes with the tempera-
ture. The controller collects signal and works
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out a cooling temperature.

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4.11 Monitoring System
Monitor
A B
CAN signal
A
Controller
C
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F1 F2 F3 F4 F5
Esc Enter
E
AM
Each sensor
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Power
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Battery
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ZX335-1002073
Fig. 4-205
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● The machine condition is monitored by the ● Information on the monitor display includes
sensors mounted on different locations of primarily:
the machine. The controller processes the
1. Alert information in case of machine fail-
signals and transmits the signals to the
ure
monitor display, informing the operator of
the machine condition. 2. Operating condition (coolant tempera-
ture, hydraulic oil temperature, fuel level,
● The monitor panel also contains mode se- etc. )
lector, functional keys and machine opera-
tion control outputs.

4.11.1 Monitor
SECD_5I7D
$ %
C A
E RI
AM
F1 F2 F3 F4 F5
Esc Enter
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WX215-1204002H
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Fig. 4-206
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Outline IMPORTANT
● The monitor is used to display monitoring ● Technical specification allows a screen to
information and select a working mode. have not-more-than 10 dark spots (not il-
luminated) or bright spots.
● The monitor has a CPU (Central Process-
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ing Unit) which processes, displays, and ● It is normal to have blue bright spots on the
outputs information. screen when the monitor is on for a quite
period of time.
● The monitor uses a LCD (Liquid Crystal
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Display). ● It is normal to have blinking strips on the

screen when the monitor initializes.
Port I/O signals
No. Signal name I/O

1 Digital input A Input
3 CAN high
4 CAN low
8 Trigger power (24V)
9 Power supply (24V)
10 Ground
12 Ground

4.11.2 Monitor panel
NOTICE A A B
● Stop operation immediately when the

alert indicator is on. Check and repair
related parts.
● The monitor does not display all work- B
ing conditions of the machine.
A
● Do not solely depend on what is dis-
C
played on the monitor when maintain-
ing and checking the machine.
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F1 F2 F3 F4 F5
The monitor panel performs the functions of
E
monitoring and displaying, selecting a working C Esc Enter
mode, and switching on/off an electrical ele- AM

ment.
XP235-13001
Overview Fig. 4-207

The monitor consists of three parts:
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A: Alert indicators
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B: LCD display
C: Operation keys
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4.11.2.1 Alert and signal indicators

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Alert indicator
When the excavator has a problem, the alert
indicator flashes five times along with five
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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

4.11.2.2 LCD display

When start switch of excavator is turned to
the ON position, the monitor is energized by
machine batteries and enters the initializing
Sany Hydraulic Excavator
screen. As shown by the figure on the right, a
fully displayed screen includes the following 1 S 1 10
information:
2
(1) Working mode
C H
(2) Coolant temperature gauge
A
(3) Fuel level gauge 3
C
E F
(4) Failure code
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4 9
(5) Total service hours 0032h25m
11/11/01 8
5 E101 09:32:24 7
(6) Function icons 6 s AUTO
n/min
E
(7) Local time AM XP235-13003
(8) Local date Fig. 4-209
(9) GPS signal indication
(10) Engine speed level
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Coolant temperature gauge

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There are a total of 13 segments (yellow) for

the full range from zero to 120 degrees.
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A: When the engine is just started.

B: When temperature is between zero and 110
degrees. A
C: When temperature is over 110 degrees,

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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
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degrees, the alert indicator goes off auto-

matically.
B
C
XP235-13004
Fig. 4-210

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.
A
C: Fuel level is 100%.
C
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B
E
AM
C
XP235-13005
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Fig. 4-211
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4.11.2.2 Operation keys

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The operation keys include function keys and

navigation keys.
A F1 F2 F3 F4 F5
A: Function keys
Esc Enter
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B: Navigation keys B
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XP235-13006
Fig. 4-212

Function keys
There are five function keys, i.e. F1, F2, F3, F4 and F5. These keys are defined by the icons dis-
played above them.
● Function of the same key may vary as the icon above it changes.
● A key is disabled when no icon is displayed above it.
Common icons and corresponding keys are given in the following table.
A
Icon dis-
Function keys Functions Display range
played
C
F1 s Change working mode. H→S→L→B
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F2 AUTO
n/min Shift to full speed/auto idling. Full speed/auto idling
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F3 Shift to high/low travel speed. High/low speed
F4 Enter an option/setup item.

AM Same as the Enter key
View system information. ——

F5
Back to previous page. Same as the ESC key
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Operation keys
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Operation keys Functions
Enter Enter an option/setup item.

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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.
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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.

4.11.3 Monitor display and operation

Sany Hydraulic Excavator
4.11.3.1 Default page
S 1
Default page is shown during normal operation
of the excavator.
C H
Operation
1. Working mode
Press the key F1 to change working mode E F
A
to H, S, L or B in a cycle manner. 11/11/01
0032h25m
C
E101 09:32:24
H mode - Heavy-duty operation
s AUTO
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n/min
S mode - Standard operation

XP235-13007
L mode - Light-duty operation Fig. 4-213
E
B mode - Breaker operation
NOTE: S is the default mode after the machine
is powered on.
AM
2. Selecting auto idling 3. Selecting high/low travel speed
Press the key F2 to disable/enable auto idling Press the key F3 to switch between high and
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function. low travel speeds. When the symbol ap-

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pears above the key F3 , press the key to

When the icon appears above the key F2 ,
AUTO
select high speed travel; when the symbol

n/min
press the key to disable auto idling; when the

appears above the key F3 , press the key to
icon appears above the key F2 , press the
LA
select low speed travel.

n/min
key to enable auto idling.

NOTE: When the machine is powered on, low
NOTE: When the machine is powered on, auto
speed is the default travel speed.
idling is enabled as default.
4. Viewing failure information
● Auto idling is active as default. When all
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control levers are in neutral position for When alert indicator of the monitor is on, a fail-
more than 0.2 seconds, engine speed will ure code will appear on bottom line of monitor
drop by 100 rpm immediately and then screen. Meanwhile, a red tick appears above
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enter auto idling after another 3 seconds the key F4 . Press the key to see failure infor-
(controller will reduce engine speed to mation.
idling) in order to reduce fuel consumption
5. Viewing system information
and noise.
Press the key F5 to see system information.
● In idling, if the controller detects any ma-
neuver or gear change, engine speed will NOTE: To see system information requires
restore respective level. password. Please contact your Sany distribu-
tor.

4.11.3.2 Password entry to system information
Press F5 on the default page to enter the

password entry to system information. You
need to enter the correct password prior to ac-
System Information
cess to System Information.
Key operation
Please enter password:
● Press F1 or or to increase or de-
crease the number on the digit with the
A
cursor.
C
● Press F2 or or to move the cursor to
the left or right digit.
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● Press F3 to enter System Unlock.
● Press F4 to enter Backlight Adjustment.
E
● Press F5 or ESC to return to the default AM XP235-13008
page.
● Press Enter to check the validity of pass- Fig. 4-214
word. If the password is valid, you have ac-
cess to the Main Menu.
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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 Infor-
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mation. Main Menu

This page contains a list of system functions.
You can pick up an item and enter respective Operating Information
page. Failure Information

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Throttle Help Info

Key operation Language Selection
SYS Clock Setup
● Press F1 or or to scroll up or down
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GPS Information
the menu. When you scroll down the
menu, the highlight returns to the top item
Running parameters of engine,
after the bottom one. main pump and main valve.
● Press F2 or Enter to enter highlighted item.

● Press F4 to go to System Setup.
XP1251203007
● Press F5 or ESC to return to the default
page. Fig. 4-215

4.11.3.4 Engine & throttle signals

Select Running information on the Main Menu
and press F2 or Enter to see Engine & Throttle
Signals. Engine & Throttle Signals
This page contains operating parameters of

Coolant Temp ℃：10
engine and throttle signals.
Fuel Level %：10
Key operation Eng Oil Press kPa：10
● Press F1 to see Pilot Pressure Signals. Throttle Gear N：10
A
Engine Speed rpm：10
● Press F5 or ESC to return to the Main
C
Menu. Gear Position V：10
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Throttle Position V：10
E
AM XP1251203008
Fig. 4-216
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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.
This page shows pilot pressure signals. Pilot Press Signals
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Boom UP kg：10
Key operation Boom DOWN kg：10
● Press F1 to see Main Pump & Main Valve Arm IN kg：10
Signals. Arm OUT kg：10

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Bucket DIG kg：10

Bucket DUMP kg：10
Menu.
Swing kg：10
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Left travel kg：10
Right Travel kg：10
XP2051203009
Fig. 4-217

4.11.3.6 Main pump & main valve signals

Press F1 on the page of Pilot Pressure Sig-
nals to see Main Pump & Main Valve Signals.
This page shows main pump and main valve Main Pump & Main Valve
signals.
Pump_1 Main Press Kg：10
Pump_2 Main Press Kg：10

Key operation
Prop Valve_1 Current mA：10
● Press F1 to see Engine & Throttle Signals.
Prop Valve_2 Current mA：10
A
● Press F5 or ESC to return to the Main Bucket Confl valve ○
Menu.
C
Swing Priority valve ○
Boom Priority valve ○
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High/Low Speed Shift ○
E
AM
Fig. 4-218
XP2051203010
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4.11.3.7 Failure codes

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Select Failure Codes on the Main Menu and

press F2 or Enter to enter the page.
This page contains failure codes and failure Failure Information
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information. Current failure code：E101

E101：Controller failure
E102：Controller temp abnormal
Key operation E103：Sensor power abnormal
E202：Voltage high
E203：Backup battery volt low
● Press F1 to see next page of failure codes. E401：CAN bus abnormal
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E501：Fuel control dial abnormal

H101：F. pump press abnormal
● Press F5 or ESC to return to the Main H102：R. pump press abnormal
H105：F. pump valve current abnormal
Menu. H108：R. pump valve current abnormal

H112：Backup pilot press abnormal
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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

4.11.3.8 Throttle help information

Select Throttle Help Info on the Main Menu
and press F2 or Enter to enter the page.
This page contains help information for throttle Throttle Help Info
installation.
Current Gear N：
Key operation
Engine Speed rpm：
● Press F2 to select auto idling or full speed.
A
● Press F3 to select high or low speed travel. Gear Position V：
C
● When SYFCS controller is used, the icon Throttle Position V：
rpm will appear in blue or red color.
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Menu. s AUTO
n/min
rpm
E
Note: Only a SYFCS controller allows the
XP2051203013
change of rpm between blue and red colors.
AM
Fig. 4-220
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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 Language Selection
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system.
Key operation
中文系统
● Press F2 to select Chinese System ( 中文 English Systems
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系统 ).
● Press F3 to select English System.
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Menu.
● Press or to highlight a language up
中文 Eng
or down the list.
XP2051203014
Fig. 4-221

4.11.3.10 System clock setup

Select System Clock Calibration on the Main
Menu and press F2 or Enter to enter the page.
This page is used to set up system clock. SYS Clock Setup
Key operation Local time and time zone：
● Press or to increase or decrease the 1234·12·12 12:12：12 12W
number on the digit with the cursor.
A
Time and time zone setup：
● Press or to move the cursor to the 1234·12·12 12:12：12 12W
left or right digit.
C
● Press F1 or Enter to finish calibration. You
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will be prompted by “Calibration finished!
Use [↑][↓][←][→] to set p system clock.
Please restart your machine.”
E
● Press F5 or ESC to return to the default
page. AM XP2051203015
NOTE: System clock can only be set up once Fig. 4-222

after the machine is powered on. When the
machine is powered on, the prompt of suc-
cessful calibration remains on the screen if
N
you press F1 or the Enter key.

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4.11.3.11 GPS information

Select GPS Information on the Main Menu and
press F2 or Enter to enter the page.
This page shows GPS monitoring information. GPS Information
Longitude °：121.0W
Key operation Latitude °：31.40N
Press F5 or ESC to return to the default page. Altitude m：28.79P

Velocity Km/h：4.037
Number of Satellites ：0006
Note:
A
Communication Indicator ：1023
1. The letter “E” stands for East Longitude
C
Signal to noise ratio 1： dB
and “W” for West Longitude. Signal to noise ratio 2： dB
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2. The letter “N” stands for North Latitude
and “S” for South Latitude.
E
3. The letter “P” stands for a height above
the seal level and “N” for a height below AM XP20512003026
the seal level.
Fig. 4-223
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.
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5. If the elevation value is not zero and no

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value is displayed for the longitude and lati-

tude, GPS data are being received but the
location has not been precisely defined yet.
LA
6. When the communication signal is 1023,

GPRS communication is regular. When it
is 615, the GPRS communication is abnor-
mal.
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7. When the communication signal changes

from 7 to 0, the SIM card or the antenna
has a bad connection.
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from 15 to 0, GPRS service is not available,
the SIM card has insufficient fund, or GPRS
network is abnormal.
from 31 to 0, the monitoring center is
closed.
10. This page is required for remote system
locking, remote system unlocking and re-
mote downloading.

4.11.3.12 System setup

Press the key F4 on the Main Menu to enter
System Setup.
This page is used to configure your machine. System Setup
Note: Access to System Setup requires en-

tering the password. For method of entering Machine Configuration
password see “Password entry to system Service Hour Setup
information” on page 4-202. Machine Configuration Setup
A
Hydraulic Oil Temperature
Key operation
C
● Press F1 or or to scroll up or down the
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menu. When you scroll down the menu,
the highlight returns to the top item after
the bottom one.
E
● Press F2 or Enter to enter highlighted item. AM XP2051203016
Menu. Fig. 4-224
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4.11.3.13 Machine configuration

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Select Machine Configuration on the Main

Menu and press F2 or Enter to enter the page.
This page shows machine configuration infor-
LA
Machine Configuration
mation.
Note: Access to System Setup requires en- Machine Model： SY215C \V217
tering the password. For method of entering

Machine S/N： 11SY0216 00008
password see “Password entry to system
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information” on page 4-202. Engine Model： CUMMINS_II
Key operation HYD SYS Model： KPM_P

SA
● Press F5 or ESC to return to System Set- Control SYS： KC-MB-001

up.
Note: “V217” following machine model is
software version.
XP2051203018
Fig. 4-225

4.11.3.14 Service hour setup

Select Service Hour Setup on the page of Sys-
tem Setup and press F2 or Enter to enter the
page. Service Hour Setup
This page is used to set up service hours of
the machine. Current Service Hours ：
100 h 50 m
Note: Access to System Setup requires en-
tering the password. For method of entering
Service Hour Setup ：
A
100 h 50 m
information” on page 4-202.
C
Key operation
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● Press F1 or Enter to save the change af- Use [↑][↓][←] and [→] to set up service hours.
ter calibration. You will see on the screen
E
“Calibration finished! Please restart your
machine.” AM XP2051203021
● Press F5 or ESC to return to System Set- Fig. 4-226

up.
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4.11.3.15 Machine configuration setup

Select Machine Configuration Setup on the
page of System Setup and press F2 or Enter
to enter the page. Machine Configuration Setup
This page is used to set up machine configu-

Machine Model：SY215C\GPS 32
ration after monitor installation.
Note: Access to System Setup requires en- Engine Model：CUMMINS_II
tering the password. For method of entering HYD SYS Model：KPM P

A
information” on page 4-202. Controller Model：KC-MB-001
C
Machine S/N：11SY0216 00008
Key operation
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● When “215” after machine model is Use [↑][↓][←] and [→] to change machine S/N.
blinking, each pressing of F1 will bring the Model Eng Hyd Ctrl
E
number up by 10; when “32” after GPS
is blinking, each pressing of F1 will bring AM XP2051203023
the number up by 10.
Fig. 4-227
● Press F2 to change Engine Model.
● Press F3 to change Hydraulic System
N
Model.
● Press F4 to change controller model.
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● Press F5 to save the change. You will

see on the screen “Calibration finished!
LA
Please restart your machine.”

● Press or to increase or decrease the
selected machine S/N by 100.
● Press or to increase or decrease the
NY
selected machine S/N by 1. Depress the

key to increase S/N quickly.
● Press ESC to return to System Setup.
SA
● 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.

4.11.3.16 Hydraulic oil temperature

Select Hydraulic Oil Temp on the page of Sys-
tem Setup and press F2 or Enter to enter the
page. HYD Oil Temp
This page shows temperature of hydraulic oil.
Hydraulic Oil Temp ℃：49
Key operation
● Press F5 or ESC to return to System Set-
up.
C A
E RI
AM
Fig. 4-228
XP2051203028
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4.11.3.17 Screen brightness setup

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Press F4 on the page of password entry to

system information to enter the page.
This page is used to adjust backlight bright- Screen Brightness Setup
LA
ness of the screen.

Screen Brightness：20%
Key operation
● Press F1 to dim backlight.
NY
● Press F2 to enhance backlight.

● Press F3 to safe brightness change.
SA
● Press F5 to return to System Information.

Press F3 to save setup！
XP2051203029
Fig. 4-229

4.11.3.18 System lockout (level 1)

When this page appear on monitor, it indicates
that the excavator is locked out in level 1.
System Lockout
Key operation
● Press F5 to enter the page for unlocking.
Machine Model：SY205C
NOTE: After 5 seconds according to the com- Machine S/N：00008
mand, corresponding state (Level 1 lockout, Lockout State：Level 1
level 2 lockout or no lockout) will be displayed.
A
Current time：12：12：11
(Waiting for 5 seconds performs a function of
C
filtration.)
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System Locked
Contact your Sany distributor to unlock your machine.
E
AM
Fig. 4-230
XP2051203024
4.11.3.19 System lockout (level 2)

N
When this page appear on monitor, it indicates

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that the excavator is locked out in level 2.

System Lockout
Key operation
LA
● Press F5 to enter the page for unlocking. Machine Model：SY205C
Machine S/N：00008
NOTE: After 5 seconds according to the com- Lockout State：Level 2
mand, corresponding state (Level 1 lockout, Current time：12：12：11
level 2 lockout or no lockout) will be displayed.
NY
(Waiting for 5 seconds performs a function of

filtration.)
SA
System Locked
Contact your Sany distributor to unlock your machine.
XP2051203025
Fig. 4-231

EA
G RIC
E
PAAM
KNTI
ANLA
BLNY
SA

E CA
G RI
ME
PAA
IN
AT
K
ANL
Y
BSLAN

SY365(B)H-9 Crawler Hydraulic Excavator Standard Values
Standard Values
C A
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5 Table of Standard Values
5.1 Standard Values for Engine-Related Parts .............................................................. 5-3
E
5.2 Standard Values for Chassis-Related Parts ............................................................ 5-4
AM
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Standard Values SY365(B)H-9 Crawler Hydraulic Excavator
C A
E RI
AM
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5 TABLE OF STANDARD VALUES
5.1 Standard Values for Engine-Related Parts
Applicable Models SY365(B)H-9

Engine ISUZU AA-6HK1-XQP-01
Standard values for
Item Measurement condition Unit Repair limits
A
new machine
High idling rpm 2,250 ± 25 2,250 ± 25
C
Engine speed Low idling rpm 1,050 ± 25 1,050 ± 25
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Rated speed rpm 2,000 2,000
Intake pressure
Air cleaner outlet location kPa Min 133 Min 133
(Negative
E
Arm-in relief ＋ max rpm {mmH2O} {Min 1,000} {Min 1,000}
pressure)
Exhaust color At sudden acceleration
At high idling
AM
Bosch
Index
Max 25
—
35
—
Valve clear- Intake valve mm 0.4 0.3– 0.5
ance Exhaust valve mm 0.4 0.3 – 0.5
N
Compression Oil temp：75℃ Mpa Min 3.0 2.5

pressure Engine speed 250 rpm {kg/cm2} {31} {26}
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Blow-by pres- Coolant temp：working range arm- kPa Max 0.98 1.96
sure in relief ＋ max rpm {mmH2O} {Max 100} {200}
LA
MPa Min 0.29 0.25

High idling
Engine oil pres- {kg/cm2} {Min 3.0} {2.5}
sure MPa Min 0.10 0.07
Low idling
{kg/cm2} {Min 1.0} {0.7}
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Engine oil temp Full speed range (in oil pan) ℃ 80 – 110 120
Between fan belt pulley and alterna-

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Fan belt ten- tor belt pulley

mm 8.5 Min 7，Max 10
sion Deflection when pressed with finger
force of 58.8 N {6 kg}
Between fan belt pulley and com-

A/C compres- pressor belt pulley
mm 5–8 5–8
sor belt tension Deflection when pressed with finger
force of 58.8 N {6 kg}

5.2 Standard Values for Chassis-Related Parts

Standard Value
cate- Permissible
Item Measurement Condition Unit for New Ma-
gory Value
chine
● Engine coolant temperature: Within
operational range
● Hydraulic oil temperature: Within
A
2 pumps at relief operational range rpm 2,050±50 2,050±50
● Engine running at high idle
C
● Heavy-load operating mode (H)
Engine Speed
● Arm-in relief condition
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● Engine coolant temperature: Within
operational range
● Hydraulic oil temperature: Within
E
2 pumps at relief +
operational range
boosting (if avail- rpm 2,050±50 2,050±50
able)
● Heavy-load operating mode (H)
AM
● Arm-in relief condition + boost switch
on
Speed when auto ● Engine running at high idle
N
deceleration is op- ● Auto idling switch on rpm 1,350±50 1,400±100

erated ● All control levers neutral
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Raise mm 11.5±0.5 11.5±0.5

Boom control valve
Lower mm 9.5±0.5 9.5±0.5
● Engine stopped
Spool Stroke
LA
● For measur- In mm 11.5±0.5 11.5±0.5

Arm control valve
ing points see Out mm 9.5±0.5 9.5±0.5
Control Valve
Bucket control valve Curl/dump mm 9.5±0.5 9.5±0.5
on page 3-10.
Swing control valve Travel (L&R) mm 9.5±0.5 9.5±0.5
NY
Travel control valve Forward & Reverse mm 9.5±0.5 9.5±0.5

Boom control lever mm 85±10 85±10
Arm control lever ● Engine stopped mm 85±10 85±10
SA
● Control lever grip at center

Bucket control lever ● Max. reading up to stroke end (except mm 85±10 85±10
Travel of Control Lever
Swing control lever lever play in NEUTRAL position) mm 85±10 85±10

Travel control lever mm 115±12 115±12
● Engine stopped
● Slightly push
Work Equipment mm Max 15 Max 20
the control lever
with your hand.
Play of control lever Stop pushing
when you feel
clear resistance Travel mm Max 20 Max 25
● Max. reading up
to stroke end


Cate- Standard Value for Permissible
Item Measurement Condition Unit
gory New Machine Value
Boom control Max 19.6 Max 24.5
Operating Force of Control Lever and
lever {Max 2.0} {Max 2.5}

Arm control Max 19.6 Max 24.5
● Hydraulic oil temp：Within op-
Bucket con- erational range Max 15.6 Max 21.6
trol lever {Max 1.6} {Max 2.2}
Pedal
● Engine running at high idle N
A
Swing control ● Control lever grip at center {kg} Max 15.6 Max 21.6
C
lever ● Pedal at tip {Max 1.6} {Max 2.2}
● Max reading at stroke end
RI
Travel control Max 30.4 Max 39.2
Travel control Max 93.1 Max 107.6
E
pedal {Max 9.5} {Max 11}
● Hydraulic oil temp：Within op- AM
erational range
Unloaded 3.5 ± 1.0 3.5 ± 1.0
● Working mode：H
pressure {36 ± 10} {36 ± 10}
● Hydraulic pump output pressure
with all control levers in neutral
N
position
TI
Boom relief 34.3 ± 1.0 33.3 – 35.3

erational range {350 ± 10} {340 – 360}
● Operate corresponding control
lever after the engine runs at 34.8 ± 1.0 33.3 – 36.8
Arm relief
LA
high idling speed. {355 ± 10} {340 – 375}

Hydraulic Pressure
● Working mode：H
● Hydraulic pump output pressure 34.8 ± 1.0 33.3 – 36.8
Bucket relief with all measurement circuits {355 ± 10} {340 – 375}
MPa
relieved
{kg/cm2}
NY
● Hydraulic oil temp：Within op- 25.5 ± 1.0 24.5 － 27.5

Swing relief erational range {261 ± 10} {250 － 280}
● Operate corresponding control
lever after the engine runs at
SA
high idling speed.

● Working mode：H 33.4 ± 1.0 32.4 – 34.4
Travel relief
● Hydraulic pump output pressure {342±10} {330 – 351}
with all measurement circuits
relieved
erational range
Control circuit
● Engine running at high idle 3.9±0.2 3.7 – 4.1
source pres-
● Self pressure reducing valve {40±2} {37 – 41}
sure
output pressure with all control
levers in NEUTRAL position

Cate- Standard Value

Permissible
Item Measurement Condition Unit for New Ma-
gory Value
chine
● Hydraulic oil temp：Within operational range
Swing brake angle

● Working mode: H
degree Max 100 Max 130
● Swing circle misalignment amount when stopping
mm (—) (—)
after one turn
● For measuring posture see Swing 1 on page
A
3-10.
C
● Hydraulic oil temp：Within opera-
Time taken to start
tional range 90° sec. 3.1 ± 0.3 Max 3.7
RI
swing
● Working mode: H
● Time required for passing points
E
90° and 180° from starting point
● For measuring posture see Swing 180° AM sec. 4.4 ± 0.4 Max 5.5
1 on page 3-10.
Time taken to swing

Swing
● Working mode: H
+4
● Time required for 5 turns after making initial one sec. 31 Max 35
N
-2
turn
● For measuring posture see Swing 1 on page
TI
3-10.
● Engine stopped
LA
Hydraulic drift
● Keeping the upper structure transverse on a

grade of 15° . For more information see Swing 2
on page 3-10. mm 0 0
● Notching a mating mark on inner and outer races
of the swing circle
NY
● Mating mark misalignment amount during 5 min-

utes.
Motor leak-

SAage
● Swing lockout switch: ON ml/min Max 5 Max 10

● Leakage amount for one minute during swing
relief
tional range
● Engine running at high idle Lo 11.8± 3 8.8-14.8
Travel speed
(unloaded)
● Working mode: H
Travel
● Time required for track shoes to

sec.
make 5 turns after making one
initial turn
● For more information on measur- Hi 7.6 ± 3 4.6-10.6
ing posture see Travel 1 on page
3-11.


Standard
Cate- Permissible
Item Measurement Condition Unit Value for New
gory Value
Machine

Travel speed
Lo 22 ± 2.5 19.5-24.5
(Actual run)
● Working mode: H
● Level ground sec.
● Time required for traveling 10 m after 10 m trial
A
run Hi 14 ± 2.5 11.5-16.5
● For measuring posture see Swing 2 on page 3-10.
C
RI
● Working mode: H
Deviation
● Travel Speed: Low

● Hard level ground mm Max 800 Max 900
E
● Amount of deviation (χ) while traveling 20 m after ini-
Travel
tial 10 m trial run

AM
● For measuring posture see Travel 2 and 3 on page
3-11.
Hydraulic drift
● Engine stopped
● Park the machine on a grade of 12° , with the sprock-
N
mm 0 0
et in the downhill direction
TI
● Measure the sliding distance for 5 minutes

● For measuring posture see Travel 4 on page 3-12.
travel motor
amount of
LA
Leakage

● Traveling with the sprocket locked mm 13.6 27.2
● Oil leakage amount for one minute with traveling in re-
lief condition
NY
Bucket
● Hydraulic oil temp: Within operational range

tips
mm Max 600 Max 900

● Flat and level ground
● Bucket full of earth or with rated load (0.8m3: 1,440 kg)
SA
● Boom horizontal, arm fully retracted and bucket cylin-

cylinder
Arm cylin- Boom
der fully extended

mm Max 20 Max 27
Work Equipment
● Engine stopped
Hydraulic drift
● Work equipment control lever in neutral position

● Measure total amount of falling for 15 minutes by mea-
suring the falling every 5 minutes immediately after ini-
der
mm Max 20 Max 20
tial setting
★ Bucket tip lower distance
★ Boom cylinder: Cylinder retracting distance
Bucket cylinder
★ Arm cylinder: cylinder extending distance

★ Bucket cylinder: cylinder retracting distance
mm Max 35 Max 40
● For measuring posture see Work Equipment 1 on page
3-12.


Cate- Standard Value for Permissible
gory New Machine Value
erational range
● Working mode: H
Boom ● Time required for the bucket UP sec. 3.8 ± 0.3 Max 4.8
A
to raise from the ground to its
stroke end
C
● For measuring posture see
RI
Work Equipment 2 on page
3-12.
IN sec. 3.5 ± 0.3 Max 4.5
E
erational range
Work Equipment Speed
● Engine running at high idle AM

Work Equipment
● Working mode: H
Arm ● Time required from dumping
stroke end to digging stroke end OUT sec. 3.0± 0.3 Max 3.5
N

TI
3-13.
● Hydraulic oil temp：Within op- DIG sec. 3.1 ± 0.3 Max 3.4
LA
erational range
● Working mode: H
Bucket ● Time required from dumping
NY
stroke end to digging stroke end DUMP sec. 2.0 ± 0.3 Max 2.3
SA
3-13.

Cate- Standard Value Judgement

gory for New Machine Criteria
tional range
● Engine running at low idle
● Working mode: H
● Time required from maneuvering
Boom the joystick to the moment that the sec. Max 1.0 Max 1.2
A
bucket reaches the ground and
begins to push the machine up-
C
ward, within 50 mm off the ground
● For measuring posture see Work
RI
Equipment 5 on page 3-13.
tional range
E
Time Delay

● Working mode: H
AM
Work Equipment
Arm ● Average time required for operat- sec. Max 2.0 Max 2.8
ing the control lever back and forth
till the arm starts to move
N

TI
tional range
● Working mode: H
LA
Bucket ● Average time required for operat- sec. Max 1.0 Max 3.6
ing the control lever back and forth
till the arm starts to move
NY

Internal Leakage
Cylinders tional range 5 20

Central ml/min
SA
● Leakage amount for one (1) min-

Swivel ute with cylinder or travel mea- 10 50
Joint sured at relief condition
Performance in Combined
tional range
Amount of devia-
● Working mode: H
Operations
tion in simultane-
● Travel Speed: Low
ous operation of mm Max 200 Max 220
● Amount of deviation measured for
work equipment
20 m after traveling about 10 m on
and travel
a hard level ground
● For measuring posture see Travel
2 and 3 on page 3-11.

Machine attitudes applicable to perfor-

mance test and testing procedure of all
machine models
Control valve: Spool stroke
C A
RI
ZX335-1003002
E
Fig. 5-1
Swing 1: Swing brake angle, time taken to

AM
start swing and time taken to swing
N
TI
LA
ZX335-1003004
Fig. 5-2
NY
Swing 2: Hydraulic drift of swing

SA
15°
Sprocket
ZX335-1003006
Fig. 5-3

Travel 1: Travel speed (without load)
C A
ZX335-1003003
Fig. 5-4
RI
Travel 2: Travel speed (actual run), Travel de-
E
viation
AM 45°
N
TI
ZX335-1003005
LA
Fig. 5-5
Travel 3: Travel deviation

NY
SA
10m
ZX335-1003007
Fig. 5-6

Travel 4: Hydraulic drift of travel
12°
C A
ZX335-1003008
RI
Fig. 5-7
Work equipment 1: Hydraulic drift of work
E
equipment
AM
N
TI
LA
ZX335-1003010
Fig. 5-8
Work equipment 2: Boom speed

NY
SA
ZX335-1003012
Fig. 5-9

Work equipment 3: Arm speed
CA
ZX335-1003009
Fig. 5-10
RI
Work equipment 4: Bucket speed
E
AM
N
TI
LA
ZX335-1003011
Fig. 5-11
Work equipment 5: Boom delay

NY
SA
ZX335-1003013
Fig. 5-12

Work equipment 6: Arm delay
C A
ZX335-1003014
RI
Fig. 5-13
E
Work equipment 7: Bucket delay
AM
N
TI
LA
ZX335-1003015
Fig. 5-14
NY
SA

EA
G RIC
E
PAAM
KNTI
ANLA
BLNY
SA

E CA
G RI
ME
PAA
IN
AT
K
ANL
Y
BSLAN

SY365(B)H-9 Crawler Hydraulic Excavator Testing and Adjusting
Testing and Adjusting
C A
RI
6 Testing and adjusting
6.1 Engine Speed - Test and Adjust............................................................................... 6-3
E
6.2 Exhaust Gas Color - Test ......................................................................................... 6-5
AM
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
N
6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13

TI
6.5.1 Testing.......................................................................................................... 6-14

6.5.2 Adjusting ...................................................................................................... 6-18
LA
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
NY
6.8 Track Tensioner - Test and Adjust .......................................................................... 6-21

6.8.1 Testing.......................................................................................................... 6-21
SA
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
Testing and Adjusting SY365(B)H-9 Crawler Hydraulic Excavator
6.14 Hydraulic Drift of Work Equipment - Test ............................................................. 6-34

6.15 Remaining Pressure in Hydraulic Lines - Relieve................................................ 6-36
6.16 Oil Leakage Amount - Test................................................................................... 6-37
6.17 Air in Each Component - Purge ........................................................................... 6-41
C A
E RI
AM
N
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LA
NY
SA

6 TESTING AND ADJUSTING

6.1 Engine Speed - Test and Adjust
Testing
Start the engine and keep the engine running
until coolant temperature enters operational Main Menu
range. Key in the password on the monitor
A
and check if the engine speed is normal in Operating Information
each gear position. Failure Information
C
Throttle Help Info
Testing Items: Language Selection
RI
SYS Clock Setup
1. Engine speed at low idle
GPS Information
2. Engine speed at fuel control dial position
E
11 (H and S modes) Running parameters of engine,
AM 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
XP1251203007
Fig. 6-1
N
TI
LA
NY
SA

Calibration
1. Preconditions for auto speed calibration:
A. Start the engine.
Throttle Help Info
B. Check the throttle position voltage for
gear position 1 on the Throttle Help Info
page on the monitor. Normal voltage Current Gear N：
should be 1.3±0.3V under normal
speed range of 1050±50. If the voltage Engine Speed rpm：
is out of the specified range, manually
A
Gear Position V：
adjust the throttle pull rod. Otherwise
C
abnormality would occur in speed Throttle Position V：
calibration and a red question mark“?”
RI
would appear after Engine Speed on
the Throttle Help Info page on the
monitor.
s AUTO
n/min
rpm
E
2. Enter the speed calibration page. AM XP2051203013
Press F5 on the default page of monitor Fig. 6-2

and key in the password to access the
Main Menu. Choose Throttle Help Info on
the Main Menu to enter the page like the
N
figure on the right.

TI
3. Speed calibration
Press F4 on the Throttle Help Info page to
execute speed calibration. The system en-
LA
ters speed calibration (when the icon turns

red) and it automatically shifts to full speed
(when the icon turns red).
4. Successful calibration
NY
If the calibration is done successfully, the

icon for calibration indication turns blue.
SA
The switching to full deceleration requires

pressing F2 to switch it manually.

6.2 Exhaust Gas Color - Test
● Tools used for testing exhaust gas color
No. Part Name

1 Smoke meter
2 Opacimeter
A
CAUTION
C
● Be careful not to touch any hot part
RI
when installing or removing a testing
equipment.
E
1. Testing with smoke meter AM
A. Put the filter paper in the smoke meter.
B. Insert the waste gas intake pipe into
the exhaust pipe.
N
C. Start the engine and keep the engine

running until engine coolant tempera-
TI
ture is within the operational range.

D. When engine speed increases sud-
LA
denly or is kept at high idle, direct

ZX335-1004002
exhaust gas through smoke meter to
the filter paper. Fig. 6-3
E. Remove the filter paper from the smoke
meter. Read the smoke value through
NY
the apparatus provided.

F. Remove the testing tools after testing.
SA
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

B. Open the opacimeter and preheat it for

about 15 minutes.
C. Start the engine and keep the engine
running until engine coolant tempera-
ture is within the operational range.
D. When engine speed increases sud-
denly or is kept at high idle, use the
opacimeter to read the smoke value of
exhaust gas.
A
E. Remove the testing tools after testing. ZX335-1004004
C
Make sure the machine goes back to Fig. 6-5
its normal state.
E RI
AM
N
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LA
NY
SA

6.3 Valve Clearance - Adjust
● Service Standard (Unit: mm)

Correction meth-
Location Service Item Standard Value Limits
od
— Valve clearance (with engine cold) 0.4 — Adjust
● Special tools
C A
Symbol Tool name and shape Part Number Application
Flat-head screwdriver
RI
Adjustment of valve clearance (carried
E
MH060008
AM on machine)
ZX335-1004006
Check and adjust the valve clearance in cold state as per the following procedure:
N
TI
LA
NY
SA

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
A
the crankshaft pulley is in line with the
timing pointer.
C
● Turn the No.1 piston or the No.6 piston
RI
to the TDC of compression stroke. ZX335-1004007
Fig. 6-6
Note: When the rocker arm at the intake side
E
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.
AM
Turning the engine by one more turn, the TDC
of compression stroke of No.1 piston and No.6
piston swaps.
N
3. When the No.1 piston is at the TDC, adjust

TI
the valve clearance in a sequence marked

with a black dot ( ● ).
LA
Cylinder 1 2 3 4 5 6
Exhaust ● ○ ● ○ ● ○
Intake ● ● ○ ● ○ ○
NY
A. When a feeler gauge is used for such

measurement, resistance to a moving ZX335-1004008
SA
feeler gauge in the clearance should be

Fig. 6-7
felt.
B. If the feeler gauge moves easily in the
clearance, it is impossible to obtain
accurate result.
4. If the measured value is out of specifica-
tion, readjustment shall be performed
according to the following method.

6.3.2 Adjusting
1. In adjustment of valve clearance, loosen Adjusting screw
the locknut before adjusting the adjusting
screw. A standard clearance is achieved
when slight resistance to the feeler gauge Locknut
is felt when pulling it out from the clear-
ance.
2. After adjustment, hold the adjusting screw
with a screwdriver to prevent it from turn-
A
ing, and tighten the locknut.
C
Locknut: 21-30 N.m{2.1- 3.1 kgf.m}
Valve clearance
RI
ZX335-1004009
3. Go on with the next step until all valve
Fig. 6-8
clearances marked with a black dot ( ● )
have been adjusted
E
4. Recheck the clearances with the feeler AM
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
N
make the job easy.

TI
LA
NY
SA

6.4 Compression force - Test
● Service standard
Correction
Location Service Item Standard value Limits
method
Every cylinder (200
3.0MPa {30.6kgf/cm2} 2.5MPa {25.5kgf/cm2} Check
Compression rpm/h)
—
force Inter-cylinder pres-
— 390 kPa { ≤ 4kgf/cm2 } Check
sure difference
C A
● Special tool
RI
Symbol Tool name and shape Part number Application
Pressure gauge connector 5-85317-001-0 (JKM- Checking the compres-
E
AM 1015) sion force
1. Reduction of compression force can be an

indication for engine overhaul.
N
2. Check the compression force regularly

and pay attention to its variation from time
TI
to time. Understanding the variation of

compression force is helpful for trouble-
shooting. In addition, in a new vehicle or
LA
when new parts are installed for replace-

ment, the pressure may be higher due to
running-in of the piston ring, valve seat, Pressure gauge connector
ZX335-1004010
etc. The pressure will become normal as
NY
the parts wear. Fig. 6-9

3. Before testing, make sure that the engine
oil, start motor and battery are in normal
SA
condition.
4. The vehicle is to meet the following condi-
tions.
A. Preheat the engine until engine coolant
temperature reaches 75~85℃ .
B. Switch off all lamps and auxiliary
devices.
C. Place the gear lever in a neutral posi-
tion.

5. Remove the entire fuel injector.

6. Cover the fuel injector mounting opening
with a rag.
7. Activate the start motor in order to run the
engine. Check the cloth if it is stuck with
foreign substances.
8. According to the substances (engine oil
and/or coolant) adhering to the cloth, the
WARNING
following factors might be involved.
A
● When coolant and/or engine oil is found
A. When engine oil is found, it might be attached to the rag, running the engine
C
improper sealing caused by piston ring. may cause the hot coolant and engine
RI
Check the piston ring. oil to squirt out through the mounting
B. When engine oil and coolant are found, hole of the fuel injector. This is very
it might be cracking of cylinder. Replace dangerous. Never touch or look into the
E
the crankcase. fuel injector mounting hole when the
AMengine is running.
9. Mount the gasket and to the fuel injec-
tor mounting hole and fix them with the
injector cap. Install the compression force
gauge.
N
10. Start the engine and measure the com-

pression force of each cylinder. Calculate
TI
the differential pressure between the

cylinders.
LA
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
NY
compression force again.

● If the compression force is higher, it is
SA
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.

C A
E RI
AM
N
TI
LA
NY
SA

6.5 Fuel Injection Timing - Test and Adjust
● Service standard
Correction
Location Service Item Standard value Limits
method
— Fuel injection timing (BTDC) 8 degrees 7~9 degrees Adjust
● Tightening torque (Unit: N·m)
C A
Symbol Part tightened Tightening torque Remark
RI
— Body, fuel delivery valve 39~44 —
— Nut, injection tube 28~32 —
E
● Common tool (Unit: N·m) AM
Symbol Tool name and shape Part number Application
Universal con-
necting rod with
N
extension Inspection and adjust-

MH061099 ment of fuel injection
TI
A
timing
14
A ZX335-1004011
LA
NOTICE
NY
● Take care not let dust or foreign ma-

terials get into the fuel injection pump
when adjusting the injection timing.
SA

6.5.1 Testing
1. Align the TDC mark on the crankshaft pul-

ley with the pointer. Remove the cap of the
inspection hole on the timing gear cover in
front of the fuel injection pump. Aligning point
Check if the pointer on the nut-fixing plate

on the gear of fuel injection pump is aligned
with the outstanding mark on the gear
A
chamber of fuel injection pump.
C
In case of misalignment, turn the crankshaft
pulley one more turn and repeat the above
RI
steps in order to obtain proper alignment.
Check if the marking lines are aligned with
E
each other. ZX335-1004007
(The marking lines have been aligned prop- Fig. 6-10

AM
erly when assembling the body of fuel injec-
tion pump and fixing the flange at factory)
Now, test the angle of crankshaft at the be-
ginning of fuel injection.
N
TI
2. Turn the crankshaft pulley counterclock-

wise approximate 30 degrees.
LA
1
NY
SA
ZX335-1004012
Fig. 6-11

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.
C A
ZX335-1004013
Fig. 6-12
RI
4. Remove from No.1 plunger the valve body
E
① , seat ② , spring ③ and spool ④ . AM 1
5. Reassemble the valve body ① and tighten
it to the specific torque. Do no reassemble
the spring, seat and spool now. Leave
2
them for later reassembly.
N
3
TI
4
LA
ZX335-1004014
Fig. 6-13
6. Secure the fuel control lever in the fully

NY
open position.
SA
ZX335-1004015
Fig. 6-14

7. Slowly turn the crankshaft pulley clockwise

while operating the hand pump to feed the
fuel constantly.
Stop operating the pump immediately when
no fuel is seen coming out of No.1 fuel de-
livery valve.
The crankshaft angle is now the engine’s
fuel injection beginning angle.
C A
ZX335-1004016
Fig. 6-15
RI
8. Observe and make sure that the mark
E
(of fuel injection beginning angle) on AM
crankshaft pulley is in line with the timing TD
C
pointer.
The timing mark is the engine’s fuel injec-
tion beginning angle. Discharge the remain-
N
ing fuel from the body of delivery valve. Damping pulley
Make sure that no fuel is delivered from the

TI
delivery pump.
Note: Engines of the same type may have a

LA
fuel injection pump that is different in injec- ZX335-1004017

tion timing. To obtain an engine of required
Fig. 6-16
specification, please contact machine supplier
or local ISUZU engine service station. These
NY
specifications are provided by ISUZU or en-

gine manufacturer.
SA

9. Remove the body of fuel delivery valve

from No.1 plunger.
10. Install the internal parts (valve seat, spring Body
and spool) on the body.
11. Reassemble the fuel delivery valve AS on
Seat
No.1 plunger and tighten it to the specific
torque.
Spring
12. Install the injection tube to No.1 cylinder
and tighten it to the specific torque.
A
Spool
C
ZX335-1004018
RI
NOTICE Fig. 6-17
● Do not tighten the fuel injection pump
body more than specified. The pump
E
body is aluminum and it can be de- AM
formed by over-tightening, resulting in
unfavorable impact on the operation of
control rack.
N
TI
LA
NY
SA

6.5.2 Adjusting
1. Align the timing pointer with the specific

mark on the crankshaft pulley.
2. Perform step 3 through step 6 described
in the testing procedure.
3. Loosen the four (4) nuts on the fuel injec-
tion pump.
A
Loosen the nuts.
4. Injection timing turns the fuel injection (Also loosen the nuts on the back.)
C
pump in advance along the drive shaft of
fuel injection pump in order to make it face
RI
outward (getting away from the cylinder ZX335-1004019
block).
Fig. 6-18
Injection timing turns the fuel injection pump
E
in retard along the drive shaft of fuel injec- AM
tion 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
N
angle.
TI
5. Keep operating the hand pump to transfer

the fuel while slowly turning the fuel injec-
tion pump. Stop turning the injection pump
LA
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.
NY
6. Tighten the four (4) nuts of fuel injection

pump.
7. Remove again the fuel delivery valve body Pressure gauge connector
SA
and assemble the spool, spring and seat. ZX335-1004010
Tighten the valve assembly to the specific Fig. 6-19

torque.
8. Install the injection tube of No.1 cylinder
and tighten it to the specific torque.

6.6 A/C Compressor Belt Tension - Test and Adjust
6.6.1 Testing Compressor belt pulley
Press the intermediate point of the belt be-

tween the drive pulley and the compressor belt A
pulley with a finger force of about 58.8 N(6
kgf), and check the deflection (A) of the belt,
which shall be 5~8 mm (0.20 in~0.31 in).
C A
RI
Drive belt pulley
ZX335-1004021
Fig. 6-20
E
6.6.2 Adjusting AM
● If the belt deflection is abnormal, adjust it
according to the following procedure. 4
1. Loosen the bolts (1) and (2). 1

N
2. Move the compressor (3) and the bracket

(4) together to adjust belt tension.
TI
3. After positioning the compressor (3),

tighten the bolts (1) and (2). 2
LA
4. Recheck belt tension after adjustment. 3
ZXT335-1004022
Note: Fig. 6-21

NY
● Check each belt for damage. Check the

V-groove and the V-belt for wear. In addi-
tion, it is especially important to keep the
SA
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.

6.7 Swing Bearing Clearance - Test
● Tool used for testing swing bearing clear-

ance
Symbol Part Number Part Name

H 60033930 Dial gauge
● The following steps are to be followed H
A
when testing the clearance of swing bear-
ing.
C
ZX335-1004023
RI
WARNING Fig. 6-22
● Park your machine on a level ground.
E
Lower your work equipment to the
ground. AM
● Do not put your hands or feet under the
undercarriage during testing.
1. Fix the dial gauge (H) to the track frame

N
and make the pointer point the lower end

TI
of the outer race.

2. Place the work equipment to the maximum
reach position. Raise the bucket to a
LA
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.
NY
3. Reset the dial gauge (H) to zero. ZX335-1004024
4. Set the arm almost perpendicular to the Fig. 6-23

ground and lower the boom until the front
SA
track shoe tilts.

At the moment, the front of upper structure
rises while the rear lowers.
5. Read the dial gauge (H).
150～200mm
The value indicated by the dial gauge (H)

is the clearance of the bearing.
6. Restore the machine to the condition of
step 2. Check the dial gauge (H) to see if it
reads zero.
ZX335-1004025
Repeat step 3 through step 5 if the dial
Fig. 6-24
gauge (H) reads a value other than zero.
6.8 Track Tensioner - Test and Adjust
6.8.1 Testing
1. Move your machine forward at a distance
that is equal to the length of track on the
ground. Keep running the engine at low 3 2
idle. Park your machine slowly. a
2. Place a straight edge on top of the track

grousers between the idler (1) and the
A
front carrier roller (2).
C
A straight edge of angle steel is recom-
RI
mended for this purpose as angle steel
1
bends little. In addition, an L-shaped beam
has good performance against bending. ZX335-1004026
E
3. Measure the maximum clearance (a) Fig. 6-25
between the upper surface of track and the
bottom of straight edge.
AM
Max clearance (a): 10~30 mm(0.4~1.2 in)
N
TI
LA
NY
SA

6.8.2 Adjusting
If the track tension is incorrect, adjustment is
to be made in the following way.
1. Decreasing the tension
A. Loosen the valve (1) to discharge
grease. Tighten the valve after dis-
charging.
1
A
WARNING
C
2
● Never loosen the valve over one turn.
RI
If the valve is loosened too much, the
ZXT335-1004027
grease under high pressure may cause
the valve to shoot.
E
B. Recheck the track tension as per the
AM
above method after adjustment.
2. Increasing the tension
N
A. Add grease through the grease fitting

(2) with a grease gun.
TI
B. Recheck the track tension as per the

above method after adjustment.
LA
● 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
NY
seriously worn. Replace the pins and

bushings, or remove one track shoe.
SA
ZX335-1004028
Fig. 6-26

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
—
A
B210770000084 Adaptor
C
● The hydraulic pressure in work equipment,
RI
swing and travel (hydraulic pump output
pressure) circuits can be viewed on the
monitor.
E
6.9.1 Testing
AM
1. Preparatory work before measuring
Lower the work equipment to the ground
N
and stop the engine. After the engine is

stopped, operate the control levers for sev-
TI
eral times in order to release the remaining

pressure in hydraulic circuits. Open the
butterfly nut on the breather valve. Press
LA
the relief button to release pressure in the

hydraulic tank.
A. Remove the plug (1) and plug (2) for

NY
testing the hydraulic pressure.

Plug (1): For oil circuit of back hydraulic
pump
SA
Plug (2): For oil circuit of front hydraulic 1

pump
B. Install the priming adaptor and connect
it to the hydraulic tester.
Use an oil pressure gauge with a ca-
pacity of 40 MPa {408 kg/cm2}.
ZXT335-1004029
C. Start the engine and keep it running Fig. 6-27
until the hydraulic pressure rises to a
point within the operational range.

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.
A
B. Test the hydraulic pressure when the engine is running at high idle and the cylinder is in
relief condition.
C
The hydraulic pressure indicated is the pressure when the main relief valve is in relief con-
RI
dition.
4. Testing the swing relief pressure
E
A. Start the engine. Reach out the work equipment as far as possible. Lower the work equip-
ment on the ground in order to restrict swinging. AM
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 re-
lief condition.
N
The relief pressure of swing motor is lower than the main relief pressure.
TI
5. Testing the relief pressure of travel circuit

LA
A. Start the engine and lock the travel

mechanism.
Place the pin ① between the sprocket
and the track frame in order to block
NY
the travel mechanism.

B. Test the hydraulic pressure when the
1
SA
engine is running at high idle and the

travel circuit is in relief condition.
The hydraulic pressure indicated is the
ZXT335-1004031
pressure when the main relief valve is
in relief condition. When the travel cir- Fig. 6-28
cuit is in relief condition, the pressure
indicated is always the pressure at high
relief.

6.9.2 Adjusting
The unloading valve and safety valve for the

boom are not adjustable.
1. Adjusting the main relief pressure (at the
high pressure setting side)
If the high relief pressure in work equip- 3

ment and travel circuits is abnormal, adjust
the high pressure setting side of the main
A
relief valve (3) according to the following
C
procedure.
RI
A. Disconnect the pilot hose. ZXT335-1004900
B. Loosen the locknut (4). Turn the adjust- Fig. 6-29

ing screw (5) to adjust the pressure.
E
The pressure increases as the retainer AM
is turned right.
The pressure decreases as the retainer
is turned left. 4
N
Each turn of the retainer approximates:

12.5 MPa {128 kg/cm2}
TI
Locknut:
53.5±4.9 Nm{5.5±0.5 kgm} 5
LA
C. Check the pressure again after adjust-

ment. Test the pressure according to ZX335-1004033
the procedure described above.
Connect the pilot hose before testing Fig. 6-30
NY
the pressure.
Adjustment of the high pressure setting
SA
side will affect the low pressure setting

side. The low pressure setting side is,
therefore, to be adjusted too.

C A
E RI
AM
N
TI
LA
NY
SA

2. Adjusting the swing relief pressure

If the swing relief pressure is abnormal,
adjust the swing motor relief valve (6) ac-
cording to the following procedure.
6
6
77
A
8
C
8
RI
ZXT335-1004034
Fig. 6-31
E
A. Loosen the locknut (7). Turn the adjust- AM 7
ing screw (8) to adjust the pressure.
Pressure increases as the retainer is
turned right. The pressure decreases
as the retainer is turned left.
N
Each turn of the retainer approximates:

TI
6.71 MPa { 68.4 kg/cm2}

Locknut:
LA
8
78-103 Nm{8.0-10.5 kgm}
B. Check the pressure again after adjust- ZX335-1004035
ment. Test the pressure according to Fig. 6-32

the procedure described above.
NY
SA

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.

—
B210770000084 Adaptor
A
Lower the work equipment to the ground and stop the engine. After the engine is stopped, oper-
C
ate the control levers for several times in order to release the remaining pressure in hydraulic cir-
RI
cuits. Open the butterfly nut on the breather valve. Press the relief button to release pressure in
the hydraulic tank.
E
1. Remove the hydraulic pressure testing
plug (1). AM
2. Install the priming adaptor and connect it
to the hydraulic tester.
● Use an oil pressure gauge with a capacity
N
of 6 MPa {61 kg/cm2}

TI
3. Start the engine and keep it running until

the hydraulic pressure rises to the opera- 1
tional range.
LA
4. Test the oil pressure with the engine run-

ning at high idle and all control levers in 2
neutral position.
ZXT215-1004007
Fig. 6-33
NY
6.10.2 Adjusting
SA
1. If the oil pressure measured is lower than

3.5 MPa {36 kgf/cm²}, loosen the locknut (2) 3 2
and screw in the stud (3). Observe pressure
change on the gauge at the same time.
Tighten the nut (2) when desired pressure is
reached.
2. Remove all measuring tools after testing.
Make sure that the
ZX215-1004031
Fig. 6-34

6.11 Solenoid Valve Output Pressure - Test

Tools used for testing the output pressure of solenoid valve

—
B210770000084 Adaptor
● Make sure that the initial pressure of control oil circuit is normal before testing the output
A
pressure of solenoid valve.
C
Lower the work equipment to the ground and stop the engine. After the engine is stopped, oper-
ate the control levers for several times in order to release the remaining pressure in hydraulic cir-
RI
cuits. Open the butterfly nut on the breather valve. Press the relief button to release pressure in
the hydraulic tank.
E
1. Disconnect the hose of solenoid valve in AM
order to test the pressure at the outlet.
6
No. Solenoid valve to be tested
5
1 High travel speed valve
N
4
2 Backup proportional valve 3
TI
3 Backup proportional valve 2

1
4 Bucket confluence valve
5 Backup
LA
6 Pilot pressure valve

W365613091
Fig. 6-35
NY
2. Install a tee to location (A) on each solenoid valve and connect the hose.
SA
3. Mount the adaptor onto the tee and connect it to the hydraulic tester.
● Use a hydraulic tester with a capacity of 6 MPa {61 kg/cm2} .
4. Start the engine and keep it running until the hydraulic oil temperature rises to the operational
range.
5. Run the engine at full speed. Operate the control levers to open or close each solenoid valve,
and measure the pressure.
● The function of each solenoid valve can be checked through the monitor's monitoring func-
tion. (This is a special function of the monitor.)
6. Remove all measuring tools after measurement. Make sure that the machine returns to its
normal condition.

Pilot locking solenoid valve
Functioning state Function

Lock OFF
Hydraulic lockout control
Free ON
Travel speed shift solenoid valve
Functioning State Function
A
When the 2nd level overheat setting is on
C
Fuel control dial reads lower than 1500 rpm.
RI
When travel speed switch is in Lo position
OFF
Travel signal OFF
If pressure of both front and back pump is
E
When travel speed
switch is in Hi posi- 24.5 MPa {250 kg/cm2}
AM
tion Travel signal ON
If pressure of both front and back pump is
15.3 MPa {150 kg/cm2} ON
Other states
N
TI
LA
NY
SA

6.12 Pilot Valve Output Pressure - Test

● Tools used for testing the output pressure of pilot valve

—
B210770000084 Adaptor
● Make sure that the initial pressure of con-
A
trol oil circuit is normal before testing the
C
output pressure of pilot valve.
RI
1. Remove the pilot oil pressure switch or
plug.
E
No. Oil circuit No. Oil circuit
AM
1 Left travel 7 Boom DOWN
2 Right travel 8 Left swing
3 Arm IN 9 Bucket DIG
N
4 Right swing 10 Arm OUT 1 2 3 4 5 6 7 8 9 10

TI
5 Bucket DUMP
6 Boom UP ZXT335-1004902
LA
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
NY
range.
4. Measure the output pressure with the engine running at high idle and all control levers of the
tested circuit in neutral position.
SA
● When the measured output pressure reads the following values, the pilot valve is normal.
5. Remove all the tools after testing. Make sure that the machine returns to its normal condition.
Control lever Hydraulic pressure

Neutral position 0{0}
Close to the average initial pres-
Full stroke sure of oil control circuit
(See Table of Standard Values)

C A
E RI
AM
N
TI
LA
NY
SA

6.13 Work Equipment and Swing Pilot Valves - Adjust
● If the play of work equipment or swing 2

control lever is too big, adjustment can be
made through the following steps. 3
1. Remove the work equipment and swing 1

pilot valve assembly.
2. Remove the bellows (1).
4
A
3. Loosen the locknut (2). Screw on the disc
(3) until it contacts with the four heads of
C
plunger (4).
RI
● Do not move the plunger. ZX215-1004032
4. When the disc (3) is fixed, tighten the
E
locknut (2) to the specified torque.
Locknut: 98~127 Nm {10~13 kgm}
AM
5. Restore the bellows (1).
6. Restore the work equipment and swing
pilot valve assembly.
N
TI
LA
NY
SA

6.14 Hydraulic Drift of Work Equipment - Test
● If hydraulic drift occurs to the work equip-

ment (cylinder), check it according to the
following procedure. It is to determine
whether the failure is caused by cylinder
seal or control valve.
1. Check the boom and bucket cylinders.
A
A. Park your machine in an attitude as
shown in the illustration on the right,
C
and stop the engine.
RI
● Load the bucket fully with soil or apply
rated load to the bucket.
E
B. Operate the control levers in order to
keep the boom in the UP position and AM
the bucket in the DIG position.
● If the lowering speed increases, it is ZX215-1004033
failure of cylinder seal.
● If nothing changes, it is failure of con-
N
trol valve.
TI
● Operate the control levers with engine

start switch in the ON position.
LA
● If the pressure in accumulator drops,

recharge the accumulator after running
the engine for about 10 seconds.
2. Check the arm cylinder.
NY
A. Park your machine in an attitude as

shown in the illustration on the right.
The distance between the arm cylinder
SA
and the digging stroke end is 100 mm.

Stop the engine.
B. Operate the control levers in order to
place the arm in the DIG position.
● If the lowering speed increases, it is the
failure of cylinder seal.
● If nothing changes, it is the failure of
ZX215-1004034
control valve.
● Operate the control levers with engine
start switch in the ON position.

● If the pressure in accumulator drops, recharge the accumulator after running the engine
for about 10 seconds.
[Ref.] If the hydraulic drift is caused by failure of the cylinder seal, the reason for increase of low-
ering speed during the above operation is described below:
A. If the machine is set in the above position (where the holding pressure is applied to the head
end), the oil leaks from the head end to the rod end. The pressure in the rod end is increased
as a result.
B. As the pressure in the rod end decreases, the pressure in the head end increases to keep a
balance. This process is repeated until balance is reached at a certain level depending on the
A
amount of leakage.
C
C. When the pressure is balanced, the lowering speed decreases. If the control levers are oper-
RI
ated 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.
E
3. Check the pilot valve.
AM
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
N
about 10 seconds.
TI
● 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.
LA
NY
SA

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.
A
1. Stop the engine, loosen the butterfly nut on the breather valve, and press the release button
C
to release the pressure in hydraulic tank.
2. Turn the engine start switch to the ON position and operate the control levers for several
RI
times.
● The pilot lock valve must be energized. Operate the control levers with the engine start
E
switch in the ON position.
AM
● 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.
N
TI
LA
NY
SA

6.16 Oil Leakage Amount - Test
1. Testing the oil leakage amount of boom

cylinder
A. Start the engine and keep the engine
running until the hydraulic oil tempera-
1
ture reaches the operational range. And
then fully extend the boom cylinder.
A
To release the pressure remaining in
the lines see “Remaining Pressure in
C
Hydraulic Lines - Relieve” on page 6-36.
RI
B. Disconnect the hose (1) on the cylinder
rod end and plug the hose opening.
E
Take care not to disconnect the hose
on the cylinder head end. AM ZXT335-1004039
C. Start the engine and apply relief pres- Fig. 6-36
sure to the head end of the cylinder
while the engine is running at high idle.
D. Hold this state for 30 seconds and then
N
test the amount of oil leakage for one

TI
minute.
E. Make sure that the machine returns to
its normal condition after testing.
LA
2. Testing the oil leakage amount of arm

cylinder
NY

SA
then fully extend the arm cylinder.

To release the pressure remaining in
the lines, See: Chapter 4 Testing and 2
Adjusting, “Remaining Pressure in
B. Disconnect the hose (2) on the cylinder ZXT335-1004040
rod end and plug the hose opening. Fig. 6-37

on the cylinder head end.

C. Start the engine and apply relief pres-

D. Hold this state for 30 seconds. Test the
amount of oil leakage for one minute.
A
3. Testing the oil leakage amount of bucket
cylinder
C
RI
then fully extend the bucket cylinder. 3
E
To release the pressure remaining in AM
the circuits see “Remaining Pressure
in Hydraulic Lines - Relieve” on page
6-36.
B. Disconnect the hose (3) on the cylinder ZXT335-1004041
N
rod end and plug the hose opening. Fig. 6-38

TI

on the cylinder head end.
C. Start the engine and apply relief pres-
LA

D. Hold this state for 30 seconds and then
test the amount of oil leakage for one
NY
minute.
SA

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
A
at high idle. Measure the amount of oil
C
leakage under this condition. ZXT335-1004042
RI
● Hold the state described in step Fig. 6-39
3) for 30 seconds. Measure the
amount of oil leakage for one min-
E
ute.
● After the first measurement, swing
the upper structure 180º and mea-
AM
sure the leakage again in the same
way.
D. Make sure that the machine returns to
N

TI
5. Testing the oil leakage amount of the travel

LA
motor
A. Remove the cover of the travel motor.
B. Start the engine and lock the travel.
NY
Insert the pin ① between the sprocket

and the track frame in order to prevent
traveling.
SA
ZXT335-1004031
Fig. 6-40

C. Disconnect the drain hose (6) of the 6 6

travel motor. Blind the hose end with a
cap.
D. Start the engine and apply swing relief
pressure while the engine is running
at high idle. Measure the amount of oil
leakage under this condition.
WARNING
C A
● During testing, misoperation of the con- ZXT335-1004043
trol levers can cause serious accidents.
RI
Fig. 6-41
Make sure that all signals are correct.
E
● Hold the condition described in step AM
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
N
the cylinder and of the cylinder and

piston. Repeat the testing several
TI
times.
LA
NY
SA

6.17 Air in Each Component - Purge
Purging Steps
Item to Be Purged
1 2 3 4 5 6
Hydraulic Engine Oil Cylin- Swing Travel Operation
Job Description Pump Starting der Motor Motor Starting
● Changing the hydraulic oil
○ ○ ○ ○ ○ ○
● Cleaning the filter element
(Note) (Note)
A
● Replacing the return filter element ○ ○
C
● Repairing/replacing the hydraulic
pump ○ ○ ○ ○
RI
● Disassembling the suction hose
● Repairing/replacing the control valve ○ ○ ○
E
● Replacing the oil cylinder
○ ○ ○
● Disassembling the cylinder piping AM
● Replacing the swing motor
○ ○ ○
● Disassembling the swing motor
● Replacing the travel motor
○ ○ ○
● Disassembling the travel motor
N
TI
Note:
Purge air from the swing motor and travel motor only when the oil in the motor cases is drained.
LA
1. Purging air from hydraulic pump

1
A. Loosen the plug (1) and make sure that
oil leaks through the plug.
NY
B. If you are sure of the leak, tighten the

plug (1).
SA
Plug: 7.8~9.8 N·m{0.8~1.0 kgf·m}

● Engine starting precaution:
When engine is started after bleeding the air
as described above, run the engine at low
ZXT335-1004500
idle for 10 minutes.
Fig. 6-42

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).
A
● 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
C
installation because its piston is unable to reach the boom-down side stroke end after installa-
RI
tion.
● 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
E
speed under zero load in order to purge the air. Immediate pressurization and loaded operation
AM
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.
N
4. Bleeding air from travel motor

TI
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.
LA
E. If you are sure of the leak, tighten the plug (1).

Bleeder plug: 27.5 - 35.3 Nm {2.8 - 3.6 kgm}
NY
SA

EA
G RIC
E
PAAM
KNTI
ANLA
BLNY
SA

E CA
G RI
ME
PAA
IN
AT
K
ANL
Y
BSLAN

SY365(B)H-9 Crawler Hydraulic Excavator Troubleshooting
Troubleshooting
C A
RI
7 Troubleshooting
7.1 Checks before Troubleshooting ............................................................................... 7-5
E
7.2 Failure Symptoms and Troubleshooting Codes ....................................................... 7-6
AM
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
N
7.3.4 SWP connectors .......................................................................................... 7-22

TI
7.3.5 A/AMP connectors ....................................................................................... 7-23

7.3.6 DT connectors.............................................................................................. 7-24
LA
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
NY
SA

Troubleshooting SY365(B)H-9 Crawler Hydraulic Excavator
C A
E RI
AM
N
TI
LA
NY
SA

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.
A
● 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.
C
● Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
RI
● When disconnecting wiring, always disconnect the negative (–) terminal of the battery
first.
E
● When removing the plug or cap from a location which is under pressure from oil, water,
AM
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,
N
and to prevent reoccurrence of the fault.

TI
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.
LA
1. When carrying out troubleshooting, do not hurry to disassemble the components. If compo-
nents are disassembled immediately any fault occurs:
● Parts that have no connection with the fault or other unnecessary parts will be disassembled.
NY
● 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.
SA
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?

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
A
to be necessary.
C
4. Confirming fault
Confirm the extent of the fault yourself, and judge whether to handle it as a real fault or as a
RI
problem with the method of operation, etc.
When operating the machine to reenact the troubleshooting symptoms, do not carry out any
E
investigation or measurement that may make the problem worse.
5. Troubleshooting
AM
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.
N
A. Start from the simple points.

TI
B. Start from the most likely points.

C. Investigate other related parts or information.
LA
6. Measures to remove root cause of fault

Even if the fault is repaired, if the root cause of the fault is not repaired, the same fault will oc-
cur again. To prevent this, always investigate why the problem occurred. Then, remove the
root cause.
NY
SA

7.1 Checks before Troubleshooting
Item Criterion Remedy

1. Check fuel level and type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level — Add oil

4. Check hydraulic oil strainer — Clean, drain
5. Check swing drive oil level — Add oil
A
6. Check engine oil level (in oil pan) — Add oil
C
7. Check coolant level — Add water
RI
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
E
—
mechanical Electrical equipment
1. Check for looseness, corrosion of battery terminal and

AM Tighten or replace
wiring
2. Check for looseness, corrosion of alternator terminal —
Tighten or replace
and wiring
3. Check for looseness, corrosion of start motor terminal — Tighten or replace
N
and wiring
TI
equipment
1. Check for abnormal noise and smell — Repair

Hydraulic,
2. Check for oil leakage — Repair

LA
3. Bleeding air — Bleed air

1. Check battery voltage (with engine stopped) 20-30V Replace
2. Check electrolyte level — Add or replace
Electrics, electrical equipment
3. Check for discolored, burnt, exposed wiring — Replace

NY
4. Check for missing wiring clips and hanging wiring — Repair

5. Check for wet wires (esp. wet connectors or terminals) — Disconnect con-
nector and dry
SA
6. Check for blown or corroded fuses

7. Check alternator voltage (with engine speed at middle
or higher) — Replace
8. Check operating sound of battery relay (when start After running for Replace
switch is turned ON or OFF) several minutes:
27.5~ 29.5V
Replace
—

7.2 Failure Symptoms and Troubleshooting Codes

Troubleshooting
No. Symptom Code dis-
E mode H mode (Engine)
played
Action to be taken concerning Service Code, Failure code and Failure Code
1 Display Failure code in monitor panel
Accord-
Display Service Code in electrical system after ing to
2
checking failure history displayed
Display Failure Code in mechanical system after
A
3 code
checking failure history
C
Engine-related failure
Engine does not start up easily. (It always takes
RI
4
some time to start up the engine)
5 Engine misfires. E-1
E
Color of exhaust gas is too dark.(Incomplete com-
6
bustion) AM
7 Engine pickup is poor.
8 Engine runs rough or is unstable. E-2
9 Engine is short of output, or lacks power H-2
10 Auto Idle fails. E-5 H-5
N
Excessive engine oil consumption, or color of ex-

11
TI
haust gas is blue

12 Premature engine oil contamination
13 Excessive fuel consumption
LA
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
NY
17 Excessive vibrations are caused

Failure related to work equipment, swing and travel
18 Power supply of machine cannot be cut off. E-3
SA
There are abnormal noises from around hydraulic

19 H-4
pump
20 All work equipment, travel and swing do not move H-3
Speeds of all work equipment, travel and swing are
21 H-1
slow
When Machine Swings and Travels Simultaneously,
22 H-13
Travel Speed Lowers Largely

Troubleshooting
played
Work equipment-related failure
23 All the equipment do not work E-7
24 Cylinder do not work singly H-9
25 Drift of cylinder is too large H-10
26 Work equipment time lag is too big H-11
A
Other work equipment moves, when specific
27 H-12
work equipment is relieved
C
28 Boom-up speed or power is low. E-8 H-6
RI
29 Arm speed or power is low. E-9 H-7
30 Bucket speed or power is low. E-10 H-8
Travel-related failure
E
31 Travel speed or power is low. AM E-11 H-15
32 Dual Speed Travel Not Functioning E-14
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 H-17
N
36 Track shoe does not move (only on one side) H-18

TI
Swing-related failure
37 Machine does not swing H-19
LA
Swing acceleration is poor, or swing speed is

38 H-20
slow
Upper structure overruns remarkably when
39 H-21
stopping swinging
40 Large shock is made when stopping swinging H-22
NY
41 Large sound is made when stopping swinging H-23

42 Hydraulic drift of swing is large H-24
SA

Troubleshooting
played
Monitor panel-related failure
43 Monitor display is blank. E-12
44 Monitor displays nothing. E-13
Engine coolant temperature reading is incor-
45 E-15
rect.
46 Fuel level reading is incorrect. E-16
A
47 Arm-in pilot pressure reading is incorrect. E-18
C
48 Arm-out pilot pressure reading is incorrect. E-19
49 Boom-up pilot pressure reading is incorrect. E-20
RI
Boom-down pilot pressure reading is incor-
50 E-21
rect.
Bucket-close pilot pressure reading is incor-
E
51 E-22
rect. AM
Bucket-open pilot pressure reading is incor-
52 E-23
rect.
53 Swing pilot pressure reading is incorrect. E-24
54 Left travel pilot pressure reading is incorrect. E-25
Right travel pilot pressure reading is incor-
N
55 E-26
rect.
TI
Other failure
56 Preheat function fails. E-6
57 Wiper does not work. E-17
LA
NY
SA

7.3 Connector Location and Electrical Circuit Diagram
Num-
Stereo-
Connector No. Type ber of Component
gram
pins
CN-101M A 2 Platform lamp E-5
CN-102M S 1 Fuel level sensor F-6
CN-104M A 2 Boom lamp (L) E-7
CN-105M A 2 Boom lamp (R) E-7
A
T-117 Terminal 1 High-temp switch K-7
C
T-101 Terminal 1 Battery relay coil (+) M-2
RI
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
E
T-105 Terminal 1 AMPreheater 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
N
T-109 Terminal 1 Engine oil pressure switch J-7

TI
T-110 Terminal 1 Preheater resistance wire terminal J-7

T-111 Terminal 1 Start motor terminal B K-7
LA
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
NY
K2 R 5 Head lamp relay X-6

K6 R 5 Work lamp relay X-6
K4 R 5 Pilot valve relay X-6
SA
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

Num-
Stereo-
gram
pins
A
C
CN-502F D 12 Intermediate connector R-5
RI
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
E
CN-142M A 35 AM 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
N

TI

CN-106M A 2 Hyd oil temp sensor I-7
LA
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
NY
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
SA
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

Num-
Stereo-
gram
pins
CN-303M H 8 Work lamp switch R-6
CN-305M H 8 Washer switch R-6
CN-304M H 8 Wiper switch R-6
CN-104M A 2 Horn switch R-6
CN-003F S 12 Air conditioner W-4
CN-150F AMP 2 Front pump solenoid valve I-7
A
CN-151F AMP 2 Rear pump solenoid valve I-7
C
CN-135F AMP 2 Boom priority 2 solenoid valve J-6
RI
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
E
CN-131F AMP 2 High/low travel speed valve
AM 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
N
F-100 W 1 Left horn I-6

TI
CN-140M AMP 35 Controller W-6

CN-141M AMP 35 Controller W-6
LA
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
NY
CN-215F HL 7 Radio W-6

PF021 _ _ Fuse box X-4
CN-1-001 AMP 2 Left speaker AD-7
SA
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

Connector No. Description

S SWP type, Yazaki
A/AMP AMP, Japan
D DT type, made in Japan
H Hebi
HL Hulane
L Ling Xing
DF Delphi, U.S.
A
W AMP, Japan
C
Terminal Round
E RI
AM
N
TI
LA
NY
SA

7.3.1 Connector location layout
CN-105M CN-104M CN-102M
A
7
C
E RI
6
AM
5
N
CN-101M
TI
4
LA
NY
3
SA
ZX305-1005001
A B C D E F
Fig. 7-1

CN-111F CN-113M CN-155M

CN-113F T-111
CN-115M T-135
CN-116M
CN-182P T-110
CN-120M
T-109
CN-121M
A
CN-122M T-112
C
CN-123M CN-800F
RI
CN-124M
T-107
CN-125M
T-117
CN-126M
E
CN-128M AM F-300
CN-129M
N
TI
CN-211M
LA
CN-131F
CN-132F
CN-133F
NY
CN-134F
T-105 T-106
CN-135F T-101
SA
T-102
CN-136F
KB
F-100
T-104
F-101
T-103
T-118
Z T-500
ZX305-1105041
Fig. 7-2

CN-304M CN-305M CN-307M CN-502F

9 CN-303M
CN-302M
CN-104M
F-506
F-507
8
F-508
A
F-509
C
F-501
RI
7 F-502
F-503
E
F-504
6
F-505
AM
N
5 CN-142M
TI
LA
4
NY
CN-7-707
3
SA
1
ZX305-1105042
N O P Q R S T
Fig. 7-3

CN-1-111M CN-506F
T-202
CN-502F F-103
K5
CN-1-112F
K6
K2
CN-503F
K4
CN-504M
K3
K7
A
CN-505F
C
K9
RI
CN-181M
CN-507M
CN-615M
E
CN-180M
AM KH
N
TI
LA
NY
CN-616M
SA
PF021
CN-215F
CN-003F
CN-201F
ZX305-1105043
T U V W X Y Z
Fig. 7-4

CN-304M CN-305M CN-307M CN-502F

9 CN-303M
CN-302M
CN-104M
F-506
F-507
8
F-508
A
F-509
F-501
C
7 F-502
RI
F-503
E
F-504
6 AM
F-505
5
N
CN-142M
TI
4
LA
NY
CN-7-707
3
SA
1
ZX305-1105042
N O P Q R S T
Fig. 7-5

7.3.2 Diagram of system electrical elements
CN-7-707F F1 20A PF021

(A-2) 22 20
Cigar F2 10A
CN-7-113M 14 13 CN-506F
(D-12) lighter F3 5A (S-16)
29 1 23 20
1 29 1 2 64 1 1 64
22 2 2 22 24 F4 15A 63 2 2 63
CN-7-705M
21
9
3 3 65 3 3 65
25 F5 5A 21
00A 4 4 00A
5 5 20b F6 10A 21
1 6 6 26 F7 5A
CAN+ 2 CAN+ 7 7
38 F8 20A
20 28
37
7 7 28
37
CAN- 3 8 8 00# 21 8 8
00# 9
CAN-
- 9 66 9 9 66
4 60a 10
61a 11
10 60a 27 F9
10A
21 14 10 10 14
5 11 61a 28 F10
5A
20
60
22
11 11
22
12 12 12 12
6 29 F1120A 21
90
13 13
24V 7 70 F125A 14 14 90
29 21
24V 8 22 90 F13
20A
21
GND 9 00# F145A
10 10A
20
GND 11 00#
100 F15 20 66
12 20b
38
C A
CN-204F
(D-12)
24 1 24
1
25 2 25
2
37 3 3 37
14 14
RI
4 4
60
36
5 5 60
36
Charging indicator
6 6
35H 35H 60
7 7 14
F-507
33 8 8 33 F-506
50A
35L 9 9 35L 506
1 1
2 2
00A 3
3
7
CN-501F
(A-3) Fuel control dial
35L
35H
37
36
33
72
CN-203M 69
(D-12)
E
69 69
61
1 1
62 2 62 25
61
2
3 3 61 14
22 4 22
13
4
5 5 13
6 6
50A 50A
7 7
8 8 57
6
AM 00A 9
70 10
72 11
9
10
11
00A
70
72
00A
00#
21
26
0#
24
CN-7-112F 23
(D-3)
CN-502M 70
To controller circuit CAN+
(D-12)
CN-112M
1
CAN- 1 1
2
2 2
S 57 3 3 57
3
60a 00A 4 4 00A
1 1 00# 5 5 00#
61a 6 6
2 2
7 7
Sunlight sensor CN-7-706M 8 8
N
(S-2)
60a
14 F-509
Preheat indicator 61a
5 69 F-508
14 6 6 14
TI
60 5 5 60
CN-506M
Compressor clutch 57 T-107 (D-8)
Servce lamp
Start relay Lockout relay

Pilot switch
Refuel
LA
27 105
4
1 2 3 4 5 1 2 3 4 5
CN-205M
(A-2) 1 2 3 4 5 1 2 3 4 5
105
0 11a 11b 0 11a
610
F-103 11b
60
NY
Safety 0
relay F-104
Low-temp
21
3 switch
F-105
F-105
12
2 2
CN-505F
T-101 66
TERMINAL B BR ACC R1 R2 C
Start HEAT
OFF
switch
SA
ON
START
22 62 13 61 11
1 1
2 2
2 T-101 T-102 T-104 T-120

CN-504M
15 0 20 21
Start protection relay 1 2 3 4 5
1 2 3 4 5
KB
T-135 T-102 T-116
12 21 14 60 21 22 646563 62 0 64 6365
1 2 3 45 B A P1P2 1 2 3 45
1 2 3 45 Battery relay 1 2 3 45
36
25
11 0 11C 0 35L
T-500 T-501 24 33 25 37 35H 72 70
1 - + - + E E E
Parking relay
CN-503F
(H-8)
CN-507F
(H-8)
CN-505F
(H-8)
CN-508F
(H-8)
Work lamp Washer Wiper Head lamp
Start Chassis Parking
Chassis motor Alternator switch switch switch switch
Chassis motor
ground
ground ground ZX305-1105035
A B C D E F
Fig. 7-6

● This circuit diagram has been compiled by extracting the wiper system and the switch control
systems from the general electrical circuit diagram.
Preheat
controller Horn relay Work lamp relay Head lamp relay Preheater relay CN-124F
(S-6)
50A 1 1
K5 K6 K2 KH 507 2 2 1 Throttle
2
9
1 2 3 4 5 1 2 3 4 5 MT- 3 3 motor
1 2 3 4 5 1 2 3 4 5 3
5 AC-2000
CN-181M
(D-6)
6
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 00A 5 5
1 2 3 4 5 6 33
1 2 3 4 5
31 0 23 32 0 24 34 72 0 70 71 68 14 16 17
14 66 61 0 69 MT+ 6
6
Horn switch
23 31
A
T-107
C
RI
Preheater
T-105
21
T-106
16 7
E
CN-1-110M
(D-6)
Wiper
35L
0 1 1
35H
37
36
14
33
72
69
61
AM 36
35H
35L
25 2
3
4
2
3
4
M
25
MT+
5 5
6
MT-
507
50A
00A
CN-112M
57
(A-2)
66
0 0
Washer motor
21 1 1
M
N
26
37 2 37
0# 2
24 CN-506F 6
23 (S-16)
70
6
61a
TI
60a Head lamp (R)
5
20b 0 0
1 1
38 71 77
2 2
Head lamp (L)

0 0
1 1
71 77
LA
2 2
CN-150M
R+ (S-8) F-104
1 1 (W-1)
R-
L+
2
3
2
3
1 1
Horn
4
L- 4 4 CN-506M
0# (D-16)
5 5 32
6 6
32
F-103
71
6 6 34 16 16
34 (W-1)
NY
0
7 7 1 1
26
8 8
CN-101M
3
Revolving frame
(A-2) work lamp
0
1 1
SA
34
2 2
20b
1 CN-104M Left boom
R+ (A-2) work lamp
L+
2 1 1 0
3 2 2 34
0#
4
20b
5 CN-105M Right boom
R- (A-2)
6 1 1 0
work lamp
L-
CN-107M
7 2 2 34
2
To radio control panel
Radio speaker (R)
57 1
61a
0 57 4 Radio speaker (L)
60a
1 2
5
CN-109M 0#
6 Cab lamp
0
1 0
38
7 1
26 26
2 2
8
1
38
CN-207F
To A/C control panel
Fig. 7-7 ZX225-1105036
G H I J K L

7.3.3 Diagram of electrical control system

CN-502F
CN-152M (D-16)
(AMP-2)
240Ω 50
511 4 4
1
0 00
2 13 13
CN-616M
(AMP-81)
1 00#
2 42
5
509
11
13
15
108B
19
510
30
8 31
34
511
108A
38
A
508
48
200
L. travel pilot pressure 49 50
204
Bkt-dump pilot pressure 50
207 00
Boom-down pilot pressure 51
202
Arm-out pilot pressure 52 200
C
502
Rear pump main pressure53
00 201
54 00 202
55 50 203
56 CAN-
58 204
RI
CAN+
60 208
11C
65 201 207
7
R. travel pilot pressure 67
208
Swing pilot pressure
68 206
205
Bkt-dig pilot pressure 69 206 205
Boom-up pilot pressure 70
203 602
Arm-in pilot pressure
71 501
Front pump main pressure72 603
00
73 50 604
74
E
50
75 607
CAN+
77 CAN- 608
78 702
80 703
6
AM 501
502
508
509
510
511
CN-615M 108A
(AMP-40)
607
82
83
610 108B
611
84 702
27
N
88 0
703
89
608 42
98
604
5 99
100
602
603
TI
101
105
113
00#
114
00#
115
42
119
42
120
121
LA
4
NY
3
TERMINAL
B BRACCR1 R2 C
SA
HEAT
OFF
ON 27
START 42
22 13
2 T-101 T-102 T-104 T-103
13 0 20 21
1 2 3 45
1 2 3 45
KB
Battery relay
A B C A B
T-500 T-107
- +- +
1 CN-112M
(D-3) CN-115M
(D-3)
Battery To monitor circuit
GND 120 Ω
ZX335-1105037
A B C D E F G
Fig. 7-8

● This circuit diagram has been compiled by extracting the pressure collecting system and the
solenoid valve control systems from the general electrical circuit diagram.
CN-120M
9
(DF-3)
50
00
A
B
A
B
L. travel pilot
200 C C pressure sensor
CN-121M
(DF-3)
50 A
00 B
A
B
R. travel pilot
CN-122M
(DF-3)
50 A A
00 B B
Arm-out pilot
CN-129M
(DF-3)
50
00
A A Arm-in pilot
A
B B
CN-128M
(DF-3)
50 A A
00 Bucket-dump pilot
8
B B
CN-123M
C
50 50
(DF-3)
00
A
B
A
B
Swing pilot
00 208 C C pressure sensor
CN-125M
200 50
(DF-3)
A A
00 Boom-down pilot
RI
201 207
B B
C C pressure sensor
202 CN-126M
203 50
(DF-3)
A A
00 Boom-up pilot
204 206
B B
C C pressure sensor
208 CN-124M
(DF-3)
50 A
207 00 B
A
B
Bucket-dig pilot
205
pressure sensor
7
C C
206 CN-115M
(DF-3)
50
205 A A
Front pump
E
00 B B
501
CN-116M
502 50
(DF-3)
A
00 B
A
B
Rear pump
602 502 C C pressure sensor
603
604
607
608
AM 602
0
603
CN-132F
(AMP-2)
CN-135F
(AMP-2)
1
2 Boom priority-1
-prptnl valve
702
6
1 1
0 2 2 Boom priority-2
703
CN-134F -prptnl valve
(AMP-2)
508 604 1 1
0
509 2 2
Bkt confluence
510 CN-131F -prptnl valve
(AMP-2)
607
511 0
1 1
2 2 High speed
N
108A
CN-133F travel valve
(AMP-2)
608 1 1
0 2 2 Swing priority
108B CN-111F prptnl valve
TI
(AMP-2)
27
0
702
0
1
2
1
2 Front pump 5
CN-113F prptnl valve
(AMP-2)
42 703 1 1
0 2 2
Rear pump
508 T-109 prptnl valve
Engine oil
prsur switch
LA
509 CN-101M
Fuel level
510
T-116
Coolant temp 4
sensor
CN-113M
(AMP-2)
511 1 Hyd oil temp
42
2
sensor
CN-125F
(S-2)
1 1
108A Engine speed
NY
2 2 108B sensor
3
SA
Pilot valve relay

Pilot switch
1 2 3 4 5
CN-205F
(A-2)
1 2 3 4 5
CN-136F
2
(AMP-2)
1 1
2
2 Pilot valve
1
ZX225-1105038
H I J K L M
Fig. 7-9

7.3.4 SWP connectors
Male (plug) Female (socket)
A
7222-7414-40 7123-7414-40 (1 pin)
C
E RI
AM
7222-1424-40 7123-1424-40 (2 pins)
N
TI
LA
7222-7464-40 7123-7464-40 (6 pins)

NY
SA
7222-7484-40 7123-7484-40 (8 pins)
7222-7564-40 7123-7564-40 (16 pins)

W365-130707
Fig. 7-10
7.3.5 A/AMP connectors
Male (plug) Female (socket)
A
Part No. ：282104-1 Part No. ：282080-1 (2 pins)
C
E RI
282105-1
AM 282087-1 (3 pins)
N
TI
174354-2 174352-2 (2 pins)

LA
NY
SA
1473252-1 1473255-1 (40 pins)
1473244-1 1473247-1 (81 pins)

W365-130709
Fig. 7-11

7.3.6 DT connectors
Housing (plug) Housing (socket)

A B B A
DT06-2S DT04-2P
C A
A
B
RI
A B
E
C AM C
DT06-3S DT04-3P (3 pins)
1 6 6 1
N
2 5 5 2
TI
3 4 4 3
DT06-6S DT04-6P (6 pins)

LA
5 8
8 5
NY
1 4 4 1
DT04-8P (8 pins)
SA
DT06-8S
12 7 7 12
1 6 6 1
DT06-12S DT04-12P (12 pins)
W365-130710
Fig. 7-12

7.4 Troubleshooting with an Event Code
Information contained in troubleshooting table ............................................................. 7-26

E015 Power voltage abnormal ..................................................................................... 7-27
E212 Irregular throttle motor current or defective motor connection ............................ 7-28
E240 Hydraulic oil temperature abnormal .................................................................... 7-29
E320 Front pump output pressure abnormal ................................................................ 7-30
E321 Rear pump output pressure abnormal ................................................................ 7-31
A
E322 Bucket-dig pilot pressure abnormal..................................................................... 7-32
C
E323 Bucket-dump pilot pressure abnormal ................................................................ 7-33
RI
E324 Arm-in pilot pressure abnormal ........................................................................... 7-34
E325 Arm-out pilot pressure abnormal ......................................................................... 7-35
E
E326 Boom-up pilot pressure abnormal ....................................................................... 7-36
E327 Boom-down pilot pressure abnormal .................................................................. 7-37
AM
E328 Left travel pilot pressure abnormal ...................................................................... 7-38
E329 Right travel pilot pressure abnormal ................................................................... 7-39
E330 Swing pilot pressure abnormal ............................................................................ 7-40
N
E332 Motor built-in potentiometer irregular .................................................................. 7-41

TI
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
LA
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
NY
E145 CAN bus abnormal .............................................................................................. 7-48

SA

Information contained in troubleshooting table
Failure code Service Code Failure symp-

Title of failure shown in failure history
Code displayed —— tom
Failure information Failure is described on the monitor display.
When failure is detected, the controller has taken action to protect the affected
Controller reaction
system or equipment.
Machine reaction Symptom that is shown on the machine due to action of controller.
C A
Cause Standard values and troubleshooting references
RI
1
2 <Inclusion>
E
Possible causes and standard values
3 • Standard value under normal condition can be used to judge pos-

AM
sible causes
4
• Reference for passing the above "Good" or "No Good" judgement
Possible causes
of trouble (Given
N
numbers are ref- <Symptom of Wiring Harness Failure>

erence numbers,
TI
which do not in- • Open circuit

dicate priority) Faulty contact with connector or open circuit in wiring harness
5
LA
• Faulty grounding
An ungrounded wiring is grounded.
• Short circuit
A wiring has mistaken contact with a 24 V electric circuit.
NY
Related circuit diagram

SA
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.

E015 Power voltage abnormal

Failure code Failure
Power voltage abnormal
E015 symptom
Failure description Voltage of power supply is higher than 36V during machine operation.
Controller reaction Driving of motor and solenoid valve is cut off automatically by the system.
Machine symptom Engine fails to accelerate and machine moves slowly.
A
★ Turn the start switch to the OFF position and leave it in the position for trouble-
Power fail- shooting.
C
1
ure
Check battery voltage. Volt Under 25 V
RI
★ Turn the start switch to the OFF position before proceeding. Turn the start
Alternator switch to the START position for trouble shooting.
2
abnormal
Measure between alternator terminal B and ground. Volt Around 28 V
E
3 AM
4
N
TI
Start switch
HEAT
LA
OFF
ON
START
13
NY
Charging indicator
G
SA
14 R L 60
B E
- + - +
Battery relay 0 Alternator 0
Safety relay
M
C B
S Start motor
S R
E
E
13 11b 0
0 Delay relay 0
ZX225-1105002
Fig. 7-13

E212 Irregular throttle motor current or defective motor connection

g
Failure code Throttle motor loading circuit is abnormal and the engine
Failure symptom
E212 acceleration fails.
Failure description Motor feedback voltage is lower than 0.25V or higher than 4.75V
Controller reaction The controller stops the motor driving system when this failure is detected.
Symptom on machine Engine acceleration fails and the machine acts slowly. .
A
C
Ɣ Turn engine start switch to the OFF position before troubleshooting.
Failure of throttle Keep it in the OFF position while troubleshooting is performed.
1
RI
motor coil
Between Ĺ and ļ of CN-124M Resistance 12.2ȍ

2 Open circuit of har- Keep it in the OFF position while troubleshooting is performed.
E
ness Unplug the controller and measure the resistance
AM Resistance 12.2ȍ
between the pins 32 and 33.
Keep it in the OFF position while troubleshooting is performed.
Short circuit of har-
3 Unplug the connector CN-124M and measure the
ness (grounded)
resistance between motor Ĺ ( ļ ) and the hous- Resistance Above 2Mȍ
N
ing.
TI
No troubleshooting can be done for failure occurs in the inner of controller.

Internal failure of
4 (Except for the above reasons, the controller must be replaced in case of
controller
failure.)
LA
5
NY
Controller
CN-124M Throttle motor
SA
50A# Green
Sensor 25 1 1
507# White
Throttle feedback volt 7 2 2
MT- Red
MT- 33 3 3 M
GND 4 4
16
00A Yellow
5 5
MT+ 32
MT+ Blue
6 6
Operator station Chassis harness
ZX225-1105001
Fig. 7-14

E240 Hydraulic oil temperature abnormal

0 yd au c o te pe atu e ab o a
Failure code Hydraulic oil temperature is abnormal. Only
Failure symptom
E240 alarm output is effective.
Controller detects a temperature resistance of hydraulic oil that is lower than
Failure description
10 ohms or higher than 120 ohms and it lasts more than 3s.
Only alarm output is effective. The alarm resets automatically when conditions
Controller reaction
become normal.
Symptom on machine ——
C A
RI
Ɣ Turn the start switch to the OFF position and then keep it in the ON
Failure of sen- position to perform troubleshooting.
1
sor
Between CN-113M ķ and ground Voltage 0.2-4.75V
E
Open circuit of Keep it in the OFF position while troubleshooting is performed.
AM
2
harness
Between CN-113M ķ and pin 21 of controller Resistance Under 1 :
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting.
3 of harness Keep it in the OFF position while troubleshooting is performed.
(grounded) Between CN-113M ķ and ground Resistance Above 1M :
N
Ɣ Turn engine start switch to OFF position. Keep it at ON position to per-

Failure of 24V
TI
4 form troubleshooting.
power supply
Between CN-113M ĸ and ground Voltage About 24V
LA
CN-115F
0#
1 1
NY
240 ohms
Controller
2 2
SA
CN-113M Hyd oil temp sensor
511 Signal
Hyd oil temp sensor 21 1 1
2 2 24V PWR
24V PWR
ZX225-1105016
Fig. 7-15

E320 Front pump output pressure abnormal
Failure code Front pump output pressure is abnormal. Only

Failure symptom
E320 alarm output is effective.
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200
Failure description
msec when the power is on.
Controller reaction Only alarm output is effective.
A
C
Failure of 5V Keep it in the ON position while troubleshooting is performed.
RI
1
power supply
Between CN-151M A and B Voltage About 5V
E
Open circuit of
2
signal line
AM
Between CN-151M C and pin 29 of controller
Resistance
Under 1ȍ
Between CN-115M B and ground Under 1ȍ
3 of signal line Keep it in the OFF position while troubleshooting is performed.
N
(grounded) Between CN-151M C and ground Resistance Above 2Mȍ

TI
Failure of sen- Turn the start switch to the ON position and keep it in the ON position
4 while troubleshooting is performed.
sor
Between CN-151M C and ground Voltage 0.5±0.2V
LA
5
NY
Controller CN-151M Front pump

press. sensor
Front pump signal 501#
29 C Signal
SA
collecting port
00#
GND 23 B GND
50#
5V PWR 12 A 5V
ZX225-1105003
Fig. 7-16

E321 Rear pump output pressure abnormal

p p p p
Failure code Reading of rear pump output pressure is abnor-
Failure symptom
E321 mal. Only alarm output is effective. .
Failure description
C A
RI
Failure of 5V Turn the start switch to the ON position and keep it in the ON position
power supply
E
AM
Open circuit of
2
signal line Between CN-116M C and pin 19 of controller Under 1ȍ
Resistance
N

TI

sor
LA
5
NY
Controller Rear pump

CN-116M
press. sensor
SA
Rear pump signal 502#

19 C Signal
collecting port
00#
20 B GND
GND
50#
5V PWR 12 A 5V
ZX225-1105004
Fig. 7-17

E322 Bucket-dig pilot pressure abnormal
Failure code Bucket-dig pilot pressure is abnormal. Only alarm

Failure symptom
E322 output is effective. .
Failure description
Symptom on machine The bucket-dig motion is slow.
A
C
Ɣ Turn engine start switch to the OFF position before troubleshooting. Turn
RI
Failure of 5V the start switch to the ON position and keep it in the ON position while
1 troubleshooting is performed.
power supply
E
AM
Open circuit
2
of signal line Between CN-124M C and pin 10 of controller Under 1 :
Resistance
Between CN-124M B and ground Under 1 :
N
(grounded) Between CN-124M C and ground Resistance Above 2M :

TI
Failure of the start switch to the ON position and keep it in the ON position while
sensor
LA
5
NY
Controller Bucket-dig pilot

CN-124M pressure sensor
Bucket-dig pilot press. 10 205#
SA
C
signal collecting port Signal
00#
11 B GND
GND
50#
12 A 5V
5V PWR
ZX225-1105005
Fig. 7-18

E323 Bucket-dump pilot pressure abnormal
Failure code Reading of bucket-dump pilot pressure is abnor-

Failure symptom
E323 mal. Only alarm output is effective.
Failure description
Symptom on machine Bucket-dump motion is slow.
C A
RI
power supply
E
AM
Open circuit
2
of signal line Between CN-128M C and pin 33 of controller Under 1ȍ
Resistance
N
3 of signal line Keep it in the OFF position while troubleshooting is performed. .

TI

Failure of sen- the start switch to the ON position and keep it in the ON position while
4
LA
sor troubleshooting is performed.

5
NY
Controller Bucket-dump pilot

CN-128M pressure sensor
SA
204#
Bucket-dump pilot press. 33 C
signal collecting port Signal
00#
11 B GND
GND
50#
12 A 5V
5V PWR
ZX225-1105006
Fig. 7-19

E324 Arm-in pilot pressure abnormal
Failure code Reading of Arm-in pilot pressure is abnormal. Only

Failure symptom
E324 alarm output is effective. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec
Failure description
when the power is on.
Symptom on machine Arm-in motion is slow.
C A
RI
1
E
power supply troubleshooting is performed.
Between CN-129M A and B

AM Voltage About 5V
Open circuit
2
of signal line Between CN-129M C and controller pin 35 Under 1ȍ
Resistance
N
TI

LA
sensor
5
NY
Arm-in pilot
SA
Controller CN-129M press. sensor

203#
Arm-in pilot pressure 35 C Signal
signal collecting port
00#
GND 11 B GND
50#
5V PWR 12 A 5V
ZX225-1105007
Fig. 7-20

E325 Arm-out pilot pressure abnormal
Failure code Reading of Arm-out pilot pressure is abnormal.

Failure symptom
E325 Only alarm output is effective. .
Failure description
Symptom on machine Arm-out motion is slow.
C A
RI
power supply
E
AM
Open circuit
2
of signal line Between CN-122M C and pin 22 of controller Under 1 :
Resistance
Between CN-122M B and ground Under 1 :
N

Resistance Above 2M :
TI
(grounded) Between CN-122M C and ground

Failure of Turn the start switch to the ON position and keep it in the ON position
4
LA
sensor while troubleshooting is performed.

5
NY
Controller Arm-out pilot

SA
CN-122M press. sensor

Arm-out pilot pressure 22 202#
C Signal
00#
GND 11 B GND
50#
5V PWR 12 A 5V
ZX225-1105008
Fig. 7-21

E326 Boom-up pilot pressure abnormal
Failure code Reading of boom-up pilot pressure is abnormal.

Failure symptom
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200 msec
Failure description
when the power is on.
Symptom on machine Boom-up motion is slow.
C A
RI
power supply
E
AM
Open circuit
2
of signal line Between CN-126M C and controller pin 8. Under 1ȍ
Resistance
N

TI
sensor
LA
5
NY
Controller Boom-up pilot

SA
206#
Boom-up pilot pressure 8 C Signal
00#
11 B GND
GND
50#
12 A 5V
5V PWR
ZX225-1105009
Fig. 7-22

E327 Boom-down pilot pressure abnormal
Failure code Reading of boom-down pilot pressure is abnor-

Failure symptom
E327 mal. Only alarm output is effective. .
Failure description
Symptom on machine Boom-down motion is slow.
C A
RI
power supply
E
AM
Open circuit
2
of signal line Between CN-125M C and controller pin 9 Under 1ȍ
Resistance
N

(grounded)
TI
Between CN-125M C and ground Resistance Above 2Mȍ

Failure of Turn the start switch to the ON position and keep it in the ON position
LA
sensor
5
NY
Controller Boom-down pilot

SA
207#
Boom-down pilot pressure 9 C Signal
00#
11 B GND
GND
50#
12 A 5V
5V PWR
ZX225-1105010
Fig. 7-23

E328 Left travel pilot pressure abnormal
Failure code Reading of left travel pilot pressure is abnormal.

Failure symptom
Failure description
Symptom on machine Left travel speed is low. Travel deviates.
C A
RI
power supply
E
AM
Open circuit of
2
Resistance
N

(grounded)
TI
Between CN-120M C and ground Resistance Above 2Mȍ

LA
sor
5
NY
Controller Left travel pilot

CN-120M
pressure sensor
200#
SA
Left travel pilot press. 34 C Signal

00#
11 B GND
GND
50#
12 A 5V
5V PWR
ZX225-1105011
Fig. 7-24

E329 Right travel pilot pressure abnormal
Failure code Reading of right travel pilot pressure is abnormal.

Failure symptom
Failure description
Symptom on machine Right travel speed is low. Travel deviates.
C A
RI
power supply
E
2
Open circuit of
signal line
AM
Between CN-121M C and pin 30 of controller Under 1ȍ
Resistance
N
3 of signal line
TI
sor
LA
5
NY
Controller Right travel pilot

CN-121M
pressure sensor
Right travel pilot press. 201#
C Signal
SA
signal collecting port 30
00#
11 B GND
GND
50#
5V PWR 12 A 5V
ZX225-1105012
Fig. 7-25

E330 Swing pilot pressure abnormal
Failure code Reading of swing pilot pressure is abnormal. Only

Failure symptom
E330 alarm output is effective. .
Failure description
Symptom on machine Swinging motion is slow.
C A
RI
power supply
E
AM
Open circuit of
2
Resistance
N

TI
sor
LA
5
NY
Controller CN-123M Swing pilot pressure sensor

SA
Swing pilot pressure 208#

18 C Signal
00#
11 B GND
GND
50#
5V PWR 12 A 5V
ZX225-1105013
Fig. 7-26

E332 Motor built-in potentiometer irregular
Failure code The potentiometer built in the motor is irregular. It returns

Failure symptom
E332 to auto deceleration when time point is detected.
When machine power is on, throttle position feedback has a voltage other than
Failure description
0.25-4.75V lasting more 50 msec.
Controller reaction Returns to auto deceleration.
Symptom on machine The throttle fails to increase engine speed.
C A
Causes Standard values and troubleshooting references
RI
Failure of Ɣ Turn the start switch to the OFF position and then keep it in the ON position
1 5V power to perform troubleshooting.
source Between CN-155M ķ and Ļ Volt About 5V
E
Ɣ Turn the start switch to the OFF position before troubleshooting. Kee the
Open circuit switch in the OFF position to perform troubleshooting.
AM
2
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
3 switch in the OFF position to perform troubleshooting.
signal line
N
(grounded) Between CN-155M ĸ and ground Resistance Above 2Mȍ

TI
LA
Controller CN-142M Throttle position

CN-113 CN-502 CN-155M
507# Throttle
NY
Throttle position 507# 507# 507#

7 6 6 7 7 2 2 position
feedback
00A# 00A# 00A# 00A#
GND 16 4 4 4 4 5 5 GND
SA
50A# 50A# 50A# 50A#

Sensor 5V 25 3 3 6 6 1 1 5V
ZX225-1105045
Fig. 7-27

E434 Front pump proportional solenoid current abnormal (A)
Failure code Front pump proportional solenoid current is abnor-

Failure symptom
E434 mal. The system operates slowly.
Abnormality occurs in loaded circuit of proportional solenoid. Current which is
Failure description above 1.3A lasts for 3 second. Differential current occurs in drive protection
loop.
Controller reaction Stop the solenoid when failure is detected. Power supply must be restored.
A
Symptom on machine System operates slowly.
C
RI
Open circuit of
1
harness Between CN-111F ķ and pin 28 of controller Under 1ȍ
E
Resistance
Between CN-111F ĸ and ground
AM Under 1ȍ
(grounded) Between CN-111F ķ and wire 0# Resistance Above 1Mȍ
Failure of pro-
N

3 portional valve
Unplug the connector CN-111F, and measure the
TI
coil Resistance 17.5ȍ

resistance between solenoid valve's ķ and ĸ
Failure of con-
LA
troller
this failure.)
5
NY
Controller
CN-150F Front pump SV
SA
702# Signal
Front pump SV 28 1
signal output port
0#
GND 3 2 GND
ZX225-1105014
Fig. 7-28

E435 Rear pump proportional solenoid current abnormal (A)
Failure code Rear pump proportional solenoid current is abnor-

Failure symptom
Failure description above 1.3A lasts for 3 second. Differential current occurs in drive protection
loop.
A
C
RI
Open circuit of
E
1

AM Resistance
Between CN-113F ĸ and ground Under 1ȍ
N

Failure of pro- Keep it in the OFF position while troubleshooting is performed.
3 portional valve
TI
coil Unplug the connector CN-113F, and measure the

Resistance 17.5ȍ
resistance between solenoid valve's ķ and ĸ .
Failure of con-
LA
troller
this failure.)
5
NY
Controller
SA
CN-151F Rear pump SV

703#
Rear pump SV 1 Signal
17
signal output port
0#
GND 3 2 GND
ZX225-1105015
Fig. 7-29

E436 Front pump proportional solenoid current abnormal (B)
Failure code Front pump proportional solenoid current is ab-

Failure symptom
E436 normal. The system operates slowly.
Failure description
under 0.2 A lasts for 3 seconds and PWM output is greater than 10V.
C A
RI
Open circuit of
1
E
Resistance
Short circuit
AM
2 of harness
N
Failure of pro-
3 portional valve Unplug the connector CN-150F, and measure
TI
coil the resistance between solenoid valve's ķ and Resistance 17.5ȍ

ĸ.
Failure of con-
LA
troller
this failure.)
5
NY
Controller
SA
CN-150F Front pump SV

702# Signal
Front pump SV 28 1
signal output port
0#
GND 3 2 GND
ZX225-1105014
Fig. 7-30

E437 Rear pump proportional solenoid current abnormal (B)
Failure code Rear pump proportional solenoid current is abnor-

Failure symptom
Failure description
under 0.2 A lasts for 3 seconds and PWM output is greater than 10V.
C A
RI
Open circuit of
1
harness Between CN-151F ķ and pin 17of controller Under 1ȍ
E
Resistance
Short circuit
AM
2 of harness
Failure of pro- Keep it in the OFF position while troubleshooting is performed.
N
3 portional valve Unplug the connector CN-151F, and measure

TI
coil the resistance between solenoid valve's ķ and Resistance 17.5ȍ

ĸ
Failure of con-
LA
troller
this failure.)
5
NY
Controller
SA
CN-151F Rear pump SV

703#
Rear pump SV 1 Signal
17
signal output port
0#
GND 3 2 GND
ZX225-1105015
Fig. 7-31

E543 Engine speed abnormal
Failure code Engine speed is abnormal. Only alarm output is

Failure symptom
E543 effective.
Failure description CPU detects out that engine speed is too low (below 100 rpm).
Only alarm output is effective. The alarm resets automatically when conditions
Controller reaction
become normal.
C A
RI
Normal condi- Code 43 will be displayed on the monitor when the engine start switch is
1
tion turned from the OFF position to the ON position.

E
Open circuit of
2
harness Between CN-125M ķ and pin 16 of controller
AM Under 1ȍ
Resistance
Between CN-125M ĸ and pin 6 of controller Under 1ȍ
(grounded) Between CN-125M ķ and ground Resistance Above 1Mȍ
N

TI
Failure of sen- Keep it in the OFF position while troubleshooting is performed.

4 sor Unplug the connector CN-125M, and measure
the resistance between ķ and ĸ of the speed Resistance 2.3 r 0.2k :
sensor.
LA
5
NY
Controller
Engine speed sensor
SA
CN-125M
108A
Engine speed collection 16 1 Signal
108B
GND 6 2 GND
ZX225-1105017
Fig. 7-32

E244 Fuel control dial setting voltage abnormal
Failure code Fuel control dial setting voltage is abnormal and engine
Failure symptom
E544 returns auto deceleration.
When power is on, voltage of fuel control dial other than 0.25-4.75V lasts for over
Failure description
200 msec.
Controller reaction Throttle is moved to idle position.
Symptom on machine Engine returns auto deceleration.
A
C
Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the
RI
5V power ON position while troubleshooting is performed.
1
failure
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
E
2 OFF position while troubleshooting is performed.
of signal AM
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
3 cuit of OFF position while troubleshooting is performed.
signal line
(grounded) CN-501F ľ and ground Resistance Above 2Mȍ
N
Short circuit Ɣ Turn the start switch to the OFF position before troubleshooting. Keep it in the
of signal ON position while troubleshooting is performed.
TI
4 line (con-
tact with
power sup- CN-501F ľ and ground Volt Under 5V
LA
ply)
5 OFF position while troubleshooting is performed.
Dial failure
Unplug connector CN-501F and measure fuel con-
Resistance 5K±15%ȍ
trol dial Ľ and Ŀ .
NY
SA
CN-7-113M CN-209F CN-501F

50# Yellow
Sensor 5V 25 3 3 3 3 7 7
Red Fuel
9 9
506#
GND 16 4 4 9 9 control
Blue dial
2 2 0#
Fuel control dial 19 5 5 8 8
setting voltage
Operator station
ZX225-1105018
Fig. 7-33
E145 CAN bus abnormal
Failure code
Failure symptom Abnormality of CAN bus activates alarm.
E145
Failure description Time-out of CAN bus communication lasts for over 3s.

Symptom on machine ----
A
C
CAN re- OFF position while troubleshooting is performed.
RI
1 sistance Between CN-7-709 A and B Resistance 60ȍ
failure
Between CN-185 A and B Resistance 60ȍ
E
OFF position while troubleshooting is performed.
AM
Open circuit Unplug controller connector and measure pin
2 Under 1ȍ
of Harness 12 and CN-7-112 A.
Resistance
Unplug controller connector and measure pin
Under 1ȍ
11 and CN-7-112 B.
Control-
N
No troubleshooting can be done for failure occurs in the inner of controller. (Except
3 ler internal
for the above reasons, the controller must be replaced in case of this failure.)
TI
failure
CN-185M CN-7-709M
LA
A A
120 ohms 120 ohms
Controller B B
CN-7-112F CANH
CANH 12 A 35
CANL
NY
CANL 11 B 12
42
Monitor
CN-7-113M 5
F11 15A CN222F
43 24
4 1
SA
0
7 2 11
F13 10A CN-221M 0
9 31
21 20
PWR PWR
ZX335-1005040
Fi
Fig. 77-34
30

7.5 Troubleshooting Electrical System (E-Mode)
E-1 Engine does not crank .......................................................................................... 7-51

E-2 Engine runs rough or is unstable .......................................................................... 7-54
E-3 Power supply of machine cannot be cut off .......................................................... 7-55
E-4 Throttle motor not working .................................................................................... 7-56
E-5 Auto idle not functioning ........................................................................................ 7-57
A
E-6 Preheat function fails ............................................................................................ 7-59
E-7 All components not working .................................................................................. 7-60
C
E-8 Boom-up speed or power is low............................................................................ 7-61
RI
E-9 Arm speed or power is low .................................................................................... 7-62
E-10 Bucket speed or power is low ............................................................................. 7-63
E
E-11 Travel speed or power is low............................................................................... 7-65
AM
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
N
E-16 Incorrect fuel level reading .................................................................................. 7-70

TI
E-17 Wiper does not work ........................................................................................... 7-71

E-18 Incorrect arm-in pilot pressure reading ............................................................... 7-72
LA
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
NY
E-23 Incorrect bucket-dump pilot pressure reading..................................................... 7-77

E-24 Incorrect swing pilot pressure reading ............................................................... 7-78
SA
E-25 Left travel pilot pressure reading incorrect .......................................................... 7-79

E-26 Right travel pilot pressure reading incorrect ....................................................... 7-80

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.
Failure information Symptom on machine

Related information Failure occurred and troubleshooting information
C A
Standard values and troubleshooting referenc-
Cause
RI
es
<Inclusion>
E
● Standard value under normal condition can

AM
be used to judge possible causes
● Reference for passing the above "Good" or
"No Good" judgement
Possible causes of trouble

N
(Given numbers are refer- <Symptom of Wiring Harness Failure>

1
ence numbers, which do not ● Open circuit
TI
indicate priority) Faulty contact with connector or open cir-

cuit in wiring harness
LA
● Faulty grounding
An ungrounded wiring is grounded.
● Short circuit
A wiring has mistaken contact with a 24 V
NY
electric circuit.
SA

E-1 Engine does not crank
Trouble Engine cannot be started.

Related information

★ Turn engine start switch to the OFF position before troubleshooting. Keep
Low battery it in the OFF position while troubleshooting is performed.
A
1
capacity
Battery voltage Voltage ≥ 24V
C
Internal fail- ★ Turn engine start switch to the OFF position before troubleshooting. Keep
RI
2 ure of engine it in the OFF position while troubleshooting is performed.
start switch OFF position: between wire 22# and wire 11# Resistance ≥ 1M Ω
★ Turn engine start switch to the OFF position before troubleshooting. Keep
E
it in the OFF position while troubleshooting is performed.
Failure of pilot Lockout control in unlocked position: between
3 AM ≤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)
N
4 Failure of Engine starting motor Start switch Voltage

TI
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
LA
ON position to perform troubleshooting.

Open circuit Wire 21# and start motor terminal B ≤1 Ω
5
of harness
Wire 12# and start motor terminal S Resistance ≤1 Ω
Start relay terminal L and safety relay terminal S ≤1 Ω
NY
SA


Failure of fuse Battery terminal "+" (wire 20#) and control dial
6 Resistance ≤1 Ω
F1 wire 22#
★ Turn engine start switch to the OFF position before troubleshooting.
Short circuit
7 of harness Start relay terminal S and ground ≥1M Ω
(grounded) Resistance
Start motor input terminal S and ground ≥1M Ω
★ Turn engine start switch to the OFF position before troubleshooting. Turn
A
the start switch to the ON position and keep it in the ON position while
Internal failure
of alternator
C
Alternator terminal R and ground Voltage ≤ 1.5V
RI
★ Turn engine start switch to OFF position. Move it to ON position when
performing troubleshooting.
9 Start relay
Between relay coils ≥ 300 Ω
Resistance
Between start relay terminal B and line 11# ≤1 Ω
E
★ Turn engine start switch to the OFF position before troubleshooting. Turn
AM
the start switch to the ON position and keep it in the ON position while
Failure of troubleshooting is performed.
10
parking unit Check parking relay —
Resistance
Measure resistance of motor coil. Approx 63 Ω
N
TI
LA
NY
SA

21 16 2 1 17
F13-160A 14 4 3 GR-1 GLOW PLUG
Preheat
TERMINAL B BR ACC R1 R2 C 61
1
68 relay
3 4
HEAT 66 69
2 6
OFF 5 HL2
ON Low-temp switch PReheat indicator
START 0 Preheater R0
Preheat controller
S0 22 62 61 11
Start switch 64
897044-4180 13 3 6 65
5 A
B
1 2 63 P2
A
E3 P1 E
k7
0
C
Parking relay HLR Charging indicator
Parking motor
22 G
RI
14 14 R L 60
F1-20A P600G B E
F2-10A
0
21 E2 Engine
20
B1
E
B2 Safety relay
M1 B
AM C B 12 M
S
k1 11 11a 11b S R 60
- + - + E
Battery E
0 Start motor
relay 620
k11 0
k3 Lockout relay k3 Start relay
0 0
0
27 606
BAT-1 Battery
F7-10A 105
N
SQ1 Pilot switch

D-1
K4 Pilot valve relay 0 VA7
15 15a 22 0
TI
Pilot solenoid valve

D-10 0
k-8 Shutdown relay
ZX225-1105020
LA
Fig. 7-35
NY
SA

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.

Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in
Open circuit of the OFF position while troubleshooting is performed.
A
1
harness Unplug the connector controller, and measure
Resistance 2.3±0.2 Kȍ
C
the resistance between pin 16 and pin 7.
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in
RI
Internal failure the OFF position while troubleshooting is performed.
2
in sensor
Between CN-125M A and B Resistance 2.3±0.2 Kȍ
E
Short circuit Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it in
3 of harness the OFF position while troubleshooting is performed.
AM
(grounded) Between CN-125M A and ground Resistance Above 1Mȍ
Internal failure No troubleshooting can be done due to internal failure. (Failure lies in the control-
4
of controller ler if the reasons above are ruled out)
N
5
TI
LA
Controller HCU_J1
CN-125M
（S-2） RPM sensor
RPM sensor 16 A Signal

NY
input signal
GND 7 B GND
SA
ZX225-1105021
Fig. 7-36

E-3 Power supply of machine cannot be cut off
Failure information Engine cannot be stopped.

Engine stalls when start switch it turned to OFF position. There
Related information
is no time delay for power cutout.

Possible causes and standard
Failure of battery When the engine start switch is operated, if the operation of battery relay con-
1
relay tact is heard, the battery is normal. Turn the start switch OFFĺONĺOFF.
A
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep
values
Breakdown of
C
2 it in the OFF position while troubleshooting is performed.
surge diode
Between battery relay wire 20# and wire 21# Resistance Above 1Mȍ
RI
3
E
AM
21 16 2 1 17
F13-160A 14 4 3 GR-1 GLOW PLUG
Preheat
N
1
61 3
68 relay
4
HEAT 66 69
2 6
OFF
TI
5 HL2
ON Low-temp switch PReheat indicator
START 0 Preheater R0
Preheat controller
S0 22 62 61 11
Start switch 64
LA
897044-4180 13 3 6 65
5 A
B
1 2 63 P2
E3 P1 E
k7
Parking relay 0 HLR Charging indicator
Parking motor
22 G
NY
14 14 R L 60
F1-20A P600G B E
F2-10A
0
21 E2 Engine
20
B1
SA
B2 Safety relay
M1 B
C B 12 M
S
k1 11 11a 11b S R 60
- + - + E
Battery E
0 Start motor
relay 620
k11 0
k3 Lockout relay k3 Start relay
0 0
0
27 606
BAT-1 Battery
F7-10A 105
SQ1 Pilot switch
D-1
K4 Pilot valve relay 0 VA7
15 15a 22 0
Pilot solenoid valve
D-10 0
k-8 Shutdown relay
ZX225-1105020
Fig. 7-37

E-4 Throttle motor not working
Failure information Engine speed does not increase or decrease.

Turn the fuel control dial but engine speed does not
Related information
change.

Preheat Ɣ Turn he start switch to the ON position and keep it in the ON position while trouble-
shooting is performed.
A
1 fuse fail-
ure. The monitor shows failure code 41. Coolant temperature and oil level are normal.
C
Ɣ Turn he start switch to the ON position and keep it in the ON position while trouble-
Sensor
RI
shooting is performed.
2 power
abnormal Measure the voltage between motor plug, 50# wire
Volt 5.0V
and ground.
E
Unplug the connector of the harness between throttle motor and chassis.
Throttle Measure the resistance between the blue and red
AM 8~15ȍ
3 motor wires.
failure Resistance
Measure the resistance between the yellow and
5kȍ ± 10%
green wires.
Throttle Ɣ Turn he start switch to the ON position and keep it in the ON position while trouble-
N
4 motor shooting is performed.

failure The monitor shows failure codes 41, 12, 13, 14 and 32.
TI
LA
NY
SA

E-5 Auto idle not functioning
Failure information Auto idle speed do not work

Engine speed do not decrease wen the mode is auto idle
Related information
speed and grip keeps still in NEUTRAL position

Ɣ Turn engine start switch to OFF position. Start the engine and keep it run-
A
ning to perform troubleshooting.
Error of boom-
1
up signal Levers in NEUTRAL, pressure signal transmitted 0 KG
C
Pressure
Lever in operation, pressure signal transmitted 0-39 KG
RI
Error of boom-
2
down signal Levers in NEUTRAL, pressure signal transmitted 0 KG
E
Pressure
Lever in operation, pressure signal transmitted
AM 0-39 KG
Error of arm-in
3
signal Levers in NEUTRAL, pressure signal transmitted 0 KG
Pressure
N
TI
Error of arm-out
4
signal Levers in NEUTRAL, pressure signal transmitted 0 KG
Pressure
LA
Error of bucket-
5
dig signal Levers in NEUTRAL, pressure signal transmitted 0 KG
Pressure
NY
SA


Ɣ Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.
Error of Bucket- Levers in NEUTRAL, pressure signal
6 0 KG
dump signal transmitted
Pressure
Lever in operation, pressure signal
0-39 KG
transmitted
A
Error of swing Levers in NEUTRAL, pressure signal
7 0 KG
signal transmitted
C
Pressure
0-39 KG
RI
transmitted
Ɣ urn engine start switch to OFF position. Start the engine and keep it
E
Levers in NEUTRAL, pressure signal
8 Error of travel 0 KG
transmitted AM
signal Pressure
0-39 KG
transmitted
N
Error of attach- Levers in NEUTRAL, pressure signal

9 0 KG
ment signal transmitted
TI
Pressure
0-39 KG
transmitted
Failure of con- No troubleshooting can be done for it is internal failure. (If it is not caused
LA
10
troller by one of the factors listed above, it should be the failure of controller.)
NY
SA

E-6 Preheat function fails
Failure information Engine does not preheat.

Related information

A
Failure of pre- it in the OFF position while troubleshooting is performed.
1
heat fuse
Between wire 21# and preheat relay wire 16# Resistance Under 1ȍ
C
When the preheat function is activated, if operation of the preheat relay

Failure of pre-
RI
2 contact is heard, the relay is normal. The start switch is to be switched
heat relay
HEATĺOFFĺHEAT.
Short circuit
E
3 of harness
(grounded) AM
Between preheat controller pin 3# and start switch
Under 1ȍ
wire 61#
Failure of pre-
N
Between preheat controller pin 4# and preheat relay

4 heat control- Under 1ȍ
wire 68#
ler Resistance
TI
Between preheat controller pin 1# and preheat relay

Under 1ȍ
wire 14#
Between preheat controller pin 2# and low temp
Under 1ȍ
LA
switch wire 66#
17 GR-1 GLOW PLUG

21 16
2 1
HEAT F13-160A 14 4 3
NY
OFF Preheat relay

1
ON 61 68 P600G Preheater R0
3 4
START 66 2 6 69
20 21
S0
5 HL2
SA
Low temp SW - + - +
Start switch 22 62 13 61 11 Preheat indicator
21n4-10430 13 0 Preheat controller BAT-1 Battery
14 k1
Batt. relay
11 F2-10A
0
F1-20A
20
Control switch harness Cab harness Chassis harness
ZX225-1005039
Fig. 7-38

E-7 All components not working
Failure information The machine is motionless while operated after starting.

Related information

Ɣ Turn engine start switch to OFF position. Start the engine and keep
it running to perform troubleshooting.
A
Failure of lockout Item Lockout control lever Resistance
1
C
switch
Between wire 105# and wire LOCK Under 1ȍ
RI
27# FREE Above 1Mȍ
Short circuit of Keep it in the OFF position while troubleshooting is performed.
2
E
wire (grounded)
Between 105# and ground Resistance Above 1Mȍ
3
Failure of coil
inside lockout
AM
solenoid valve Between CN-136F 1 and 2 Resistance About 34ȍ
4
N
TI
LA
1 2 3 4 5
1 2 3 4 5
0
105 27
CN-302M CN-136F
NY
105 CN-201F CN-205F (D-12) (AMP-2)

(D-12) 606 606 1
1
1 4 0
Pilot 8 0 2
SA
switch 2 10
27
+24V
Cab harness Chassis harness
ZX225-1005040
Fig. 7-39

E-8 Boom-up speed or power is low
Failure information Boom-up speed or power is low.

Pilot pressure of the boom in operation can be
Related information
checked on the monitor.

A

Failure of sen-
C
1
sor Levers in NEUTRAL, boom-up pressure signal 0 KG
Pressure
RI
Lever in operation, boom-up pressure signal 0-39 KG
Short circuit Keep it in the OFF position while troubleshooting is performed.
2 of harness
E
(grounded) Between harness ( from controller pin 8 to CN- Above
Resistance
126M A) and ground
AM 1Mȍ
3
harness
Between controller pin 11 and CN-126M B Resistance Under 1ȍ
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the
4
N
troller controller if the reasons above are ruled out)

TI
Controller Boom-up pilot

206#
LA
Boom-up pilot pressure 8 C Signal

00#
11 B GND
GND
50#
12 A 5V
5V PWR
NY

SA
ZX225-1105009
Fig. 7-40

E-9 Arm speed or power is low
Failure information Arm speed or power is low during operation.

Pilot pressure of the arm in operation can be checked on the
Related information
monitor.

Ɣ Turn engine start switch to OFF position. Start the engine and keep it running
to perform troubleshooting.
A
Failure of
1 Levers in NEUTRAL, arm-in and arm-out pressure
sensor 0 KG
signals Pressure
C
Levers in operation, arm-in and dump pressure signal 0-39 KG
RI
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it
in the OFF position while troubleshooting is performed.
Short circuit
2 of harness Between harness (from controller pin 35 to CN-
E
(grounded) 129M A) and ground
Resistance Above 1Mȍ
Between harness (from controller pin 22 to CN-
AM
122M A) and ground
Ɣ Turn engine start switch to the OFF position before troubleshooting. Keep it
Open circuit in the OFF position while troubleshooting is performed.
3
of harness Between controller pin 11 and CN-129M B
Resistance Under 1ȍ
N
Between controller pin 11 and CN-122M B

TI
Failure of No troubleshooting can be done due to internal failure. (Failure lies in the control-
4
controller ler if the reasons above are ruled out)
Arm out
LA
CN-122M
（DF-3） press. sensor
A Signal
B GND
5V
NY
C
Controller
SA
Arm out Arm in

CN-129M
press. sensor 22 press. sensor
（DF-3）
Arm in Signal
35 A
press. sensor
11 B GND
Sensor GND
Sensor 5V 12 C 5V
Operator Station Chassis harness
ZX225-1105022
Fig. 7-41

E-10 Bucket speed or power is low
Failure information Bucket speed or power is low during operation.

Pilot pressure of the bucket can be checked on the moni-
Related information
tor.

A
Failure of sen- Levers in NEUTRAL, bucket-dig/dump pressure
1 0 KG
C
sor signals
Pressure
Levers in operation, bucket-dig/dump pressure
RI
0-39 KG
signals
E
Short circuit
2 of harness Between harness (from controller pin 10 to CN-
AM
(grounded) 124M A) and ground
128M A) and ground
3
N
harness Between controller pin 11 and CN-124M B

TI
Defective buck- Ɣ Turn engine start switch to the OFF position before troubleshooting.
4 et conÀuence Keep it in the OFF position while troubleshooting is performed.
solenoid valve Between CN-134F 1 and 2 Resistance About 34ȍ
LA
5
NY
SA

CN-128M Bucket dump

A Signal
B GND
C 5V
Controller
A
Bucket dump CN-124M Bucket dig
C
press. sensor 33 （DF-3） press. sensor
Bucket dig
RI
10 A Signal
press. sensor
Sensor GND 11 B GND
Sensor 5V 12 C 5V
E
Bucket confluence 27 AM
signal
CN-134F Bucket confluence
（AMP-2） Proportional valve
1 Signal
N
2 GND
TI

LA
ZX225-1105023
Fig. 7-42
NY
SA

E-11 Travel speed or power is low
Failure information Travel speed or power is low during operation.

Pilot pressure of travel operation can be checked on the
Related information
monitor.

A
Failure of sen- Levers in NEUTRAL, left and right travel pressure
1 0 KG
C
sor signals
Pressure
Levers in operation, left and right travel pressure
RI
0-39 KG
signals
E
Short circuit
2 of harness
120M A) and ground
(grounded)
AM
Resistance
Above
1Mȍ
121M A) and ground
3
N
harness Between controller pin 11 and CN-120M B

TI
4
LA
CN-121M
R. travel press. sensor
（DF-3）
A Signal
B GND
NY
C 5V
Controller
SA
HCU_J2
CN-120M
R. travel press. sensor L. travel press. sensor
30 （DF-3）
L. travel press. sensor 34 A Signal
Sensor grounding wire B GND

11
Sensor 5V 12 C 5V
HCU_J1
Fig. 7-39 ZX225-1105024

Fig. 7-43
E-12 Blank monitor display
Failure information Monitor display is blank after the machine is powered on.
Related information

Ɣ Turn engine start switch to OFF position. Then, keep it at OFF position to
perform troubleshooting.
A
1 Failure of fuse
Between wire 42# and ground About 24V
Voltage
C
Between wire 43# and ground About 24V
RI
Open circuit Between CN-7-113M pin 1 and CN-222F pin 4 Under 1ȍ
2
of harness
E
Between CN-7-113M pin 2 and CN-222F pin 7 Resistance Under 1ȍ
Between CN-7-113M pin 9# and ground
AM Under 1ȍ
Short circuit
Between harness (from CN-7-113M pin 1 to CN-
3 of harness Above 1Mȍ
222F pin 4 and ground
N
Between harness (from CN-7-113M pin 2 to CN-

Above 1Mȍ
222F pin 7 and ground
TI
Failure of No troubleshooting can be done for it is internal failure. (If it is not caused by
4
monitor one of the factors listed above, it should be the failure of monitor.)
LA
CN-185M CN-7-709M
A A
120 ohms 120 ohms
B B
Controller HCU-J2
CN-7-112F
CANH
NY
CANH 12 A 35
11 CANL
CANL B 12
Monitor
42
CN-7-113M 5
F11 15A CN-222F 43
4 1 24
SA
F13 10A 0
7 2 11
CN-221M
0 31
9
21 20
PWR PWR
ZX335-1005050
Fig. 7-44

E-13 Monitor displays nothing
Display of monitor is illuminated but no information is

Failure information
shown on the screen after machine is powered on.
Related information

Failure of it in the OFF position while troubleshooting is performed.
1
A
resistance
Between CN-1-185M A and B Resistance 120 ȍ
C
RI
Open circuit
2
of harness Between CN-7-112F pin A and controller pin 12 Under 1ȍ
Resistance
Between CN-7-112F pin B and controller pin 11 Under 1ȍ
E
AM
Short circuit
Between harness (from CN-7-112F pin A to con-
3 of harness Above 1Mȍ
troller pin 12) and ground
Between harness (from CN-7-112F pin B to con-
Above 1Mȍ
troller pin 11 and ground
N
Failure of
No troubleshooting can be done for it is internal failure. (If it is not one of the
4 monitor or
TI
failures stated above, it should be the failure of monitor or controller.)

controller
LA
CN-185M CN-7-709M
A A
120 ohms 120 ohms
B B
Controller HCU-J2
CN-7-112F
CANH
CANH 12 A 35
NY
11 CANL
CANL B 12
Monitor
42
CN-7-113M 5
F11 15A CN-222F 43
4 1 24
F13 10A 0
SA
7 2 11
CN-221M
0 31
9
21 20
PWR PWR
ZX335-1005050
Fig. 7-45

E-14 Dual speed travel not functioning
Failure information Only low speed travel is functioning during operation.

Press the Hi/Lo button on the monitor to change
Related information
travel speed.

Failure of dual Ɣ Turn engine start switch to the OFF position before troubleshooting.
1 speed travel Keep it in the OFF position while troubleshooting is performed.
A
solenoid valve Between CN-131F A and B Resistance About 34ȍ
C
RI
Open circuit
2
of harness Between CN-131F pin A and controller pin 7 Under 1ȍ
Resistance
Between CN-131F pin B and controller pin 3 Under 1ȍ
E
Short circuit Keep it in the OFF position while troubleshooting is performed.
AM
3 of harness
Between harness (from CN-131F pin A to con-
(grounded) Resistance Above 1Mȍ
troller pin 7) and ground
4
N
Controller
TI
CN-131F High speed travel

（AMP-2） solenoid valve
High speed travel
7 A Signal
solenoid valve
LA
GND 3 B GND
NY
ZX225-1105025
SA
Fig. 7-46

E-15 Incorrect engine coolant reading
Engine coolant temperature sensor cannot correctly reÀect cur-

Failure information
rent coolant temperature.
Related information Coolant temperature can be checked on the monitor.

Standard values for engine coolant temperature sensor
A
50ć 130ȍ
Failure of cool-
1 ant temperature 80ć 48.5±4.2ȍ
C
sensor
100ć 26.7±2.5ȍ
RI
110ć 20ȍ
2
E
lead
Between wire 510# and controller pin 32
AM Resistance Under 1ȍ
3
lead (grounded)
Between wire 510# and ground Resistance Above 1Mȍ
N
Lead short to Keep it in the ON position while troubleshooting is performed.

4
24V circuit
Wire 510# to ground Voltage Under 1V
TI
Controller
LA
510
Coolant temperature sensor 32
NY
SA
ZX335-1005053
Fig. 7-47

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.

Fuel level sen-
A
1 Pin Fuel level Resistance
sor error
FULL (Upper limit) Approx. 10 ȍ
C
Between wire 509# and ground
EMPTY (Lower limit) 85-95ȍ
RI
2
lead
Between wire 509# and controller pin 17 Resistance Under 1ȍ
E
Short circuit of Ɣ Turn engine start switch to the OFF position before troubleshooting.
AM
3 lead (ground- Keep it in the OFF position while troubleshooting is performed.
ed) Between wire 509# and ground Resistance Above 1Mȍ
Lead short to Keep it in the OFF position while troubleshooting is performed.
4
N
24V
Wire 509# grounded Voltage Under 1V
TI
Controller
LA
509
Fuel level sensor 17
NY
SA
ZX335-1005054
Fig. 7-48

E-17 Wiper does not work
Failure information Wiper does not work.

Related information

Internal Fail- Ɣ Turn engine start switch to the OFF position before troubleshooting.
1 ure of wiper Keep it in the OFF position while troubleshooting is performed.
A
motor Between wiper wire 25# and ground Resistance ˚ 10ȍ
C
RI
Between CN-403F 1 and CN-1-110 2 Under 1ȍ
Open circuit of
2 Between wiper switch wire 35L# and
lead Under 1ȍ
E
CN-1-110M 5 Resistance
Between wiper switch wire 35L# and
AM Under 1ȍ
CN-1-110M 4
3 lead (ground-
ed) Harness from CN-403F 1 to CN-1-110M
2 short to ground
N
TI
4
LA
Wiper switch
CN-401F CN-204M CN-1-110M 25
（D-12）（D-12） CN-203F （D-6）
2 2 （D-12）
F5 5A 36 2 2 36
6 6 6 35L 35L M
NY
25 12 3 3
35H 35H
7 7 4 4
CN-403M
（D-12） 5 5
1
SA
21
PWR
Operator station
ZX225-1005049
Fig. 7-49

E-18 Incorrect arm-in pilot pressure reading
Failure information Reading of arm-in pilot pressure is incorrect.

Related information

Failure of 5V Keep it in the OFF position while troubleshooting is performed.
1
power supply
A
Between CN-129M ķ and Ĺ Voltage Approx. 5V
C
2
RI
signal line
Between CN-129M ĸ and controller pin 35 Resistance Under 1ȍ
3
E
signal line
Between CN-129M ĸ and ground
AM Resistance Above 2Mȍ
4
sor
Between CN-129M ĸ and ground Voltage 0.5V- 4.5V
5
N
TI
Controller
CN-129M Arm in
LA
（DF-3） pressure sensor

Arm in
35 2 Signal
pressure sensor
Sensor GND 11 3 GND
Sensor 5V 12 1 5V
NY

SA
ZX225-1105026
Fig. 7-50

E-19 Incorrect arm-out pilot pressure reading
Failure information Reading of arm-out pilot pressure is incorrect.

Related information

Failure of 5V Keep it in the OFF position while troubleshooting is performed.
A
power supply
Between CN-122M ķ and Ĺ Voltage About 5V
C
RI
2
signal line
E
3
signal line
4
sor
N
5
TI
LA
Controller
CN-122M Arm out
Arm out
22 2 Signal
pressure sensor
NY
Sensor GND 11 3 GND
Sensor 5V 12 1 5V
SA
ZX225-1105027
Fig. 7-51

E-20 Incorrect boom-up pilot pressure reading
Failure information Incorrect Boom-up Pilot Pressure Reading

Related information

1
A
while troubleshooting is performed.
power supply
C
Open circuit of
RI
2 Keep it in the OFF position while troubleshooting is performed.
signal line
E
3
signal line AM
Between CN-126M ĸ and ground Resistance Above 2Mȍ
sor
N
5
TI
LA
Controller
CN-126M Boom up
Boom up
NY
8 2 Signal
pressure sensor
Sensor GND 11 3 GND
Sensor 5V 12 1 5V
SA
ZX225-1105028
Fig. 7-52

E-21 Incorrect boom-down pilot pressure reading
Failure information Boom-down pilot pressure reading is incorrect.

Related information

A
power supply
C
RI
2
signal line
E
3
signal line AM
sor
N
TI
5
LA
Controller
CN-125M Boom down
Boom down
NY
9 2 Signal
pressure sensor
Sensor GND 11 3 GND
Sensor 5V 12 1 5V
SA
ZX225-1105029
Fig. 7-53

E-22 Incorrect bucket-dig pilot pressure reading
Failure information Bucket-dig pilot pressure reading is incorrect.

Related information

A
power supply
C
RI
2
signal line
E
3
signal line AM
Ɣ Turn engine start switch to OFF position. Then, keep it at OFF posi-
Failure of sen- tion to perform troubleshooting.
4
sor
N
5
TI
LA
Controller
CN-124M Bucket dig
Bucket dig
10 2 Signal
pressure sensor
NY
Sensor GND 11 3 GND
Sensor 5V 12 1 5V
SA
ZX225-1105030
Fig. 7-54

E-23 Incorrect bucket-dump pilot pressure reading
Failure information Bucket-dump pilot pressure reading is incorrect.

Related information

A
power supply
C
Open circuit of
RI
signal line
E
3
signal line
sor
N
5
TI
LA
Controller
CN-128M Bucket dump
NY
Bucket dump Signal

33 2
pressure sensor
Sensor GND 11 3 GND
Sensor 5V
SA
12 1 5V
ZX225-1105031
Fig. 7-55

E-24 Incorrect swing pilot pressure reading
Failure information Swing pilot pressure reading is incorrect.

Related information

A
power supply
C
RI
2
signal line
E
Short circuit of AM
3
signal line
sor
N

TI
5
LA
Controller
CN-123M
NY
（DF-3） Swing pilot press. sensor
Swing pilot press. sensor 18 2 Signal
GND
SA
Sensor GND 11 3
Sensor 5V 12 1 5V
ZX225-1105032
Fig. 7-56

E-25 Left travel pilot pressure reading incorrect
Failure information Left Travel Pilot Pressure Reading is incorrect.

Related information

A
power supply
C
RI
2
signal line
E
3
signal line AM
sor
N
TI
5
LA
Controller
CN-120M Left travel pilot
NY
Left travel pilot

34 2 Signal
pressure sensor
Sensor GND 11 3 GND
SA
Sensor 5V 12 1 5V
ZX225-1105033
Fig. 7-57

E-26 Right travel pilot pressure reading incorrect
Failure information Right travel pilot pressure reading is incorrect.

Related information

A
power supply
C
Open circuit of
RI
signal line
E
3
signal line
sor
N
5
TI
LA
Controller
CN-121M R. travel pilot
NY
R. travel pilot press. sensor 30 2 Signal
Sensor GND 11 3 GND
Sensor 5V 12 1 5V
SA
ZX225-1105034
Fig. 7-58

7.6 Troubleshooting Hydraulic and Mechanical Systems (H-mode)
A schematic of hydraulic and mechanical systems ...................................................... 7-82

Information contained in troubleshooting table ............................................................. 7-84
H-1 Work equipment speed slow, or swing and travel speeds slow ............................. 7-85
H-2 Engine speed drops sharply or engine stalls ......................................................... 7-86
H-3 Work equipment, swing, and travel systems do not work ...................................... 7-87
H-4 Abnormal noise in hydraulic pump ......................................................................... 7-88
A
H-5 Auto deceleration not functioning........................................................................... 7-88
C
H-6 Boom speed slow .................................................................................................. 7-89
RI
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
E
H-10 Work equipment drifts excessively ...................................................................... 7-93
AM
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
N
H-15 Travel speed low .................................................................................................. 7-99

TI
H-16 Machine not steered easily or steering power low ............................................. 7-100
H-17 Travel speed cannot be shifted .......................................................................... 7-101
LA
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
NY
H-22 Large shock produced upon swing stoppage .................................................... 7-108

H-23 High noise produced upon swing stoppage ....................................................... 7-109
SA
H-24 Swing drift excessive ..........................................................................................7-110

A schematic of hydraulic and mechanical systems
This diagram is a simpli¿cation of the diagram of the whole hydraulic system and can be referred
to in troubleshooting the hydraulic and mechanical systems.
L. pilot valve Travel pilot valve R. pilot valve
AC
Arm Swing L. travel R. travel Boom Bucket
RIGHT
DOWN
LEFT
DUMP
BWD
FWD
OUT
BWD
RI
FWD
DIG
IN
UP Pilot valve
16
Boom priority
E
1 2 3 4 15
5 6 7 8 9 10 11 12 Bucket conflu.
AM 14
Swing priority
13
Travel speed
change
Accumulator
N
TI
1
LA
19 20
NY
SA
17 18
Regulator Regulator
Servo Servo
P1 P2
M
FRONT REAR
ZX225-1105039
Fig. 7-59

6DSafety valve
6X
Suction valve
6 6 Safety & suction valve
1 Standby valve Bucket conf-

luence valve 15
confluence
Arm retai-
ner valve
1 S&S Arm regener-

S&S 2
ation valve
1 Arm 2 valve 2
14
Arm cylinder
C A
Bucket S&S
Bucket 12 S&S Standby
S&S
10 11 valve S&S valve Standby actuating element
Cylinder
9
RI
Boom retai-
ner valve
Anti-swing
Boom Boom Boom 2
9
9 S&S S&S 10
Su
valve
valve
Cylinder
Swing motor
Sa
E
Anti-swing
Su
Brake release valve
13
valve
5 Su L. travel
valve
Su 6
AM 3 Swing valve
4
13
Balance valve
Sa
Servo
R. travel
Straight travel 7 Su valve
Su 8
Balance valve
vavle
Sa
Sa
Servo
N
Sa
Left travel motor
TI
Right travel motor
1
2
LA
ZX225-1105040
Fig. 7-60
NY
SA

● 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
A
C
1
RI
E
3 Possible causes of AM
● < 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.
N
TI
5
LA
NY
SA

H-1 Work equipment speed slow, or swing and travel speeds slow
● Work equipment speed is slow or the travel and swing speeds

Failure information
are slow.
● Set working mode to S and fuel control dial at position 10 to carry
Related information
out troubleshooting.
A
● Stop the engine before troubleshooting. Perform troubleshooting while
C
the engine is running at high idle.
RI
Defective adjust-
Control levers Main relief pressure

ment or malfunc-
1 33~34.3 MPa
tion of main relief
Arm IN
E
valve {337~350 kg/cm2}
AM
If normal pressure cannot be restored after adjustment, it is possible the
failure of main relief valve or internal defect. Check the valve directly.
Malfunction of Control levers Pilot control pressure
N
2
pilot relief valve
3.9~4.1 MPa
TI
All levers in NEUTRAL

{40~42 kg/cm2}
Malfunction of
3 The regulator possibly fails. Check the servo mechanism of the regulator.
regulator
LA
Malfunction of If the trouble is caused by other factors, it might be the main pump that
4
main pump has performance deterioration, malfunction or internal defect.
NY
SA

H-2 Engine speed drops sharply or engine stalls
Failure information ● Engine speed drops sharply or engine stalls.

Related information ● Information concerned

Failure of injection
1 Injection pump may be defective. Check it directly.

pump
A
Malfunction of
2 Regulator may have malfunction. Check its servo mechanism.
C
regulator
Clogging of oil filter
RI
3 Oil filter element may be clogged. Check the element directly.
element
Carbon buildup at
4 fuel injection noz- Carbon built up at fuel injection nozzle. Check it directly.
E
zle
Clogging of air AM
5 Air cleaner may be clogged. Check it directly.
cleaner
Abnormal wear of
6 Engine may be worn abnormally. Check it directly.
engine
7 Failure of oil pump Oil pump may be defective. Check it directly.
N
TI
LA
NY
SA

H-3 Work equipment, swing, and travel systems do not work
Failure information ● Whole work equipment, swing, and travel systems do not work.
Related information

● Stop the engine before troubleshooting. Perform troubleshooting
A
C
Pilot lockout control lever Pilot relief pressure
Malfunction of pilot
1 LOCKED 0 {0}
relief solenoid valve
RI
3.9~4.1 MPa
FREE
{40~42 kg/cm2}
E
AM
Failure of relief valve Control lever Pilot relief pressure
2
(pilot pump)
3.9~4.1 MPa
{40~42 kg/cm2}
The main pump may have malfunction or internal defect. Check it by
N
following method.
Failure of hydraulic
TI
3 ● Remove the oil pressure measurement plug and start the en-
pump
gine. If oil flows out of the opening, the piston pump is in good
condition.
LA
Internal failure of the coupling can stop rotation of the pump shaft.
Check the coupling.
4 Failure of coupling
● Loosen the oil delivery line of the pilot pump. If no oil is seen, it
is probably the failure of coupling.
NY
SA

H-4 Abnormal noise in hydraulic pump
Failure information ● Abnormal noise is produced from the hydraulic pump

Related information ―

Low level of
1 Make a visual check.
hydraulic oil
A
Inferior hy-
2 Hydraulic oil probably contains air. Make a visual check.
C
draulic oil
RI
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.
E
Clogging of
It is probably the clogging of hydraulic tank strainer that causes negative
4 hydraulic tank AM
pressure in the oil suction line. Make a visual check.
strainer
Failure of
5 The main pump may have internal defect. Check the main pump.
main pump
N
H-5 Auto deceleration not functioning

TI
Failure information ● Auto-deceleration is not functioning.

LA
Related information

NY


Control levers Pilot valve output pressure
Sensor fail-
SA
1 NEUTRAL 0 {0}
ure
3.5~4.1MPa
Operation
{36~42 kg/cm2}
Failure of Control levers Pilot valve output pressure
2
pilot valve NEUTRAL 0 {0}
3.5~4.1MPa
Operation
{36~42 kg/cm2}
Controller
3 Controller may be defective. Check it directly.
failure

H-6 Boom speed slow
Failure information ● The boom moves slowly.

Related information

A
C
Malfunction of right Boom control lever Pilot valve output pressure
1 pilot valve (boom
RI
NEUTRAL 0 {0}
circuit)
Boom UP ≥ 3.5MPa
Boom DOWN {36 kg/cm2}
E
Malfunction of boom
2 Spool of boom control valve may have malfunction. Check it directly.
control valve (spool)

AM
3 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
N
4 control valve (retain-

the valve directly.
ing valve)
TI
Malfunction or de-
fective seal of boom
The relief valve and makeup valve in boom control valve may have
5 control valve
LA
malfunction or defective seal. Check the valves directly.

(Relief valve and
makeup valve)
NY
Charge the bucket with a load of approximate 1260 kg. Cut off the oil
passage to the high-pressure side of the cylinder. Disconnect the cyl-
Failure of boom
6 inder from the main valve. Measure the displacement of piston for 15
cylinder
SA
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.

H-7 Arm speed slow
Failure information ● The arm moves slowly.

Related information

A
Malfunction of left
C
Arm control lever Pilot valve output pressure
1 pilot valve (arm NEUTRAL 0 {0}
RI
circuit)
≥ 3.5MPa
Arm IN or Arm OUT
{36 kg/cm2}
E
2 Press sensor failure the engine is running at high idle.

AM
Malfunction of arm
3 Spool of arm control valve may have malfunction. Check it directly.
Malfunction of arm
Regeneration valve of arm control valve may have malfunction.
N
4 control valve (re-

Check it directly.
generation valve)
TI
Malfunction or de-
fective seal of arm
The relief valve or makeup valve inside the arm control valve may have
5 control valve (Relief
LA
malfunction or defective seal. Check the valves directly.

valve and makeup
valve)
NY
Cut off the oil passage to the high-pressure side of the cylinder. Discon-
Failure of arm cylin- nect the cylinder from the main valve. Measure the displacement of piston
6
der for 15 minutes after the cylinder becomes stable. If the measured value is
greater than 10 mm, it is deemed that cylinder has a defective seal. For
SA
more information on the measuring procedure see "Hydraulic Drift of

Work Equipment - Test" on page 6-34.

H-8 Bucket speed slow
Failure information ● The bucket moves slowly.

Related information

A
C
Malfunction of right Bucket control lever Pilot valve output pressure
1 pilot valve (bucket NEUTRAL 0 {0}
RI
circuit)
≥ 3.5MPa
Bucket DIG or Bucket DUMP
{36 kg/cm2}
E

AM
Malfunction of
3 bucket control valve Spool of bucket control valve may have malfunction. Check it directly.
(spool)
N
Malfunction or
defective seal of
TI
Relief valve and makeup valve in bucket control valve may have mal-
4 bucket control valve
function or defective seal. Check the valves directly.
(relief valve and
makeup valve)
LA

Failure of bucket
NY
cylinder
greater than 10 mm, it is deemed that cylinder has a defective seal.
SA
For more information on the measuring procedure see "Hydraulic


H-9 Work equipment cylinders no response in separate operation
● Boom cylinder gives no response in separate operation.

Failure information ● Arm cylinder gives no response in separate operation.
● Bucket cylinder gives no response in separate operation.
Related information
A
C
RI
Work equipment control lever Pilot valve output pressure
Malfunction of pilot
1 NEUTRAL 0 {0}
valve
E
AM ≥ 3.5MPa
DIG or DUMP
{36 kg/cm2}
N
Malfunction of con-
TI
3 Spool of control valve may have malfunction. Check it directly.

trol valve (spool)
LA
NY
SA

H-10 Work equipment drifts excessively
Failure information (1) ● The boom drifts at excessive speed.

Related information

A
C
RI
Failure of boom
cylinder
greater than 10 mm, it is deemed that cylinder has a defective seal. For
E
more information on the measuring procedure see "Hydraulic Drift of
Work Equipment - Test" on page 6-34.
Failure of boom
AM
Boom retaining valve or pilot valve may be worn or sluggish. Check the
2
retaining valve valves.
Malfunction or
defective seal of
The relief valve and the makeup valve in the boom control valve may
N
3 boom control valve

have a defective seal. Check the seals.
(relief valve and
TI
makeup valve)
Failure of boom
4 Spool of boom valve may be worn excessively. Check the spool.
valve spool
LA
NY
SA

Failure information (2) ● The arm drifts excessively.

Related information

Cut off the oil passage to the high-pressure side of the cylinder. Discon-
Failure of arm nect the cylinder from the main valve. Measure the displacement of pis-
A
1
cylinder ton for 15 minutes after the cylinder becomes stable. If the measured
C
value is greater than 10 mm, it is deemed that cylinder has a defective
seal. For more information on the measuring procedure see "Hydraulic
RI
Malfunction or Relief valve or makeup valve of the arm control valve may be defective.
defective seal of Check the valves directly.
E
2 arm control valve ★ The performance of seal can be judged by replacing it with another
AM
(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
3
retaining valve valves.
Failure of arm
N
4 Arm valve (spool) may be worn excessively. Check it directly.

valve (spool)
TI
LA
NY
SA

Failure information (3) ● The bucket drifts excessively.

Related information


Failure of bucket while the engine is running at high idle.
1 Bucket control levers Leakage from bucket cylinder
cylinder
A
Bucket-dig relief 20 ml/min
Seal of relief valve or makeup valve of bucket control valve may be
C
Defective seal of defective. Check it directly.
RI
bucket control valve ★ The performance of seal can be judged by replacing it with anoth-
2
(relief valve and er relief valve or makeup valve. (Never replace it with the boom-
makeup valve) down relief valve or makeup valve as their pressures are set dif-
E
ferently. )
Defective seal of AM
Seal of bucket control valve spool may be defective. Check it direct-
3 bucket control valve
ly.
(spool)
N
TI
LA
NY
SA

H-11 Work equipment moves sluggishly
Failure information ● Work equipment moves sluggishly.

Related information
Malfunction of
A
1 arm regenera- Regeneration valve of arm may have malfunction. Check it directly.
C
tion valve
RI
Relief valve or makeup valve of control valve may have malfunction.
Malfunction of Check it directly.
control valve ● For arm and boom, whether a valve has malfunction can be judged
E
2
(relief valve and by replacing it with another relief valve or makeup valve.
makeup valve)
AM
(Never replace it with the boom-down relief valve or makeup valve as
their pressures are set differently. )
N
TI
H-12 Other work equipment moves while single oil circuit is relieved
● Other work equipment moves while single oil circuit of certain work equip-
LA
Failure information
ment is relieved.
Related information ● Set the working mode to S to perform troubleshooting.

NY
SA
Defective seal
1 Seal of control valve may be defective. Check it directly.
of control valve

H-13 Travel speed drops considerably while swinging and travelling
Failure information ● Travel speed drops considerably in swinging plus travelling operation.
● If the travel speed is low in only travelling operation, check first ac-
Related information
cording to H-15.
C A
RI
Failure of straight The straight travel valve gives no response. Check the spool and
1
travel valve the logic oil circuit drain port.
E
AM
N
TI
LA
NY
SA

H-14 Machine deviates during travel
Failure information ● Machine deviates during travel.

Related information

● Stop the engine before troubleshooting. Perform trouble-
A
shooting while the engine is running at high idle.
Travel control lever Pilot valve output pressure
C
Malfunction of travel pilot
1 Forward 3.5~3.9 MPa
valve
RI
Reverse { 36~40 kg/cm2}
Difference occurs between
0.4 MPa {4 kg/cm2}
left and right output
E
Malfunction of pilot relief

AM
Control lever Control circuit source pressure
2
valve
3.5~3.9 MPa
{ 36~40 kg/cm2}
3 Failure of regulator Check the regulator by swapping the front and back regulators.
TI
Sluggishness of propor- shooting while the engine is running at high idle.

4 Travel control lever Proportional valve output pressure
tional solenoid valve
LA
Operate both control levers ≤ 0.1 MPa

Sluggishness of travel con-
5 Check the valve spool to see whether it works well.
trol valve (spool)
Internal leakage of central
6 Check it by swapping the lines.
swivel joint
NY

7 Malfunction of travel motor Travel control lever Leakage of travel motor
SA
Travel relief 27.2 ml/min

Final drive may have internal defect. Check it directly.
● Internal defect of the final drive can be determined through
8 Failure of final drive
abnormal noise, abnormal heat, and metal powder or debris
contained in the oil drained.
Travel control levers Pilot valve output pressure
The monitor reads:
Forward or backward 3.5~3.9MPa
Failure of travel pilot pres-
9 { 36~40 kgf/cm2}
sure sensor
Output difference between the
0.4 MPa {4 kgf/cm2}
left and the right
Check it by swapping.

H-15 Travel speed low
Failure information ● Machine travel speed is low.

Related information

A
C
Malfunction of travel
1
RI
3.5~3.9 MPa
pilot valve Forward or reverse
{ 36~40 kg/cm2}
Difference occurs between front ≤ 0.4 MPa
E
output and rear output ≤ {4 kg/cm2}
AM
Malfunction of pilot Control lever Control circuit source pressure
2
relief valve
3.5~3.9 MPa
{ 36~40 kg/cm2}
N

TI

Travel speed Travel control
3.5~3.9 MPa
3 Sensor failure Low Operation
{ 36~40 kgf/cm2}
LA
3.5~3.9 MPa
High Operation
{ 36~40 kgf/cm2}
Check it by replacement.
4 Spool of travel control valve may have malfunction. Check it directly.
NY

Malfunction of
The makeup valve in travel control valve may have malfunction. Check it
5 travel control valve
directly.
SA
(makeup valve)
Failure of travel mo- while the engine is running at high idle.
6 Travel control lever Oil leakage of travel motor
tor
● Internal defect of the final drive can be determined through abnormal
noise, abnormal heat, and metal powder or debris contained in the
oil drained.

H-16 Machine not steered easily or steering power low
Failure information ● Machine is not steered well or steering power is low

Related information

● Stop the engine before troubleshooting. Perform troubleshoot-
A
ing while the engine is running at high idle.
C
Malfunction of travel Travel control lever Pilot valve output pressure
1
pilot valve Both sides in NEUTRAL 0 {0}
RI
3.5~3.9 MPa
Either side operated
{ 36~40 kg/cm2}
● Stop the engine before troubleshooting. Perform troubleshoot-
E
ing while the engine is running at high idle.

AM
Failure of travel pilot 3.5~3.9 MPa
2
pressure sensor Both sides operated
{ 36~40 kgf/cm2}
3.5~3.9 MPa
Either side operated
{ 36~40 kg/cm2}
N
Malfunction of travel Spool of travel control valve may have malfunction. Check it direct-
3
TI
control valve (spool) ly.

The makeup valve in travel control valve may have malfunction.
4 control valve (makeup
Check it directly.
LA
valve)
Seal of relief valve in travel motor may be defective. Check it di-
Failure 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.
NY
Seal of check valve in travel motor may be defective. Check it di-

Failure of travel motor rectly.
6
(check valve)
SA
● The failure of seal can be determined by swapping the front

and back motors or the left and right motors.

H-17 Travel speed cannot be shifted
Failure information ● Travel speed cannot be shifted.

Related information

A
Solenoid valve output
C
Malfunction of travel Travel speed Travel control lever
pressure
1 speed shifting sole-
RI
noid valve Lo Operated 0 {0}
3.5~3.9 MPa
Hi Operated
{ 36~40 kg/cm2}
E
2
AM
Failure of travel mo- Speed shifting assembly of travel motor may have malfunction.
tor (in speed change) Check it directly.
N
TI
LA
NY
SA

H-18 Travel system fails (only at one side)
Failure information ● One side of the tracks cannot make a turn.

Related information

Defective seat of
A
Seat of makeup valve in travel control valve may have malfunction.
1 travel control valve
Check it directly.
C
(makeup valve)
Defective seat of
Seat of relief valve in travel control valve may have malfunction.
RI
2 travel motor (relief
Check it directly.
valve)
Defective seat of
Seat of check valve in travel motor valve may have malfunction.
E
3 travel motor valve
Check it directly.
(makeup valve) AM
Speed of travel mo- while the engine is running at high idle.
4 Travel control lever Leakage from travel motor
tor drops.
N

TI
● Internal defect of final drive can be determined with abnormal

noise, overheat, and metal powder or debris contained in the oil
drained.
LA

Failure of pilot pres- The monitor read: 3.5~3.9 MPa
6 Forward or backward
sure sensor { 36~40 kgf/cm2}
NY
Output difference between the left

0.4 MPa {4 kgf/cm2}
and the right
Check it by swapping.
SA

H-19 Swing operation fails
Failure information (1) ● Upper structure fails to swing in either direction.

Related information

Malfunction of
A
1 swing motor (park- Parking brake of swing motor may have malfunction. Check it directly.
C
ing brake)
RI
Improper adjust- Swing control lever Swing relief pressure
ment or malfunc- 25.5~28.5 MPa
E
2 Swing relief
tion of swing motor {260~291 kg/cm2}
(relief valve)
AM
If oil pressure does not become normal after adjustment, swing motor
relief valve may have malfunction or internal defect. Check the relief
valve directly.
N
Failure of swing
3 Swing control lever Leakage from swing motor
motor
TI
Swing relief ≥ 10 ml/min

Swing mechanism may have internal defect. Check it directly.
Failure of swing ● Internal defect of swing mechanism can be determined with ab-
LA
4
mechanism normal noise, overheat, and metal powder or debris contained in
the oil drained.
NY
SA

Trouble (2) ● Upper structure only fails to swing in one direction.

Related information


Malfunction of Left control lever Pilot valve output pressure
1
pilot valve
A
NEUTRAL 0 {0}
Swing ≥ 3.5MPa { ≥ 36 kg/cm2}
C
Malfunction of
RI
2 swing control Spool of swing control valve may have malfunction. Check it directly.
valve (spool)
Defective seal Seal of makeup valve in swing motor may have defect. Check it directly.
E
3 of swing motor ● Failure of the seal can be determined by swapping the right and left
(makeup valve)
AM
makeup valves and check for any changes.
N
TI
LA
NY
SA

H-20 Swing acceleration poor or swing speed low
Failure information (1) ● Swing acceleration is poor, or swing speed is low.

Related information

Malfunction of
A
1 swing motor (park- Parking brake of swing motor may have malfunction. Check it directly.
ing brake)
C
RI
Improper adjust- Swing control lever Swing relief valve
E
2 Swing relief
(relief valve)
AM
If oil pressure does not become normal after adjustment, swing motor
valve directly.
N
Failure of swing
3 Swing control lever Leakage from swing motor
motor
TI
Swing relief ≤ 10 ml/min

Clogging of brake
4 Disassemble, clean and check.
control lines
LA
NY
SA

● Swing acceleration is only poor on one side, or swing speed is

Failure information (2)
low.
Related information

Malfunction of Swing control lever Pilot valve output pressure
A
1
C
Left swing
≥ 3.5MPa { ≥ 36 kg/cm2}
RI
Right swing
Malfunction of
swing motor Pressure compensation valve of swing motor may have malfunction.
2
E
(pressure com- Check it directly.
pensation valve) AM
Defective seal Seal of makeup valve in swing motor may have defect. Check it directly.
3 of swing motor ● Swap the left and right makeup valves and observe the result to de-
(makeup valve) termine whether the seal fails.
N
One-side leak- while the engine is running at high idle.

age of swing pilot Swing control lever Pilot valve output pressure
TI
4
pressure sensor NEUTRAL 0 {0}
(shuttle valve) Left swing
3.5~3.9MPa {36~40 kg/cm2}
LA
Right swing
NY
SA

H-21 Upper structure overrunning remarkably
● Upper structure overruns remarkably when it stops swinging in

both directions.
Related information
A

C
Improper adjust- Swing control lever Swing relief pressure
RI
1 Swing relief
(relief valve) If oil pressure does not become normal after adjustment, swing motor
E
AM
valve directly.
Failure of swing while the engine is running at high idle.
2 Control lever Leakage from swing motor
motor
N
Swing relief ≤ 10 ml/min

TI
● Swing acceleration is only poor on one side, or swing speed is

LA
low.
● Set the working mode at gear (10) of power mode (S) to perform
Related information
troubleshooting.
NY


SA
Malfunction of pilot Swing control lever Pilot valve output pressure

1
valve NEUTRAL 0 {0}
Left swing
≥ 3.5MPa { ≥ 36 kg/cm2}
Right swing
Malfunction of swing
2 Spool of swing control valve may have malfunction. Check it directly.
Seal of makeup valve in swing motor may be defective. Check it di-
Defective seal of
rectly.
3 swing motor (make-
● Swap the left and right makeup valves and observe the result to
up valve)
determine whether the seal fails.

H-22 Large shock produced upon swing stoppage
Failure information ● Large shock is produced when upper structure stops swinging.
Related information

A
C
Malfunction of swing Swing control lever Pilot valve output pressure
1
RI
Left swing
≥ 3.5MPa { ≥ 36 kg/cm2}
Right swing
E
Reverse prevention valve of swing motor may have malfunction.
Malfunction of swing AM
Check it directly.
2 reverse prevention
● Replace the valve with a new on to determine whether the valve
valve
fails.
Malfunction of swing
3 Swing relief valve may be worn or sluggish.
relief valve
N
TI
LA
NY
SA

H-23 High noise produced upon swing stoppage
Failure information ● High noise is produced when upper structure stops swinging.
Related information
A
Malfunction of
1 back pressure Back pressure valve may have malfunction. Check it directly.
C
valve
RI
Malfunction of
2 swing motor Relief valve of swing motor may have malfunction. Check it directly.
(relief valve)
Seal of makeup valve in swing motor may have malfunction. Check it di-
E
Malfunction of
rectly.
3 swing motor
(makeup valve)
AM
● Swap the left and right makeup valves and observe the result to deter-
mine whether the seal fails. .
The swing mechanism is suspected of an internal failure. Check the inside
of the machinery itself.
Failure of swing
N
4 ● Internal defect of swing mechanism can be determined with abnor-

mechanism
mal noise, overheat, and metal powder or debris contained in the oil
TI
drained.
LA
NY
SA

H-24 Swing drift excessive
● Hydraulic drift of swing is large (when swing holding brake is ap-

plied).
● When swing lock switch is turned ON or when swing holding
Related information brake release switch is in normal position, swing holding brake
operates and upper structure is fixed with disc brake.
A
C
Failure of swing
RI
Swing holding brake control lines and holding brake pilot valve may be
1 holding brake
defective. Check them directly.
control lines
E
Malfunction of
AM
2 swing motor Parking brake of swing motor may have malfunction. Check it directly.
(parking brake)
N
TI
● Hydraulic drift of swing is large (when swing holding brake is re-

leased).
LA
● When swing holding brake release switch is in release position,

Related information swing holding brake is released and upper structure is secured
by only hydraulic pressure.
NY
Malfunction or de-
Swing control valve spool may have malfunction or defective seal.
SA
1 fective seal of swing

Check it directly.
Failure of swing mo-

2 Seal of relief valve in swing motor may be defective. Check it directly.
tor (relief valve)
Failure of swing mo- Seal of makeup valve in swing motor may be defective. Check it di-
3
tor (makeup valve) rectly.

EA
G RIC
E
PAAM
KNTI
ANLA
BLNY
SA

E CA
G RI
ME
PAA
IN
AT
K
ANL
Y
BSLAN

SY365(B)H-9 Crawler Hydraulic Excavator Disassembly and Assembly
Disassembly and Assembly
C A
RI
8 Disassembly and Assembly
8.1 How to Read This Manual ....................................................................................... 8-5
E
8.1.1 Removing and installing an assembly............................................................ 8-5
AM
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
N
8.4 Fuel Injection Pump AS ........................................................................................ 8-10

TI
8.4.1 Removal ....................................................................................................... 8-10

8.4.2 Installation .................................................................................................... 8-12
LA
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
NY
8.6.1 Removal ....................................................................................................... 8-14

8.6.2 Installation .................................................................................................... 8-14
SA
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
Disassembly and Assembly SY365(B)H-9 Crawler Hydraulic Excavator
8.10.1 Removal ..................................................................................................... 8-31

8.10.2 Installation .................................................................................................. 8-32
8.11 Final Drive AS ...................................................................................................... 8-33
8.11.1 Disassembly ............................................................................................... 8-33
8.11.2 Assembly .................................................................................................... 8-36
8.12.1 Removal ..................................................................................................... 8-42
8.12.2 Installation .................................................................................................. 8-43
A
C
8.13.1 Disassembly............................................................................................... 8-44
RI
8.13.2 Assembly.................................................................................................... 8-49
8.14 Idler AS ............................................................................................................... 8-54
8.14.1 Disassembly............................................................................................... 8-54
E
8.14.2 Assembly.................................................................................................... 8-55
AM
8.15 Sprocket .............................................................................................................. 8-58
8.15.1 Removal ..................................................................................................... 8-58
8.15.2 Installation .................................................................................................. 8-58
N
8.16 Track AS ............................................................................................................. 8-59

8.16.1 Removal ..................................................................................................... 8-59
TI
8.16.2 Installation .................................................................................................. 8-60

8.17 Swing Bearing AS ............................................................................................... 8-62
LA
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
NY
8.18.2 Installation .................................................................................................. 8-66

8.19 Swivel Joint AS .................................................................................................... 8-67
SA
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
A
8.25 Pilot Valve AS (Work Equipment) ....................................................................... 8-85
C
8.26 Travel Pilot Valve AS ........................................................................................... 8-86
RI
8.27 Hydraulic Cylinder AS ......................................................................................... 8-87
8.27.1 Disassembly............................................................................................... 8-88
8.27.2 Assembly.................................................................................................... 8-92
E
8.28 Work Equipment AS ............................................................................................ 8-97
AM
8.28.1 Removal ..................................................................................................... 8-97
8.28.2 Installation .................................................................................................. 8-99
8.29 Air Conditioner AS ............................................................................................. 8-100
N
8.29.1 Removal ................................................................................................... 8-100

8.29.2 Installation ................................................................................................ 8-103
TI
8.30 Counterweight AS ............................................................................................. 8-104

8.30.1 Removal ................................................................................................... 8-104
LA
8.30.2 Installation ................................................................................................ 8-105

8.31 Cab AS .............................................................................................................. 8-106
8.31.1 Removal ................................................................................................... 8-106
8.31.2 Installation ................................................................................................ 8-109
NY
8.32 Cab Window Glass ............................................................................................8-110

8.32.1 Removal ....................................................................................................8-111
SA
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
8.36.3 Connector model and wiring .................................................................... 8-140
8.37 Battery ............................................................................................................... 8-141
8.37.1 Structure .................................................................................................. 8-141
A
8.37.3 Replacement ............................................................................................ 8-143
C
8.38 Start Switch........................................................................................................ 8-144
RI
8.38.1 Structure ................................................................................................. 8-144
8.38.2 Removal ................................................................................................... 8-145
E
8.38.4 Wiring ....................................................................................................... 8-146
AM
8.39 Fuse Box............................................................................................................ 8-147
8.40 Wiper ................................................................................................................. 8-148
8.40.1 Structure .................................................................................................. 8-148
N

8.40.3 Removal ................................................................................................... 8-150
TI
8.40.4 Installation ................................................................................................ 8-150

8.40.5 Angle adjustment of wiper arm................................................................. 8-151
LA
8.41 Relays ................................................................................................................ 8-152

8.41.1 Engine relays ........................................................................................... 8-152
8.41.2 Other relays ............................................................................................. 8-153
NY
8.41.4 Relay connector and wiring...................................................................... 8-154

8.42 Sensors.............................................................................................................. 8-155
SA
8.43 Connector Terminals ......................................................................................... 8-157

8.43.1 Insertion ................................................................................................... 8-157
8.43.2 Removal ................................................................................................... 8-158

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.
A
■ : Special tools that cannot be substituted and must be used.
C
● : Very important tools, which can be substituted with commercially available ones.
RI
Removal of parts
● The "Removal" section contains procedure, precautions and the amount of oil or coolant to be
discharged.
E
● The symbols used the in the "Removal" section are described below:
AM
This symbol indicates that safety-related precautions must be observed when doing the
job.
N
★ This symbol is followed by instructions or precautions when performing a procedure.

TI
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.
LA
Installation of parts
● Unless specified otherwise, installation of a part is to be performed in a reverse order of re-
moving the part.
NY
● The mark used in the "Installation" section indicates the rules and precautions related to
parts installation.
SA
● 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.

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.
A
● Matching mark must be made at where is necessary before removing a part in order to
C
avoid mistake during reinstallation.
RI
● Do not pull the wire and avoid the wire coming off its contact. To avoid excessive force im-
posing on the wire, hold the connector when disconnecting a wire.
E
● Tag the wires and the hoses in order to ensure their connecting positions. By doing so,
mistakes can be avoided during reinstallation. AM
● 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.
N
● When forcing screws are used to remove any components, tighten the screws evenly in
turn.
TI
● The surrounding area must be cleaned before removing a component. Cover the compo-
nent after removal in order to prevent invasion of dirt or dust.
LA
NY
SA

● Precautions to be observed when disassembling the lines

The lines disassembled must be blinded with plugs.
A. Thread-connected hoses
Inner Diameter (mm) Code Description

Light Thread Connection
6 B210780001189 Plug
A
8 B210780001190 Plug
10 B210780000077 Plug
C
12 B210780000078 Plug
RI
15 B210780000883 Plug
20 B210780000079 Plug
E
22 60056667 Plug
Heavy Thread Connection
AM
12 B210780001142 Plug
16 60002397 Plug
20 B210780000080 Plug
N
25 B210780000081 Plug
TI
B. Thread-connected adaptors (plug and nut used in combination)

LA
Inner Dia.(mm) Code Description Code Description

Light Thread Connection
6 B210780000903 Cone Plug 23002925 Nut
8 B210780001146 Plug B210770000011 Nut
NY
10 B210780000088 Plug B210334000011 Nut

12 B210780000089 Plug B210334000012 Nut
SA
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

2. Precautions to be observed prior to instal- performed as the following:

lation (1) Start the engine and run the engine at
● Tighten all the screws and nuts (sleeve low idle.
nuts) to specified torques. (2) Operate the work equipment control
lever in order to cycle the movement of the
● Install the hoses without twisting or in- hydraulic cylinder 4 or 5 times. Hold the cyl-
terference. inder at where it is 100 mm from its stroke
end.
● Replace the gaskets, O-rings, cotter
(3) Go on operating the hydraulic cylinder
pins and lock plates with new ones. 3 or 4 times to its stroke end.
A
● Bend the cotter pin or lock plate se- (4) You can run the engine at normal
curely. speed after this operation.
C
● Before applying the adhesive, clean the ● This procedure is to be performed be-
RI
parts of oil and dust. Apply 2 or 3 drops fore using your machine for the first
of adhesive to the threaded portion. time after repair or long storage.
● Before applying the sealant to the gas- 3. Precautions to be observed upon comple-
E
ket, clean the gasket surface of oil and tion of the operations
dust. Check the gasket for contamina-
AM
● Completely discharge the engine cool-
tion or damage. Apply the gasket sealant, tighten the drain valve, and add
ant evenly. coolant to the specified level. Run the
● Clean all parts, and correct any dam- engine to circulate the coolant through
the system. Check the coolant level
N
age, dents, burrs, or rust.

again.
TI
● Apply engine oil to the moving parts.

● Add hydraulic oil to the specified level
● Before installing a snap ring, make sure after disassembly and reinstallation of
that the snap ring is mounted properly a hydraulic unit. Run the engine to cir-
LA
in the circular groove. culate the hydraulic oil through the sys-
● Before connecting the wiring connector, tem. Check the oil level again.
clean the wiring connector of oil, dirt or ● Purge the air from the system after
water. Make sure that the wiring con- removing and repairing the lines or hy-
NY
nector is connected securely. draulic unit and reassembling the parts.

● Before using an eyebolt, check the ● To purge the air, see related informa-
eyebolt for deformation or deterioration.
SA
tion in “Testing and Adjusting”.

Screw on the eyebolt as far as possible
and align it to the direction of the hook. ● Add the specified amount of grease
(MoS2) to the work equipment related
● Before tightening the half flanges, tight- parts.
en it evenly in turn in order to prevent
over tightening on one side.
● After reassembling the hydraulic cylinder,
main pump or other hydraulic equipment
that has been disassembled and repaired,
it is necessary to purge the air from the
hydraulic cylinder prior to initial operation
of the cylinder. The purging procedure is

8.3 Start Motor AS

8.3.1 Removal
NOTICE
● Before removing the start motor assem-

bly, disconnect the cable from the nega-
tive post (-) of the battery. Insulate the
A
cable and negative post (-) with tape.
C
RI
1. Open the engine hood.
2. Disconnect the Cables (2), (3) and (4).
E
2 3
3. Remove the start motor fixing bolt (1) in 1
order to remove the start motor. AM 4
N
TI
ZXT335-1006001
Fig. 8-1
LA
8.3.2 Installation
● Installation is performed in the reverse pro-
cedure of removal.
NY
SA

8.4 Fuel Injection Pump AS
8.4.1 Removal
NOTICE
● Disconnect the negative (-) post of bat-

tery.
A
C
RI
ZXT335-1006002
Fig. 8-2
E
2. Disconnect the air hoses (1) and (2) of the
AM 1
crankcase.
2
N
TI
LA
ZXT335-1006003
Fig. 8-3
NY
3. Remove the fuel return line (3), fuel

SA
delivery line (4), fuel supply line (5) and 3

lubrication line (7). 4
● After disconnecting the hoses, cork

them to prevent fuel leak. 5
6
ZXT335-1006004
Fig. 8-4

4. Remove the six (6) fuel delivery lines (8) 8
C A
ZXT335-1006005
Fig. 8-5
RI
5. Remove the air hose (9).
E
6. Remove the bolt (10) fixing the electronic AM 9
shutdown device and the bolt (11) of gov-
10
ernor motor.
7. Remove the fuel injection pump mounting 11
nut in order to remove the fuel injection
N
pump assembly.
TI
LA
ZXT335-1006006
Fig. 8-6
NY
SA

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
A
● Install the fuel injection pump as the following:
C
A. Check the fuel injection timing.
RI
See “Fuel Injection Timing - Test and Adjust” on page 6-13.
B. Assemble the fuel injection pump assembly and tighten the nuts.
E
Nut: 9.8±2 Nm {10±0.2 kgm}
● Purge the air.
AM
Purge the air from the fuel injection system.
N
TI
LA
NY
SA

8.5 Engine Front Oil Seal
8.5.1 Removal
3
1. Remove the radiator assembly. See
“Radiator AS” on page 8-20. 2
2. Remove the engine fan (1), belt (2) and 1

pulley (3).
A
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
C
RI
ZX335-1006007
E
Fig. 8-7
AM
crankshaft belt pulley (5).
4. Remove the front oil seal (6).
6
N
5
4
TI
LA
ZX335-1006008
Fig. 8-8
NY
8.5.2 Installation
SA
cedure of removal.

8.6 Engine Rear Oil Seal
8.6.1 Removal
1. Remove the hydraulic pump assembly. 2
See “Hydraulic Pump AS” on page 8-80.
2. Remove the flywheel (1).
3. Remove the rear oil seal (2).
C A
E RI
ZX335-10
Fig. 8-9
AM
8.6.2 Installation
N
cedure of removal.
TI
Sealant
● Install the rear oil seal as the following:
A. Apply engine oil to the lip of rear oil
seal.
LA
ø2mm
B. Clean the seal surface.
C. Apply sealant along the sealing line
continuously and uniformly.
Line
NY
Sealant (Tianshan 1596) ZX335-1006010
D. Installation is to be performed within Fig. 8-10

three (3) minutes after application of
SA
sealant. It is important to keep the ap-

plied sealant in proper area.

8.7 Cylinder Head AS

8.7.1 Removal
NOTICE
● Disconnect the cable from the negative

post (-) of the battery.
A
1. Drain coolant from the engine.
C
Coolant: 26 L
RI
2. Open the engine hood. ZXT335-1006011
Fig. 8-11
E
3. Remove the air intake hose (1).
AM
1
N
TI
LA
ZXT335-1006012
Fig. 8-12
NY
4. Disconnect the lines (2) and (3) between

4
the fuel filter and the fuel injection pump. 2
SA
5. Remove the fuel filter bracket (4) and the

fuel filter assembly (5).
5 3
ZXT335-1006013
Fig. 8-13

6. Disconnect the six (6) fuel delivery lines (6). 6
C A
ZXT335-1006014
Fig. 8-14
E RI
7. Remove the cover (7) of exhaust muffler
7
connector. AM
8. Disconnect the air intake hose (8).
9. Disconnect the air intake hose (9) and the
8
crankcase breathing hose (10) between
turbocharger and intercooler.
N
9
10
TI
LA
ZXT335-1006015
Fig. 8-15
NY
SA

10. Disconnect the oil delivery line (11) and the oil return line (12).
11. Remove the turbocharger system assembly.
12. Remove the exhaust manifold (13).
C A
E RI
AM
N
11
TI
LA
13
NY
12
SA
ZX335-1006016
Fig. 8-16
13. Remove the radiator inlet hose (14) and

14
outlet hose (15).
15
C A
ZXT335-1006017
RI
Fig. 8-17
E
14. Remove the six (6) nozzle seats (16).
16
AM
N
TI
LA
ZXT335-1006018
Fig. 8-18
NY
SA

15. Remove the rocker arm cover (17).
16. Remove the camshaft assembly (18).
17. Remove the rocker arm assembly (19).
18. Remove the bolts of cylinder head and

lift the cylinder head assembly in order to
disassemble it.
19. Remove the cylinder head gasket (21).
C A
RI
8.7.2 Installation
E
cedure of removal. AM
Rocker cover bolt:
7.8-9.8N.m{0.8-1.0kgf.m}
N
Cylinder head bolt:

TI
88N.m{9.0 kgf.m }+90°

LA
Cylinder head bolt threads: engine oil

Camshaft flange surface: engine oil
Camshaft journal circumference: en-
gine oil
NY
● Adjusting valve clearance

● See “Valve Clearance - Adjust” on
SA
page 6-7.
● Adding coolant
Add engine coolant to the specific level.
ZX335-1006019
Start the engine to circulate coolant in or-
der to eliminate all foams. Check the cool- Fig. 8-19
ant level again.

8.8 Radiator AS
8.8.1 Removal
1. Open the engine hood
2. Open the pressure cap (1). Drain engine
coolant via the drain valve beneath the
coolant tank.
Coolant: Approx. 26 L 1
C A
RI
ZXT335-1006020
Fig. 8-20
E
3. Disconnect the pipes from the hydraulic oil
AM
cooler delivery port (2) and supply port (3).
Seal the ports in order to prevent the leak-
age of hydraulic oil in the hydraulic system.
N
4. Drain hydraulic oil from the cooler and from

radiator.
TI
Hydraulic oil radiator: Approx. 8 L

3
LA
ZXT335-1006021
Fig. 8-21
NY
5. Remove hose (4) of coolant tank.

SA
ZXT335-1006022
Fig. 8-22

6. Remove the inlet and outlet houses (5) and

6
(6) of the water cooler.
Hydraulic oil radiator: Approx. 5.6 L
C A
ZXT335-1006023
RI
Fig. 8-23
E
7. Remove the inlet and outlet air hoses (7)
and (8) of the intercooler. AM
8
7
N
TI
LA
ZXT335-1006024
Fig. 8-24
NY
8. Remove the four bolts (9) of the A/C radia-

tor. Remove the A/C radiator and put it in a 9
suitable place.
SA
ZXT335-1006025
Fig. 8-25

9. Remove the radiator fan guard (10).

10
C A
ZXT335-1006026
Fig. 8-26
RI
10. Remove the four bolts (11) from the bottom
E
of radiator.
AM
N
11 11
TI
LA
ZXT335-1006027
Fig. 8-27
11. Remove the bolts (12) and (13) of both left

NY
12
and right brackets.
13
SA
ZXT335-1006028
Fig. 8-28

12. Install eyebolts (14) on both sides of the

radiator and lift the radiator assembly.
● Before lifting the radiator assembly, move
the radiator assembly in axial direction until
14
the fan is free from the fan guard.
C A
ZXT335-1006029
Fig. 8-29
RI
8.8.2 Installation
E
cedure of removal.
AM
● Adjust the clearance (a) between the fan
and guard so that the clearance is uni-
form around the fan.
N
● The clearance (a) should read as the fol-

TI
lowing on the left, right, top and bottom

points.
● Standard clearance (a) (around the
LA
fan): 10 mm
● Fan dia. (b): ø830 mm
● Guard inner dia. (c): ø850 mm
NY
● Refilling engine coolant and hydraulic oil

Refill engine coolant and hydraulic oil to
the specific levels. Start the engine to cir-
SA
culate the coolant and oil. Check the cool-

ant level and oil level again.
Engine coolant: Approx. 26 L.
Hyd oil radiator: Approx. 8 L.

8.9 Engine and Hydraulic Pump AS
8.9.1 Removal
Lower the work equipment to the ground in
order to ensure safety. Stop the engine. Dis-
connect the cable from the battery negative (-)
post.
Loosen the butterfly nut on the breather valve
A
and press the relief button to release internal
pressure.
C
● Mark the lines to avoid mistakes during re-
RI
installation.
1. Remove the hydraulic tank suction filter
E
and block the opening.
2. Discharge engine coolant.
AM
Coolant: About 22.9 L
ZXT335-1006030
N
Fig. 8-30
TI
4. Disconnect lines (1), (2) and (3).

LA
2
NY
1
SA
ZXT335-1006031
Fig. 8-31

5. D i s c o n n e c t h o s e s ( 4 ) , ( 6 ) a n d ( 7 ) .
Disconnect the cables (5) and (8) of main 6
5
pump pressure sensors. 7
A
ZXT335-1006032
C
Fig. 8-32
RI
6. Remove the hose (9) and the clamps (10).
E
AM9
10
N
TI
10
ZXT335-1006033
LA
Fig. 8-33
7. Remove the main pump negative feedback

NY
12
hoses (11) and (12).
SA
11
ZXT335-1006034
Fig. 8-34

8. Remove the main pump PSV hose (13),

clamp (14) and cable (15).
13
15 14
A
ZXT335-1006035
Fig. 8-35
C
RI
9. Disconnect the engine fuel hoses (16) and 21
(17) and the engine oil hoses (18) and (19). 20 22
E
10. Disconnect the engine speed sensor
cables (20) and (21) as well as the clamp AM
(22).
16 17 18 19
N
TI
ZXT335-1006036
Fig. 8-36
LA
11. Unscrew the throttle guy connecting bolt

(23) and the electronic shutdown device
connecting bolt (24).
NY
24
23
SA
ZXT335-1006037
Fig. 8-37

12. Remove the coolant temperature sensor,

high temperature switch external cables
(25) and (26) as well as the hose clamps
(27).
25
26
A
27
C
ZXT335-1006038
Fig. 8-38
RI
13. Disconnect the compressor cables (28)
E
28
and (29) as well as the hoses (30) and (31). AM 29
31
N
30
TI
ZXT335-1006039
LA
Fig. 8-39
14. Disconnect the external cable (32) of

NY
engine oil pressure sensor and the cable

(33) of engine oil pressure sensor. 32
SA
34
15. Remove the clamps (34).
36
16. Remove the starter main cable (35).
17. Disconnect the alternator cable (36).
35
33
ZXT335-1006040
Fig. 8-40

18. Remove the hose clamp (37).
37
C A
ZXT335-1006041
Fig. 8-41
E RI
19. Disconnect the hoses (38), (39) and (40)
between the engine and the radiator. AM
20. Disconnect the air intake hose (41).
39
38
N
40 41
TI
LA
ZXT335-1006042
Fig. 8-42
NY
21. Disconnect the hose (42) between the

engine and the radiator.
SA
42
ZXT335-1006043
Fig. 8-43

22. Disconnect the radiator fan guard (43).
43
C A
ZXT335-1006044
RI
Fig. 8-44
E
23. Remove the fixing bolt (44) on each of the AM
four (4) mounting plates of the damper. Lift 44
the engine and main pump assembly.
Engine and hydraulic pump AS: 44
836 kg
N
TI
LA
ZXT335-1006045
Fig. 8-45
NY
SA

8.9.2 Installation
● 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.
A
Hydraulic tank: Approx. 380 L
C
● Start the engine to circulate the coolant in order release the foams, and check the coolant
level again.
RI
● Start the engine to circulate the hydraulic oil in the hydraulic system, and check the oil level
again.
E
● Purging the air. AM
See “Air in Each Component - Purge” on page 6-41.
N
TI
LA
NY
SA

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
A
ground in order to ensure safety. Stop
C
the engine. Operate the breather valve 1
to release internal pressure.
RI
ZX335-1006046
Fig. 8-46
E
2. Remove the motor cover plate (1). AM 3
3. Disconnect the four hoses (2) of the travel
motor and the corresponding hose connec-
tors.
4. Remove the 24 mounting bolts (3) con-
N
2
necting the final drive assembly with the
TI
sprocket. And the remove the sprocket.

5. Remove the bolts (4) connecting the final
drive with the track frame. Lift the final
LA
drive (5) in order to disassemble it. 4

ZXT3355-1006247
● Take care not to damage the surface
of mounting seal installed on the hose Fig. 8-47
base.
NY
● Never use the threaded holes to lift the

cover when lifting the final drive.
3
SA
2
SY365(B)H-9
Number of Bolts 18
Travel motor plus reducer 389 kg
ZX335-1006147
Fig. 8-48

8.10.2 Installation
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.
A
● Purging the air.
C
See “Air in Each Component - Purge” on page 6-41.
E RI
AM
N
TI
LA
NY
SA

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
A
2. Cover
C
①
Unscrew the mounting bolts. Remove the
RI
cover (1) with the help of eyebolts ① .
E
AM
1
N
ZX335-1006049
Fig. 8-49
TI
3. Spacer
LA
2
Remove the spacer (2).
NY
SA
ZX335-1006050
Fig. 8-50

4. No. 1 planetary carrier assembly

A. Remove No.1 planetary carrier assem- 3
bly (3).
C A
ZX335-1006051
RI
Fig. 8-51
E
B. Disassembling No.1 planetary carrier
assembly. AM
9 7 4 5 10 8
a. Remove the screw (4). Remove the
coverplate (5) from the planetary
carrier (6).
N
b. Remove the thrust washer (7), gear

(8), bearing (9), bearing inner race
TI
(10) and thrust washer (11). 11

6
LA
ZX335-1006052
Fig. 8-52
5. No.1 sun gear shaft 12

NY
Remove No.1 sun gear shaft (12).

SA
ZX335-1006053
Fig. 8-53

6. Thrust washer. 13 14
Remove the thrust washer (13).
7. No.2 sun gear
Remove No.2 sun gear (14).
C A
ZX335-1006054
RI
Fig. 8-54
8. Disassembling No.2 planetary carrier as- 18 19 15

sembly
E
A. Remove the screw (15). Remove the AM 16
plate (16) and the planetary gear (17) 17
from the carrier (22). 20
23
B. Remove the bearing inner race (19) 21
and outer race (18). Remove the plate
N
(20). 22
TI
C. Remove the screw (21) in order to take

down the planetary carrier (22) and ZX335-1006055
shims (23) from the body. Fig. 8-55

LA
9. Boss assembly
②
A. Remove the boss assembly (24) from
NY
the travel motor with the help eyebolts

②.
SA
24
ZX335-1006056
Fig. 8-56

B. Disassemble the boss assembly as the

following. 26 27
a. Remove the floating seal (25).

b. Remove the bearings (26) and (27)
from the boss (28).
● Take care not to damage the bear-
ing retainer while disassembling the
bearing (26).
25
A
28
ZX335-1006057
C
Fig. 8-57
RI
C. Remove the floating seal (29) from the
E
travel motor (30).
AM 29
N
TI
30
ZX335-1006058
Fig. 8-58
LA
8.11.2 Assembly
26 27
● Clean all the parts. Make sure that these
NY
parts are free from contamination or dam-

age. Apply some engine oil to the sliding
surfaces prior to installation.
SA
1. Boss assembly
A. Install the bearings (26) and (27) by
pressing them onto the boss (28).
25 28
B. Install the floating seals (25).
ZX335-1006057
Fig. 8-59

● Remove any oil or dust from the O-ring

or O-ring contact surfaces. Dry the
parts before installing the floating seals.
● After installing the floating seal, make
sure that the angle of floating seal is
within 1 mm.
● Apply a thin layer of engine oil to the
sliding surface after the floating seal ZX335-1006059
has been installed.
Fig. 8-60
C A
C. Install the floating seal (29) on the
RI
travel motor (30).
● See the above step 2 for the installa-
E
tion procedure. 29
AM
N
30
ZX335-1006058
TI
Fig. 8-61
LA
D. Place the boss assembly (24) on the

②
travel motor with the help of eyebolts
② . Carefully tap the bearing to press-
fit it.
NY
SA
24
ZX335-1006056
Fig. 8-62

2. Calculation of shim thickness

A. Measure the thickness (H) of the raised 22
part of No.2 planetary carrier (22).
ZX335-1006060
A
B. Measurement of raised thickness Fig. 8-63
C
Apply 3000 Kg load to the bearing and
RI
measure the value (H) of the raised
part of bearing.
● Turn the boss 2-3 times before applying
E
a pushing force.
● Do not use a spray gun to cushion the
bearing.
AM Load 3000Kg
h
● Do not push or strike the retaining

valve.
N
C. Shim thickness calculation: C=H-h.

TI
ZX335-1006061
Fig. 8-64
LA
D. Place the shims on the body and insert

the dowel pin. Press the carrier as-
sembly onto the dowel pin and tighten it
with screw (21). Apply locking adhesive
NY
Tensiometer
to the threads.
Screw-locking adhesive:
SA
(Kesaixin 1277)
Screw (21):
539±28 Nm {55±2.9 kgm} ZX335-1006062
● Use a tensiometer to measure the tan- Fig. 8-65

gential force of boss to motor case ro-
tation.
Tangential force: Max. 294N {30 kg}
Maximum tangential force occurs at the
beginning of direction change.

3. Assembly of No.2 planetary carrier assem- 18 19 15

bly
Assemble the No.2 planetary carrier as- 16
sembly through to the following steps. 17
● Replace the plates (20) and (16) with 20

23
new ones. 21
A. Assemble the bearings (18) and (19) 22
on the gear (17). Assemble the top and
bottom plates (16) and (20), and place
A
the gear assembly into the planetary ZX335-1006055
C
carrier (22). Fig. 8-66
RI
B. Lock it with screw (15).
Screw (15): 13 14
539±28 Nm {55±2.9 kgm}
E
● Check the flexibility of gear (17) after AM
assembling the planetary carrier as-
sembly.
4. Thrust washer
N
Install the thrust washer (13).

TI
5. No.2 sun gear

Install No.2 sun gear (14).
ZX335-1006054
LA
Fig. 8-67
6. No.1 sun gear shaft 12

NY
Install No.1 sun gear shaft (12).

SA
ZX335-1006053
Fig. 8-68

7. No.1 planetary carrier assembly

A. Install No.1 planetary carrier assembly 9 7 4 5 10 8
as the following.
● Replace the thrust washers (7) and (11)
with new ones.
a. Assemble bearings (9,10) on gear
(8). Assemble the top washer (7)
11
and the bottom washer (11). Place 6
the gear assembly in the carrier
A
assembly (6). ZX335-1006052
C
b. Secure the coverplate (5) to the Fig. 8-69
RI
planetary carrier (6) with screw (4).
B. Install No.1 planetary carrier assembly
(3).
E
3
AM
N
TI
ZX335-1006051
LA
Fig. 8-70
8. Spacer
NY
2
Install the spacer (2).
SA
ZX335-1006050
Fig. 8-71

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}
A
1
C
ZX335-1006049
Fig. 8-72
E RI
AM
N
Torque wrench
TI
LA
ZX335-1006063
Fig. 8-73
NY
10. Refilling the oil

Tighten the drain plug and refill engine oil
SA
through a filler.
Final drive case: About 4.7 L

● After the final drive has been success-
fully installed to the chassis, check the
oil to see if it has reached the specified
level.

8.12 Swing Motor and Swing Drive AS
8.12.1 Removal
Release the remaining pressure in the hydrau-
lic return circuit. See “Remaining Pressure
in Hydraulic Lines - Relieve” on page 6-36.
Lower the work equipment to the ground in 3 4
order to ensure safety. Stop the engine. Press
A
the release button of the breather valve to 6
release remaining pressure in the hydraulic
C
tank. Place the hydraulic lockout control in the
RI
locked position.
1. Disconnect the hose (1) through the hose 2
(9). 7
E
5
(1): Between oil tank and swing motor (port AM
Dr)
1
(2): Between central swivel joint and swing
motor (port Dr)
(3): Between swing motor and main valve
N
ZXT335-1006064
(port M)
Fig. 8-74
TI

port Px (port A)
LA
(port B)
port Px (port SH)
NY
(7): Between swing motor and solenoid

valve block (port PG) 9
2. Remove the 14 fixing bolts (8).

SA
3. Lift the swing motor and swing mechanism

assembly (9) in order to disassemble it.
Slowly lift the swing motor and swing 8
mechanism assembly in order to avoid
damaging the hoses and other parts.
ZXT335-1006065
Swing motor and swing drive AS:
Fig. 8-75
425.5 kg

8.12.2 Installation
cedure of removal.
Mounting bolts (swing motor and

swing mechanism AS):
490~608 Nm {50~62 kgm}
● Refilling of hydraulic oil
A
Refill hydraulic oil through the filler open-
C
ing to the specified level. Start the engine
RI
to circulate oil in the hydraulic system, and
check the oil level again.
● Purging of air
E
See “Air in Each Component - Purge” AM
on page 6-41.
N
TI
LA
NY
SA

8.13 Swing Motor and Swing Drive AS
8.13.1 Disassembly
1. Draining of oil
Open the drain plug to drain the oil from 2
the swing mechanism.
Swing drive case: Approx. 10.5 L 1
A
2. Swing motor assembly
C
A. Place the swing motor and swing
mechanism assembly on a suitable
RI
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
E
remove the swing motor assembly (2). AM ZXT335-1006066
Swing motor assembly: 67.5 kg Fig. 8-76

N
3. No.1 sun gear

2
TI

LA
NY
SA
ZX335-1006067
Fig. 8-77

4. No.1 planetary carrier assembly 3 4

A. Remove No.1 carrier assembly (3) and
the plate (4).
C A
RI
ZX335-1006068
Fig. 8-78
E
B. Disassemble No.1 carrier assembly. AM
Cut the rivets on the shaft (8) to re-
move the shaft (8), and remove in turn
the gear (6), bearing (9) and plate (7). 6 7 8 9
5
N
TI
LA
ZX335-1006069
Fig. 8-79
NY
5. Gear ring 10
Unscrew the mounting bolts to remove the

gear ring (10).
SA
ZX335-1006070
Fig. 8-80

6. No.2 sun gear 11
C A
RI
ZX335-1006071
E
Fig. 8-81
AM
12
A. Remove No.2 carrier assembly (12).
N
TI
LA
NY
SA
ZX335-1006072
Fig. 8-82

B. Disassemble No.2 carrier assembly

with hands through the following steps.
a. Hammer the pin (13) in the shaft (14) 19 16 15 18
in order to push the shaft (14) out of
the carrier assembly (19). 17
● Hammer out the pin (13) after removing 14

the shaft.
13
b. Remove the thrust washer (16) and
gear (17).
A
c. Insert the pin (15) to remove the
C
ZX335-1006073
bearing (18) from the shaft. Remove
Fig. 8-83
RI
the pin (15).
8. Snap ring 20
E
Remove the snap ring (20).
AM
N
TI
LA
ZX335-1006074
Fig. 8-84
NY
9. Disassembling the main shaft

Push 21 22
A. Place the shaft housing assembly on a
press and push the shaft assembly (21)
SA
out of the shaft housing assembly (22).
ZX335-1006075
Fig. 8-85

B. Disassemble the shaft assembly in the Push

following procedure.
Remove the bearing (23) from the shaft
(24).
23
24
C A
RI
ZX335-1006076
Fig. 8-86
E
10. Bearing
AM
26
27
Remove the bearing (25) and the oil seal
(26) from the housing (27).
N
TI
LA
25 ZX335-1006077
NY
Fig. 8-87
SA

8.13.2 Assembly 23
● Clean all the parts and check for any con-
tamination or damage. Apply engine oil to
the sliding surfaces of the parts.
1. Bearing
Press the bearing (23) into the housing (27).
A
27
C
ZX335-1006078
Fig. 8-88
E RI
2. Oil seal
Press the oil seal (26) into the housing (27).
AM 27 26
Oil seal mounting surface: gasket

sealant (Loctite 515)
N
TI
LA
ZX335-1006079
Fig. 8-89
NY
3. Housing assembly 24
A. Position the plate (28) on the shaft (24).
SA
B. Position the housing assembly (22) on

the shaft (24). Press to fit the bearing.
22
28
ZX335-1006080
Fig. 8-90

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.
C A
ZX335-1006081
RI
Fig. 8-91
E
5. No.2 Planetary carrier assembly
Reassemble No.2 carrier assembly through
AM
the following steps. 19 16 15 18
A. Assemble the plate (16) in the carrier
assembly (19). 17
N
B. Assemble the gear (17) in the carrier 14

TI
assembly (19). Put the bearing (18)

on the shaft (14). Slightly tap the pin 13
(15) into the bore after alignment. Use
LA
a rubber hammer to tap the pin. Make

sure that the pin (15) must not be ZX335-1006073
higher than the bearing (18). Fig. 8-92

C. Push the shaft assembly into the car-
NY
rier assembly (19). Be careful not to

damage the gear and the plate. Align
the pin hole of the shaft with that of the
carrier assembly, and install the pin
SA
(13). Carefully tap the pin with a rubber

hammer during installation.
● Installation of the shaft requires rotat-
ing the planetary gear. Take care not to
damage the thrust washer.

6. Assemble in turn the snap ring (20), No.2 No.2 planetary 11

20
carrier assembly and No.2 sun gear (11). carrier
C A
ZX335-1006082
RI
Fig. 8-93
E
7. Installation of gear ring 10
Apply sealant on the mating surface

indicated by (C) and tighten it with screws.
AM
Never get the sealant onto the gear ring c
(10).
Mating surface: Sealant (Loctite 515)
N
TI
LA
ZX335-1006083
Fig. 8-94
NY

A. No.1 carrier assembly is assembled as
SA
the following.
a. Install the plate (7) on the carrier 6 7 8 9
5
assembly (5).
b. Install the gear (6) onto the plate
after installing the bearing (9) into
the gear.
c. Press the shaft (8) into the gear (6)
and the carrier assembly (5). Rivet
ZX335-1006069
one end of the shaft.
Fig. 8-95
● Check if the gear rotates freely.

B. Install No.1 carrier assembly (3) and 3 4

the plate (4).
C A
RI
ZX335-1006068
Fig. 8-96
E
9. No.1 sun gear assembly
AM 2
Install No.1 sun gear (2).

N
TI
LA
ZX335-1006067
NY
Fig. 8-97
SA

10. Installation of swing motor assembly

Install the swing motor assembly after ap-
plying sealant to the mating surfaces of the
gear ring and the motor cover.
Mating surface: sealant (Loctite
515)
Swing motor assembly: 55 kg

Mounting bolts (swing motor):
A
156±5 Nm {16±0.5 kg}
C
● The 14 bolt holes of the swing motor
RI
and swing drive assembly are distribut-
ed nonuniform. The mating direction of
each hole is exclusive, as shown in the
E
illustration on the right. The installation
of swing motor requires proper align- AM
ment of the bolt holes in order to ensure
the installation orientation.
11. Refilling of lubricant
Screw on the drain plug and refill lubricant
N
through the filler to the specified level (the

TI
upper mark of oil stick).

ZX335-1006084
Fig. 8-98
LA
Swing drive case: About 4 L

NY
SA

8.14 Idler AS
8.14.1 Disassembly 7
8
1. Remove the dowel pin (1) and the support 6
(2). 13
12
10
2. Remove the floating seals (3) from the 5
support (2) and the idler (4).
3. Remove the O-ring (11). Remove the idler
A
(4) from the shaft (5) and the support as-
9
C
sembly (7). 11
3
RI
● The idler contains 80 ml oil, which 1
should be drained completely before

disassembling. Spread a cloth on the
E
floor to prevent smearing of the floor by
the oil. AM 4
2 ZX335-1006085
Fig. 8-99
4. Remove the floating seals (6) on the other 4 6

N
side from the idler (4), shaft (5) and sup-

5
port assembly (7).
TI
LA
6 7
NY
ZX335-1006086
Fig. 8-100
SA
5. Remove the dowel pin (8) in order to

remove the support (7) from the shaft (5). 5
9，10 4
6. Remove the bushings (9) and (10) from the
idler (4).
7 8
ZX335-1006087
Fig. 8-101

8.14.2 Assembly
1. Install the bushings (9) and (10) in the idler
(4).
9 10 4
C A
ZX335-1006088
Fig. 8-102
RI
2. Assemble the O-ring. Use the dowel pin (8)
E
to install the support (7) on the shaft (5). 5
AM 9，10 4
N
TI
7 8
ZX335-1006087
LA
Fig. 8-103
3. Install the floating seals (6) on the idler (4),

shaft (5) and support (7) assembly.
NY
● Floating seals
Completely remove the grease from 6
SA
the contact surfaces (hatched area in

the illustration on the right) of O-ring
and floating seal before installing the
floating seal. In addition, care must be
taken to keep the contact surface of
floating seal free from dust.
ZX335-1006089
Fig. 8-104

● After installation of the floating seals,

check that the sealing inclination should
be less than 1 mm and the seal protru-
sion be within a range of 5-7 mm. a
A
ZX335-1006090
C
Fig. 8-105
RI
4. Install the shaft (5) and support (7) assem-
7 5
bly to the idler (4).
E
4
AM
N
TI
ZX335-1006091
Fig. 8-106
LA
NY
SA

5. Install the floating seal (3) to the idler (4)

and support (2).
4 3
● Apply oil to the sliding surface of float-
2 3
ing seal. Care must be taken to keep
the sliding surface from any contami-
nants or dust.
● Remove the oil and dust from the con-
tact surfaces of the O-ring and floating
seal.
A
ZX335-1006092
C
Fig. 8-107
E RI
AM 3
N
TI
ZX335-1006093
Fig. 8-108
LA
6. Install the O-ring. Use the dowel pin (1) to 7

8
install the support (2). 6
NY
13
7. Refill oil and screw on the plug. 12
10
Oil: About 80 ml (No.18 hyperbola 5
gear oil)
SA
Plug: 205.8±49 Nm {21±5 kgm}

9
11
3
1
4
2 ZX335-1006085
Fig. 8-109

8.15 Sprocket
8.15.1 Removal
1
1. Remove the track assembly. For more
information see “Track AS” on page 8-59.
2. Swing the work equipment 90° and lift the
chassis with the help of the work equip-
①
ment. Place a block ① between the track
A
frame and the track shoe.
C
3. Remove the sprocket (1).
RI
Sprocket: 98.4 kg
ZX335-1006094
Fig. 8-110
E
8.15.2 Installation
AM
cedure of removal.
N
TI
Threads (bolt - sprocket):

Thread sealant (Kesaixin 1277).
LA
Bolts (sprocket):
927±103 N·m {94.6±10.5 kgf·m}
NY
SA

8.16 Track AS
Special tools
Mark Part Name Necessity Qty

Manual/electric hydraulic
M track removing/installing ● 1
machine
A
8.16.1 Removal
C
1. Choose a place that has enough space to
RI
spread the track. Park the machine when
the master pin is between the idler and the
carrier roller.
E
2. Lower the work equipment. Loosen the
grease fitting (1) and release the track ten-
sion.
AM
1
WARNING ZXT335-1006095
N
● The adjustment cylinder is under ex- Fig. 8-111

TI
tremely high pressure. Never loosen the

grease fitting by more than one turn.
Move the machine back and forth if no
LA
grease is seen.
3. Pull out the master pin (2) with the tool (M).
NY
2
SA
ZX335-1006096
Fig. 8-112

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

forward so that the temporary pin ② is in
front of the idler. Place the block ① .
5. Remove the temporary pin ② and the
dust seal. Move the machine backward to ②
3
spread the track (3).
A
①
C
ZX335-1006097
RI
Fig. 8-113
E
8.16.2 Installation
cedure of removal.
AM Corner Track shoe nut
(Square)
See “Track Tensioner - Test and Adjust” on
page 6-21.
R
N
● Installation procedure of track shoe bolts

R
and nuts Corner
TI
A. Bring the R side of the track shoe nut Corner

(1) to the link seat surface. Both seat R
LA
surfaces should be in close contact

when assembling the track shoe.
Seat surface
● If the track shoe bolts are installed Must be in
from the other side, the corner of nut Close contact.
NY
will interfere with the link seat surface,

causing the nut to raise and the bolt to
loosen.
SA
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

● 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
C A
ZX335-1006099
Fig. 8-115
RI
● Before installing the dust seal, apply
grease (G2-LI) to its contact surface
with the bushing.
E
AM
N
TI
LA
NY
SA

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.
A
3. Lift the swing bearing assembly (2).
1
C
ZXT335-1006100
RI
Fig. 8-116
E
Swing bearing assembly; 526 kg
AM
2
N
TI
LA
ZXT335-1006101
Fig. 8-117
NY
SA

8.17.2 Installation
cedure of removal.
Threads (bolt - swing bearing):

Thread adhesive (Tianshan 1277)
Mounting bolts (swing bearing):
A
Step 1:
C
Use a pneumatic spanner to tighten the
bolts.
RI
Step 2:
Tightened to:
E
927±103 Nm {94.6±10.5 kgm} AM
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
N
or counterclockwise. After one bolt is

tightened, tighten the next one on the
TI
diagonal position and make a mark.

C. Tighten the rest bolts in the same way.
LA
● 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
NY
install the swing bearing to the track Inner race

frame. soft zone
SA
● Apply grease to the inside of the gear

ring of the swing bearing.
All gear teeth must be covered by
grease .
Swing bearing:
ZXT335-1006102
Grease(MoS2 G2-LI):15 L Fig. 8-118

8.18 Swing frame AS
8.18.1 Removal
Fully extend the arm and the bucket. Lower
the work equipment to the ground and engage
the hydraulic lockout control.
1. Disassemble the work equipment assem-
bly. See “Work Equipment AS” on page 8-97.
A
2. Remove the counterweight assembly. See
C
“Counterweight AS” on page 8-104. 1
RI
3. Remove the four (4) hoses (1) of boom
cylinder.
Cork the hoses to stop oil flowing out.
E
ZXT335-1006103
4. Lift the boom cylinder assembly (2). AM
Fig. 8-119
5. Remove the plate (3) and the pin (4). Lift

N
TI
LA
2
NY
ZXT335-1006104
Fig. 8-120
SA

the boom cylinder assembly (2) in order to

disassemble it.
Remove the boom cylinder assembly on 4
the other side in the same way.
Boom cylinder AS: 264 kg
6. Remove the plate (5), air intake hose (6) 3
C A
ZXT335-1006105
Fig. 8-121
RI
and fan guard (7).
E
Removal of the swing frame requires
removing other parts that interfere with the AM
lifting of swing frame.
7. Disconnect the six (6) hoses over the
6 7
N
5
TI
rotary joint assembly on the side of swivel ZXT335-1006106
joint. Fig. 8-122

LA
(8): Central swivel joint (port A)-

Left travel control valve (port BTL)
(9): Central swivel joint (port C)-
NY
Left travel control valve (port ATL)

(10): Central swivel joint (port F)-
SA
Solenoid valve
(11): Central swivel joint (port G)-
Swing motor (port T)
8 9 10 11 12 13
(12): Central swivel joint (port D)-
ZXT335-1006107
Right travel control valve (port ATR)
Fig. 8-123
(13): Central swivel joint (port B)-
Right travel control valve (port BTR)
8. Remove the bolt (14).
9. Unscrew the 32 swing frame mounting

bolts in order to remove the swing frame

assembly (15). Lift the swing frame as-
sembly off the machine. 15
● Remove the front and rear mounting

bolts of the platform. Use a lever block
to adjust the swing frame so that the
platform can reach a balance both
longitudinally and laterally. Remove the
last two bolts finally.
A
Take care not to damage the central
swivel joint assembly while removing
C
ZXT335-1006108
the swing frame assembly.
RI
Swing frame assembly:
Only swing
Model Assembly (kg)
E
frame (kg)
SY365(B)H-9 14,755 3,040 AM
N
8.18.2 Installation
TI

LA
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)
NY
Mounting bolts (swing frame):

Step 1: Tighten the bolts with a pneumatic spanner.
SA
Step 2: tighten them again. 490~608 Nm {50~62 kgm}

● Refilling of hydraulic oil
Refill through the filler opening the hydraulic oil to the specified level. Start the engine to circu-
late oil in the hydraulic system, and check the oil level again.
● Purging the air
Purge the air from the travel motor. See “Air in Each Component - Purge” on page 6-41.

8.19 Swivel Joint AS
8.19.1 Removal
Release remaining pressure in the hydraulic
return circuit. See “Remaining Pressure in
● Tag each line so as to ensure correct rein-
stallation.
A
1. Disconnect the hoses (1) through (8) on
C
the central swivel joint of the travel motor.
1
RI
(1): Central swivel joint (port T) -
2
Left travel motor (port T)
E
(2): Central swivel joint (port T) - ZXT335-1006109
Right travel motor (port T)

AM
Fig. 8-124
(3): Central swivel joint (port B) -
Left travel motor (port PA)
(4): Central swivel joint (port D) - 3
N
4
8
Right travel motor (port PB)
TI
5
(5): Central swivel joint (port A) -
Left travel motor (port PB)
LA
6
(6): Central swivel joint (port C) - 7
Right travel motor (port PA)
ZXT335-1006110
(7): Central swivel joint (port E)-
Fig. 8-125
NY
Left travel motor (port X)

(8): Central swivel joint (port E) -
SA
Right travel motor (port X)

2. Disconnect the hoses (7) through (12)

between:
(9): Central swivel joint (port T) - 14
Swing motor (port Dr) 13
(10): Central swivel joint (port E) -
Solenoid valve (port PT)
11 12
(11): Central swivel joint (port C) -
A
Left travel control valve (port BTL)
9
(12): Central swivel joint (port A) - 10
C
Right travel control valve (port ATL)
RI
(13): Central swivel joint (port D) - ZXT365-1308111
Left travel control valve (port BTR) Fig. 8-126
E
(14) Central swivel joint (port B) - AM
Right travel control valve (port ATR)
3. Remove the two(2) pin rolls (16) in order to

remove the plate (15).
N
4. Remove the four bolts (a) in order to

TI
16
remove the plate (b).
15
b
LA
16
ZXT335-1006112
NY
Fig. 8-127
5. Remove the four mounting bolts (17).

SA
17
ZXT335-1006113
Fig. 8-128

6. Remove the swivel joint assembly (18).
Central swivel joint: 45 kg

18
C A
ZXT335-1006114
RI
Fig. 8-129
E
8.19.2 Installation
AM
cedure of removal. B D
Install the central swivel joint facing the di-

N
rection indicated in the illustration.

Central swivel joint
TI
(In the illustration, the machine is viewed

from the above.) Sprocket
● Refilling of oil (hydraulic tank)

LA
Refill through the filler opening the hydrau-

lic oil to the specified level. Start the engine
NY
A C
ZX335-1006115
● Purging the air
Fig. 8-130
Purge the air from the travel motor. See
SA
“Air in Each Component - Purge” on

page 6-41.

8.20 Central Swivel Joint AS
8.20.1 Disassembly
1
1. Remove the fixing bolt (1).
2
2. Remove the cover (2).
3
3. Remove the rotor (12) from the housing (6). 4
5
● Take care not to damage the sliding
surface of the seal of the rotor (12).
A
4. Remove the O-ring (3), oil seal (8) and
C
6
retainer (7) from the housing (6).
RI
5. Remove the rotary seal (9) and O-ring (10)
7
from the housing (6).
8
E
6. Remove the oil seal (11) from the rotor (12). 9
AM 10
11
8.20.2 Assembly
1. Install the oil seal (11) on the rotor (12).
N
12
● Let the lip face the dust ring of housing.
TI
2. Install the O-ring (10), rotary seal (9) in the

housing (6).
LA
13
3. Fix the rotor (12) on a work bench. Install
the housing (6) on the rotor (12).
ZX335-1006116
The clearance between the housing (6)
and the rotor (12) approximates 0.1 mm, Fig. 8-131
NY
so the rotor must be inserted slowly in the

axial direction. Take care not to damage
the rotary seal and the O-ring. Dust ring
SA
4. Use a rubber hammer to tap the housing (6)

in order to match the rotor (12) properly.
Lip
5. Install the O-ring (3) and retainer (7) on the
rotor (12).
6. Install the cover (2) and tighten the bolts Housing
(1).
ZX335-1006117
Fixing bolts: 49 Nm {5 kgm} Fig. 8-132

8.21 Hydraulic Tank AS
8.21.1 Removal
1. Drain oil from the hydraulic tank. 1
Hydraulic oil: About 260 L

2
3. Remove the engine hood (1), beam (2)
and control valve cover (3).
A
3
C
RI
ZXT335-1006118
E
Fig. 8-133
4. Remove the covering (4) and the main

AM 4
pump partition (5).
6
5. Remove the engine partition (6) and the
bracket (7) at the hydraulic tank side.
N
TI
5
LA
ZXT335-1006119
Fig. 8-134
NY
6. Remove the two(2) oil return tubes (8) and 8

(9) of the hydraulic tank.
SA
ZXT335-1006120
Fig. 8-135

7. Remove the six hoses.

(10): Oil return (T-block, pilot)
15 16
(11): Oil return D2 (main valve) 14
(12) & (13): Oil return (leak of main pump)

(14): Oil return (solenoid valve) 13
(15): Oil return D1/D3 (main valve)

(16): Oil return (swing motor) 12
A
● Tag the hoses for identification. 10 11
C
● Use socket nuts to protect the hose ZXT335-1006121
connectors and cone seals against
RI
Fig. 8-136
damage.
E
8. Disconnect the oil suction tube (17) from
the bottom of hydraulic tank and the oil
AM
suction hose (18) connected with the oil 17 18
suction tube of the main pump.
9. Remove the six (6) mounting bolts (19) 19
N
from the bottom of hydraulic tank. Lift the

TI
hydraulic tank assembly.

10. Move the hydraulic tank assembly away in
order to disassemble it.
LA
ZXT335-1006122
Hydraulic tank AS: 234 kg Fig. 8-137

NY
SA

8.21.2 Installation
cedure of removal.
Drain plug (hydraulic tank):

58.8~78.5 Nm {6.0~8.0 kgm} Screw
A
● After tightening the hose clamping
screw, check that the screw should be
C
Upper side
in the range indicated in the illustration. Lower side
RI
Screw (hose clamp):
8.8±0.5 Nm {0.9±0.05 kgm}
E
ZX335-1006123
Fig. 8-138
AM
● Install the hose clamp and tighten the
screw according to the illustration on
N
the right. Tube Hose

TI
Bolt:
LA
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 Clamp 2 Clamp 1
NY
circulate oil in the hydraulic system, and ZX335-1006124

check the oil level again. Fig. 8-139
SA
● Purging the air

See “Air in Each Component - Purge”
on page 6-41.

8.22 Control Valve AS
8.22.1 Removal
order to ensure safety. Stop the engine. Power
on the machine and relieve system pressure.
Use the breather valve to release the pressure
in the hydraulic tank. Place the hydraulic lock- 1
out control in the LOCK position.
A
2
● Tag each line so as to ensure correction
C
reinstallation.
RI
1. Remove the engine hood (1).
2. Remove the coverplate (2) on the control
valve. ZXT335-1006125
E
Fig. 8-140
AM
3. Remove the engine partition (3).
N
TI
3
LA
ZXT335-1006900
NY
Fig. 8-141
4. Remove the pressure sensor guard (4).

SA
ZXT335-1006901
Fig. 8-142

5. Remove the ten (10) pilot hoses (from left

to right) and tag them properly. The hoses
are for:
(5) Left travel
14
(6) Right travel 12 13
5 6 7 8 9 10 11
(7) Arm OUT
(8) Left swing
(9) Bucket DIG
A
(10) Boom DOWN
C
ZXT335-1006902
ZXT335-1006902
(11) Boom UP
Fig. 8-143
RI
(12) Right swing
(13) Bucket DUMP
E
(14) Arm IN
6. Remove the two(2) pilot hoses on the
AM 16
control valve and tag them properly. The
hoses for:
15
(15): Right travel forward
N
(16): Left travel forward

TI
LA
ZXT335-1006903
Fig. 8-144
7. Remove the pressure sensor harness (17).

NY
17
SA
ZXT335-1006904
Fig. 8-145

8. Remove the clamp (18) fixing the harness

of solenoid valve.
18
C A
ZXT335-1006905
Fig. 8-146
E RI
9. Disconnect the hoses (19) and (20) from
the check valve block to the pilot pump and
swing motor port (PG).
AM
N
TI
19
20
LA
ZXT335-1006906
Fig. 8-147
NY
23 22
10. Remove the boom tube clamp (21) on the
main valve.
SA
11. Remove the tubes (22) and (23) from the

main valve to boom cylinder. Seal the ports
properly.
21
ZXT335-1006907
Fig. 8-148

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
A
ZXT335-1006908
C
Fig. 8-149
RI
14. Disconnect the hoses (28), (29), (30) and 29
(31) between the central swivel joint and 30
E
the main valve. Seal the ports properly. 28 31
15. Disconnect the swing motor hoses (32)

and (33). Seal the ports properly.
AM
32
16. Disconnect the hose (34) between control 35
33
valve and swing motor port (M) and the 34
N
hose (35) between control valve and swivel

joint.
TI
ZXT335-1006909
Fig. 8-150
LA
17. Disconnect the tube or hose (36) of radia- 36

37
tor and the oil return tube (37) of hydraulic
NY
tank. Seal the ports properly.

SA
ZXT335-1006137
Fig. 8-151

18. Disconnect the hydraulic pump hoses (38)

and (39).
39
38
A
ZXT335-1006138
C
Fig. 8-152
RI
19. Remove the two pilot hoses under the
E
control valve and tag them properly.
(40) Right travel backward
AM 40 41
(41) Left travel backward
N
TI
ZXT335-1006139
Fig. 8-153
LA
20. Remove the harness and hoses of the

solenoid valve and tag them properly. 42
NY
(42) Oil return hose 43
(43) Harness
SA
(44) Negative feedback hose from solenoid

valve to front pump 45
44 46
(45) Negative feedback hose from solenoid
valve to rear pump ZXT335-1006140
(46) Oil feed hose from solenoid valve to Fig. 8-154

PT block

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
C A
ZXT335-1006141
Fig. 8-155
RI
8.22.2 Installation
E
● Installation is performed in the reverse pro- AM
cedure of removal.
N
ing to the specified level. Start the engine

TI

● Purging the air
LA

on page 6-41.
NY
SA

8.23 Hydraulic Pump AS
8.23.1 Removal
order to ensure safety. Stop the engine. Press
the release button of the breather valve to re-
lease remaining pressure in the hydraulic tank.
Disconnect the cable from the negative (-)
A
post of the battery before performing the job.
Oil stopper
C
● Tag each line so as to ensure correction
reinstallation.
RI
1. Remove the oil inlet filter element from the
ZX335-1006142
hydraulic tank and stop oil outflow with an
E
oil stopper. Fig. 8-156
If no oil stopper is used, remove the drain
plug and drain the oil from the hydraulic
AM
tank and the lines. 1
Hydraulic oil tank: About 340 L

N
2. Remove the engine hood (1)

TI
LA
WT365081301
Fig. 8-157
NY
3. Remove the rod (2) and bolts (3). Lift the

engine hood.
SA
2
ZXT335-1006144
Fig. 8-158

4. Remove the upper right coverplate (4).
C A
ZXT335-1006145
Fig. 8-159
RI
5. Disconnect the hose (5) supplying oil to the
E
lower proportional valve and the hose (6)
delivering oil from the pilot pump. Seal the
ports properly.
AM
5
6
N
TI
LA
ZXT335-1006146
Fig. 8-160
6. Remove the shutdown device line (7).

NY
SA
7
ZXT335-1006147
Fig. 8-161

7. Remove the right door (8).

8. Remove the hydraulic pump cover (9).
8
9
C A
ZXT335-1006148
Fig. 8-162
RI
9. Disconnect the oil drain hose (10) and seal
E
the ports properly. AM 13
10. Disconnect the high-pressure hoses (11)
and (12) connected to the control valve,
and seal the port properly.
12
11. Disconnect the harness (13) of the pres-
N
sure transducer. 11
TI
12. Disconnect the pilot pump oil suction hose 10

(14) and seal the port properly.
13. Disconnect the hydraulic pump oil suction
LA
14 15 ZXT335-1006149
tube (15) and seal the port properly.
Fig. 8-163
NY
14. Disconnect the solenoid valve harnesses

(16) and (17).
16
SA
17
ZXT335-1006150
Fig. 8-164

15. Remove the four bolts (18) of the hydraulic

pump. Lift the hydraulic pump assembly 19
(19) in order to disassemble it.
Hydraulic pump assembly: 186 kg
A
18
C
ZXT335-1006151
Fig. 8-165
RI
8.23.2 Installation
E
cedure of removal. Screw
AM
● After tightening the hose clamping
screw, check that the screw should be
in the range indicated on the right illus- Upper side
tration.
N
Lower side
Screw (suction hose clamp):

TI
10~13 N·m {1.0~1.3 kgf·m}

ZX335-1006123
● Install the hose clamp and tighten the Fig. 8-166
LA
screw according to the illustration on

the right.
Mating surface (hydraulic pump

NY
housing):
Tube Hose
Gasket sealant: (Loctite 515)
SA

ing to the specified level. Start the engine O-ring seal 2 O-ring seal 1
Clamp 2 Clamp 1
Hydraulic tank: About 340 L ZX335-1006124
● Purging the air Fig. 8-167

on page 6-41.

8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)
8.24.1 Removal
1. Remove the hydraulic pump assembly (1).
See “Hydraulic Pump AS” on page 8-80.
1
2. Remove the screw (2). Remove the bear-
ing cover (3). 2
3
3. Pry the oil seal (4) out with a screwdriver.
A
4
C
● Take care not to damage the shaft
RI
while prying the oil seal.
E
8.24.2 Installation AM ZX335-1006152
● Installation is performed in the reverse pro- Fig. 8-168

cedure of removal.
N
Seal lip: grease (No.1 Calcium base 4

TI
grease)
Seal circumference: grease (No.1

LA
Calcium base grease)

● Apply a thin layer of grease to the oil
seal circumference.
NY
ZX335-1006153
Fig. 8-169
SA

8.25 Pilot Valve AS (Work Equipment)
● This section discusses only the precautions when reassembling the work equipment pilot
valve assembly.
8 9
1 2 3 4 5 6 7 10
C A
RI
ZXT335-1006154
Fig. 8-170
E
● Reassembly of the work equipment pilot
AM Apply the thread adhesive (Tianshan 1277)
valve assembly to two points on the inner threads, as
indicated in the illustration on the right. The
1. Install the plate (9) in the valve body
amount of application is approximately 0.02
(8) with O-ring seal. Tighten the socket-
g.
N
headed screw (10).

U-joint (3): 98~133 Nm {10~13.5
TI
Screw (socket head): 25~33 Nm

kgm}
{2.55~3.36 kgm}
● Tightening is to be made to the speci-
2. Insert the spring (7) into the spool hole in
LA
fied torque.
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.
5~7 mm
3. Install the plate (4) on the plug (5). Tighten
NY
the U-joint (3).

4. Install the plate (2). Align the position of the
plate (2) and tighten the nut (1).
SA
Nut: 98~133 Nm {10~13.5 kgm}

● Location of each oil port is stamped on
the bottom of valve body. ZX335-1006155
Plug (5) circumference: Grease Fig. 8-171

(No.1 Calcium base grease)
Contact surface between plug (5)
U-joint working surface: Grease
and plate (2): Grease 0.3~0.8cc (G2-L1)
(No.1 Calcium base grease)
● After assembling plate (2) see “Work
Threads in valve body: Thread ad-
Equipment and Swing Pilot Valves -
hesive (Tianshan 1277)
Adjust” on page 6-33.

8.26 Travel Pilot Valve AS

● This section discusses only the precautions when reassembling the travel pilot valve assem-
bly.
Pushrod
C A
E RI
9 8 7 6
AM 4 3 2 1
5 ZXT335-1006156
Fig. 8-172
N
● Reassembly of pedal pilot valve assembly

TI
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).
LA
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).
NY
Contact surface between the plug and the dust ring (3): Grease (No.1 Calcium base
grease)
SA

8.27 Hydraulic Cylinder AS
Special tools
Tool Description Sketches Necessity Quantity
For pulling out/

pushing in the ■ 1
A
bushing
C

RI
For press fitting the
■ 1
dust ring

E
AM
For O-ring seal cor-
■ 1
rection
N

TI
For insertion For correction

LA
For inserting the

■ 1
cylinder head
For inserting the

NY
■ 1
piston

SA

8.27.1 Disassembly
1. Drain the oil and remove the tubing.
2. Fix the cylinder.
● Fix the cylinder in a vertical or level
manner. A vertically fixed cylinder can
be disassembled and assembled eas-
ily.
● The pin hole in the head end can be
A
used for fixing of the cylinder. The pin
roll can prevent the cylinder from turn-
C
ing.
RI
● Remove the tubing in case of tubing in-
terference while fixing the cylinder.
E
Secure the cylinder
AM
N
TI
LA
ZX335-1006162
Fig. 8-173
NY
3. Removal of cylinder head

Approx 1.5 m
● Unscrew the bolts with Allen Wrench.
SA
● Using an extension rod, as shown in

the illustration on the right, will make
the work easy.
ZX335-1006163
Fig. 8-174

4. Pulling out the piston rod

● Be sure to have removed the tubing
cover.
● Prepare a suitable container to collect 1 2
oil coming out of the oil port.
● After pulling out the piston rod (1) to its
limit, slowly loosen the cylinder head Sleeper
and pull it out.
A
● Remove piston rod (1) with cylinder ZX335-1006164
head (2) and place them on a wooden
C
Fig. 8-175
sleeper.
E RI
5. Securing the piston rod
AM Secure 5
● 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.
N
ZX335-1006165
TI
Fig. 8-176
LA
6. Remove of piston nut (5)

Drill bit
A. Remove the fixing screw (3) from the
3
piston nut (5).
NY
● Around the fixing screw there are two

points that have been punched against
loosening. After removing the riveted
SA
part with a hand drill, loosen and re-

move the fixing screw (3).
B. Remove the steel ball (4) inside the
fixing screw.
4 ZX335-1006166
Fig. 8-177

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
A
Fig. 8-178
C
RI
7. Removal of piston assembly
Remove in turn the piston (7), buffer sleeve 2 6 7
E
(6) and cylinder head (2).
AM
ZX335-1006168
N
Fig. 8-179
TI
8. Removal of the buffer sleeve (8) on the

Threads
head end
LA
A. Remove first the piston nut (5).

B. Use a tool like rubber hammer to tap Piston rod
the piston nut (5) slightly in order to
remove it. The piston rod and the
NY
buffer sleeve (8) should be kept intact.

Remove the elastic retainer (9).
SA
C. Slide the buffer sleeve (8) toward the

9 11
piston threads in order to remove the 10 8
With one opening (two-piece type)
two-piece stopper ring.
ZX335-1006169
D. Remove the buffer sleeve (8). Fig. 8-180
E. There is an opening in the buffer seal
(10). Take advantage of this opening to
remove the buffer seal (10).

9. Removal of piston seal

Screwdriver
A. The slide ring (12) and the guard
ring (13) can be simply removed with 14 12
Piston
hands.
B. The seal (14) can be removed with a Bench clamp
hammer and a flat-head screwdriver.
C. Remove the O-ring seal (15) with a pry
bar.
A
● The removed seals should not be re- 15 13 ZX335-1006170
used.
C
Fig. 8-181
10. Removal of buffer ring (16)
RI
● 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
E
remove it with a scraper. AM 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. 20
N
17 16 19
B. Press a tool (such as a screwdriver) ZX335-1006171
TI
against the dust ring (18) and hammer Fig. 8-182

the screwdriver to remove the dust ring
(18).
LA
● The removed seals should not be re-

used.
Press
12. Removal of bushing (19)
NY
A. Remove the elastic ring (20) from the

cylinder head (2) with a screwdriver.
B. Push the bushing (19) out with the help Block
SA
of clamps and press.

13. Removal of pin bushing (21)
21
A. Remove the dust ring (22) on the side
of cylinder barrel and piston rod with a
tool such as screwdriver.
B. Remove the bushing (21) with the help
of a suitable cushion block. Support
ZX335-1006172
Fig. 8-183

8.27.2 Assembly
Press
1. Installation of bushing (21)
Installation tool
A. Use an installation tool to press the
bushing (21) into the bushing (lubricated Block
Piston rod
with hydraulic oil) on the side of piston 21
22
rod and cylinder barrel.
B. Install the dust ring (22) with the help of 21
a suitable cushion block. ZX335-1006173
A
Fig. 8-184
C
RI
2. Assembly of cylinder head (2)
Hydraulic press
A. Use the press to push in the bushing
(19).
E
● Apply hydraulic oil to the inside of AM
cylinder head in advance. Make sure 2
Too
that the bushing (19) pushed in is
free from a raised shoulder.
N
B. Use the press to push in the dust ring

TI
(18).
19
C. Install the guard ring and the U-ring (17) Under pressure
sequentially in the U-groove.
LA
● Install the U-ring (17) in correct direc- ZX335-1006174

tion. Make sure that the U-ring is in-
Fig. 8-185
tact before installation.
NY
● Inverse installation will cause leak of

oil.
● Make sure that the U-ring is free from 18
SA
Tool
any corrugation or permanent defor- U-groove
mation after installation.
D. Installation of buffer ring (16) Press in
● Make sure that the seal is installed in

correct direction. Inverse installation
can cause high pressure between the ZX335-1006175
buffer ring (16) and the U-ring (17), Fig. 8-186
which may lead to deformation or
breakage of oil cylinder.
E. Install the elastic ring (20) to prevent
the fall of the bushing (19).

3. Assembling the piston assembly

Press in
Block Press in
A. Installation of seal (14).
● Install first the O-ring seal and the Tool
one-side guard ring (13) on the pis- 13
ton. Place the piston on the press. As
shown in the illustration on the right, Tool Tool for
the seal (14) is installed with the tools correction
indicated.
Piston
B. Correction of seal (14)
A
12 O-ring
● Install the seal (14) and the guard ring
C
14
(13) on the other side. In order to pre-
13
RI
vent the expansion of the seal (14), a
corrector must be used to correct the ZX335-1006176
seal (14) which has been stretched Fig. 8-187
E
during installation. The piston rod
may not be able to go in the cylinder AM
barrel if the seal (14) is not corrected
timely.
C. Installation of slide ring (12)
● Slightly open the slide ring (12) and
N
install it axially. Excessive opening of

TI
the slide ring (12) can fail installation.
4. Assembling the piston rod assembly

LA
Assembling tool 2
A. Fix the piston rod (1).
B. Install the cylinder (2) on the piston rod.
● Make sure that the dust ring lip or
NY
the U-ring lip is not stopped by the

shoulder of any part. Install the cyl-
inder head and the piston rod with
SA
the tools. 1 ZX335-1006177
Fig. 8-188

C. If the bottom side of cylinder contains

a buffer (not for bucket cylinder), install The opening faces the threads.
the buffer bearing and the buffer seal in Threads
the following order.

a. Let the notched side of the buffer
seal (10) face the piston while Piston rod
installing the buffer seal (10) in the
groove.
b. Install the buffer sleeve (8) accord-
A
ing to the indication in the illustration
on the right.
C
9 10 8 11
c. Install the stopper ring (11) in the
RI
With one opening (Two piece type)
groove. Install the elastic ring after
the buffer sleeve (8) is pushed Head end buffering
ZX335-1006178
to the bottom. A rubber hammer
E
Fig. 8-189
should be used for the tapping job AM
in order to avoid damaging the
piston rod and the buffer bearing.
D. If the head side of cylinder contains a
buffer, install the buffer sleeve (6) and 23 6
5
N
the buffer seal (23) according to the

following order.
TI
a. The piston nut must be installed

after installation of the buffer bear-
ing.
LA
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.
The opening faces the piston side.
NY
c. The buffer sleeve (6) must be

Rod end buffer
installed according to the illustration ZX335-1006179
on the right.
Fig. 8-190
SA
E. Tighten the piston nut (5).

Piston nut (arm):
9600 Nm {979.6 kgm}
Piston nut (boom and bucket):
6200 Nm {632.6 kgm}
● Insufficient tightening can cause oil
leakage, loose nut and thread break-
age. In addition, excessive tightening
can cause expansion of the buffer shaft
on the extending side or deformation of

piston on the contact side.

● Thoroughly clean and grease (with ba-
nana oil) the threaded portions of the
piston, nuts and piston rod before tight-
Punch
ening the nuts. Rivet
F. Treatment of the piston against loosen-

ing
● After the piston nut (5) is tightened, put
in the steel ball (4), tighten the setscrew
A
(3) and punch to rivet the two periph- 3
C
eral points.
4
RI
Setscrew (3):
66.9 Nm {6.8 kgm}
5. Install the piston into the cylinder barrel.
E
ZX335-1006180
A. Fix the barrel in a vertical or level man- AM
ner. Fig. 8-191
B. Install the piston rod into the cylinder
barrel.
Tool
N
● If fixed in a vertical manner, the pis- Nylon sleeve

ton rod falls into the barrel under its (two pieces)
TI
gravity.
● Make sure that the slide ring does
LA
not fall while the piston is inserted (Move the notch

into the barrel. 180 degrees away.)
NY
SA
ZX335-1006181
Fig. 8-192

6. Tightening of cylinder head

Tighten the bolts following the sequence 8 1
shown in the illustration on the right.
4 9
Bolt: 267 Nm {27.2 kgm}
7. Install the tubing.
12 5
6 11
C A
10 3
RI
2 7
Bolt tightening sequence
E
ZX335-1006182
Fig. 8-193
AM
N
TI
LA
NY
SA

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
A
circuit. See “Remaining Pressure in Hydrau-
lic Lines - Relieve” on page 6-36.
C
1. Disconnect the grease hose (1).
RI
5
2. Lift the boom cylinder assembly (2). 1 3
Remove the lockbolt (3).
E
3. Remove the plate (4) and then the pin roll (5
).
AM
● There are shims installed. Count the 4
shims and check the thickness. Place
the shims in a safe place.
N
4. Start the engine and retract the piston rod. 2

TI
● Secure the piston rod with a wire rope

ZXT335-1006183
in order to prevent the piston from slip-
ping out. Place the cylinder on a bench Fig. 8-194
LA
or support. The grease fitting on the

bottom side must be removed in the
later case.
● Remove the other boom cylinder in the
same way.
NY
5. Remove the two hoses (6) of bucket

cylinder and the two hoses (7) of the arm
SA
cylinder.
● Cork the hoses to prevent outflow of oil.
Tie the hoses to the valve side
6. Remove the mid-connector (8) used for
work lamp. 8
6
7 7 7 6
ZXT335-1006184
Fig. 8-195

7. Lift the work equipment and remove the

plate (9). Remove the bottom pin roll (10).
There are shims installed. Count the shims 10

and mark their locations.
A
9
ZXT335-1006185
C
Fig. 8-196
RI
8. Lift the work equipment assembly (11) in
E
order to disassemble it. 11
Work equipment assembly:

AM
Model Weight
SY365H-9 5,652 kg
N
SY365BH-9 7,102 kg
TI
ZXT335-1006186
Fig. 8-197
LA
NY
SA

8.28.2 Installation
cedure of removal.
A clearance (a: 0.5 - 1.5 mm) should be

left between the plate and the nut when
tightening the locknut.
Greasing after assembling the pin:
A
Grease (MoS2 G2-L1)
C
WARNING
RI
a
ZX335-1006187
● Never use your finger to align the pin
holes. Fig. 8-198
E
● Adjust the shim thickness in order to
AM
have a desired clearance (a: 0.5 ＜ a 12 a
4
＜ 1 mm) between the piston end (12)
and the plate (4).
N
● Standard shim thickness: 1.0 mm and

2.0 mm.
TI
Greasing after assembling the pin: ZX335-1006188

LA
Grease (MoS2 G2-LI) Fig. 8-199
WARNING
NY
● Never use your finger to align the pin

holes.
SA
● 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.

8.29 Air Conditioner AS
Special tools
ID Part Name Model Necessity Qty

Refrigerant
S - ● 1
refiller
8.29.1 Removal
C A
NOTICE S
RI
● Always disconnect the cable from nega-
tive post of the battery before you pro- ZXT335-1006189
E
ceed.
Fig. 8-200
AM
1. Drain the coolant.
Coolant: Approx 22.5 L
2. Recover refrigerant from the air-condition-
N
ing system with the tool (S).

TI
3. Remove the pad on the bottom cover (1). 1

LA
ZXT335-1006190
Fig. 8-201
NY
4. Use the start key to open the left rear cover

SA
of the cab. Remove the external air filter

element (2).
Cover 2
ZXT335-1006191
Fig. 8-202

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
A
5
C
ZXT335-1006192
Fig. 8-203
RI
7. Remove the back cover (6).
E
AM
6
N
TI
LA
ZXT335-1006193
Fig. 8-204
8. Remove the back air duct (7).

NY
7 8
9. Remove the left air duct (8).
10. Remove the baffle (9).
SA
11. Remove the right air duct (10). 10

9
ZXT365-1308197
Fig. 8-205

12. Remove the cover (11).

13. Remove the cab's center connector (12).
14. Remove the radio antenna(13).
13
12
A
11
C
ZXT335-1006195
Fig. 8-206
RI
15. Remove the air duct (14) and the control-
E
ler wiring connector (15). Disconnect the
wiring connector (16). Remove the air
conditioner relay (17). Remove the three
AM 16
17
(3) mounting bolts (18) and then the board

(19).
N
TI
19
18
15
LA
14 ZXT335-1006196
Fig. 8-207
16. Remove the air conditioner water pipes

NY
(20) and (21) as well as the dripping tube

(22) under the bottom cover.
SA
22 21
20
ZXT335-1006197
Fig. 8-208

17. Remove the air conditioner unit (23).

Also disconnect the two hoses connecting
to the bottom of the air conditioner when 23
removing the air conditioner unit.
C A
ZXT335-1006198
Fig. 8-209
RI
8.29.2 Installation
E
cedure of removal.
AM
Keep the hoses free from contamination by
dirt, dust or water while installing the return
hose of the air conditioner.
N
Make sure that the O-ring seal is present

TI
in the connection before connecting a hose

of the air conditioner.
LA
Make sure that the O-ring seals are free

from any damage or deformation.
● Apply compressor oil (ND8#) to the

NY
threads of the parts connected with the

refrigerant lines. Tighten the line connec-
tions with a double-end spanner.
SA
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).

8.30 Counterweight AS
8.30.1 Removal
1. Install lift pin (1) in lift eye of counterweight.
Slowly tighten the wire rope (2) with lifting
2
equipment to hold the counterweight.
C A
RI
ZX365-1308163
Fig. 8-210
E
2. Remove the four mounting bolts (2 ) and
AM
washers.
3. Lift the counterweight with lifting equip-
ment.
N
Take care not to damage the engine, radia-

TI
tor and cooler.

Counterweight AS: 6800 kg
LA
3
ZX365-1308164
NY
SA

8.30.2 Installation
cedure of removal.
Threads (mounting bolt - counter-

weight):
Thread adhesive (Tianshan 1277)
Mounting bolt (counterweight):
A
2,295±200 N·m {214~255 kgf·m}
C
RI
● Counterweight Installation and adjustment
A. Lift the counterweight with a crane to a Unit: mm
E
suitable position over the frame. 门

B. Push the counterweight and install the

AM c=0±5
Counterweight

bolts. Adjustment is to be made accord-
ing to the following specification.
a=10±4
● Clearance with swivel:
N
10±5 mm(L&R)
b=0±5
TI
● Clearance with bodywork door:

Swing frame
10±5 mm(L&R) ZX335-1006202
LA
● Step difference from swing frame in left Fig. 8-211

to right direction
b: max. 5 mm
● Step difference from bodywork door in
NY
left to right direction

a: 10±4
SA
● Step difference from bodywork top cov-

er in upper to lower direction
c: max. 5 mm

8.31 Cab AS
8.31.1 Removal
NOTICE

1
tive post of the battery before you pro-
ceed.
C A
1. Remove the floor mat (1).
RI
ZXT335-1006203
Fig. 8-212
E
2. Remove the back covers (2) and (3).
AM
2
N
TI
3
LA
ZXT335-1006204
Fig. 8-213
NY
3. Disconnect the left harness (4), the monitor

harness connector (5) and the window
SA
washer harness (6).

5 4
4. Remove the right air duct (7).
ZXT335-1006205
Fig. 8-214

5. Remove the fresh air filter element (8).
C A
ZXT335-1006206
Fig. 8-215
RI
6. Remove the fresh air duct (9).
E
AM
9
N
TI
LA
ZXT335-1006207
Fig. 8-216
NY
7. Remove the storage box (10) of console.

SA
10
ZXT335-1006208
Fig. 8-217

8. Disconnect the radio connector (11).

9. Disconnect the radio harness (12).
11
12
C A
ZXT335-1006209
Fig. 8-218
E RI
10. Remove the window washer fluid reservoir
(13). AM
13
N
TI
LA
ZXT335-1006210
Fig. 8-219
NY
11. Remove the window washer hose (14).

SA
14
ZXT335-1006211
Fig. 8-220

12. Remove the decorative cap (15).
15
C A
ZXT335-1006212
Fig. 8-221
RI
13. Remove the five (5) bolts (16) and the
E
four(4) nuts (17).
● Check the length of bolt before removal.
AM 16
17
N
TI
ZXT365-1308210
Fig. 8-222
LA
14. Lift the cab assembly (18) in order to

18
remove it.
Cab AS: 105 kg
NY
SA
8.31.2 Installation
cedure of removal.
ZXT365-1308211
Bolt: 200 Nm {20.4 kgm} Fig. 8-223
Nut: 210 Nm {21.4 kgm}

8.32 Cab Window Glass
10 10
9
8
1
A
10
C
RI
2
7
E
AM
6
10 11
N
4
TI
5
12
LA
10
3
ZX215-1006218
Fig. 8-224
NY
(1) Right window glass ● Cab window glasses (1), (2), (5), (7) and (9)
(2) Front window glass are adhered to the window frame.
SA
(3) Lower front glass ● When replacing front window glass (2),
(4) Cab door window glass (upper) disassemble front window assembly (12).
(5) Cab door window glass (lower) (If the cab is install with a front window as-
(6) Cab door window glass (upper) sembly, do not only replace the front win-
(7) Left side rear window glass dow glass.)
(8) Rear window glass
● For detailed information, See “Front Win-
(9) Roof window glass
dow AS” on page 8-126.
(10) Rubber sealing strip
(11) Center adjusting seal
(12) Front window assembly
(Glass and frame)

8.32.1 Removal
CAUTION
● Be careful with sharp edges that may

cut your fingers when handling broken
or cracked window glasses. Put a piece
of adhesive film (or adhesive tapes )
onto the broken or cracked window
glass to prevent possible personal in-
A
3
jury before you proceed. Remove all
C
glass fragments.
RI
ZX215-1006219
1. Removal of glass (3)
Fig. 8-225
Glass (3) is hold in place by sealing strips.
E
Pull it upward carefully to remove it.
2. Removal of glass (4) and (6)
AM
A. Remove the sealing strip from the
frame of the cab door.
B. Push the glass outward carefully from
N
inside of the cab and remove glass (4)

TI
and (6) together with the frame.
6
LA
ZX215-1006220
Fig. 8-226
NY
C. Remove glass (4) and (6) from the

frame with a screw driver.
SA
Frame
Seal
ZX215-1006221
Fig. 8-227

3. Removal of glass (8)

A. Remove the retainer from the groove
8
on the rubber with an ordinary screw
driver.
B. Put a thin bamboo chip inside part A
of the retaining rubber and detach the
retainer along the edge.
C. Pat the glass from inside of the cab and
remove it. This job requires two people.
C A
ZX215-1006222
Fig. 8-228
RI
4. Removal of glass (1), (2), (5), (7) and (9)
E
9
AM 1
2
N
TI
5
LA
ZX215-1006223
Fig. 8-229
NY
A. Remove the resin board, decor strip

and retainer along the edge of the
glass. Cab
Glass
SA
B. Punch a hole through the adhesive with Drill

a drill (or a cutter) as illustrated.
Adhesive
ZX215-1006224
Fig. 8-230

C. Pull a piece of piano string (or steel

wire) through the hole as illustrated.
Piano string
(or metal wire)
C A
ZX215-1006225
Fig. 8-231
RI
D. Fix both ends of the piano string onto
E
(Outside of cab)
two screw drivers. Pull the wire back AM Cab
and forth in order to cut the adhesive
Glass
and detach the glass from the cab. This
job requires 2-3 people.
Run the string along the center of the
N
adhesive. The string may break when

it becomes very hot. Use different
TI
sections of the string while cutting the

adhesive. Adhesive
LA
(Inside of cab)
ZX215-1006226
Fig. 8-232
NY
SA

8.32.2 Installation
1. Clean the remaining adhesive and rubber
on cab frame (contact surface) with a knife
or scraper (5).
● Remove the remaining adhesive and
rubber so that they will not affect the
application of new adhesive. Do not
scrape the original paint on the surface.
(Scraping of paint reduces the perfor-
A
mance of the adhesive.)
C
5
RI
ZXT215-1006227
Fig. 8-233
E
2. Clean the grease, dust and dirt on the
cab (8) and the glass (9) with unleaded
AM
gasoline.
● Contaminant on the contact surface re-
N
duces the performance of adhesive.

TI
● Clean the black part on the back of the

8
glass.
● After cleaning, dry the glass for at least
LA
5 minutes.
ZXT215-1006228
Fig. 8-234
NY
9
SA
ZXT215-1006229
Fig. 8-235

3. Priming coat (10)

● Priming paint expires four (4) months af-
ter production. Do not use expired paint. Cab
11
● Use the paint within two (2) hours after it
is unsealed. 10
● Use the paint within 24 hours even if it Old adhesive edge
is sealed again immediately unsealing. on cab side
(Dispose the paint 24 hours after it is un-
sealed)
A
ZX215-1006230
A. Make sure the adhesive paint and glass
C
priming paint are well agitated before Fig. 8-236
RI
application.
● If the priming paint is stored in a re-
frigerator, keep it under ambient tem-
E
perature for at least half a day before
agitation.
AM
(If the paint is unsealed immediately
after it is taken out of a refrigerator,
water will condense on it.)
N
B. Always wash a used brush (11) with

unleaded gasoline before using it.
TI
● Check the brush for contaminants af-

ter it has been washed. 8
LA
● Prepare two brushes for priming

paint, one for painted surface and the
other for glass surface.
C. Apply priming paint (for painted sur-
NY
face) evenly onto the surface where

sealing rubber is to be adhered and
where adhesive agent is to be applied
SA
ZXT215-1006231
(on the cab (8)).
Fig. 8-237
Priming paint (for painted sur-
face): Sunrise MSI Primer 24
8
● Do not apply primer more than twice;
otherwise, the performance of the
primer will be reduced.
6
● Applying location: Cover the whole
area of (a) a
● Dimension of (a): 25mm ZX215-1006232
Fig. 8-238

● 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
A
(within 8 hours).
C
ZX215-1006233
● Do not use wrong priming paint.
RI
If, for example, glass primer is mis-
takenly used, wash it with unleaded
gasoline.
E
AM
c
N
TI
ZX215-1006234
LA
Fig. 8-239
D. Apply priming paint (for glass surface)

9
onto the contact surface of window
NY
glass (9).
Glass primer:
SA
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

● Priming area: Apply the priming paint

8
on the contact surface of glass (9)
(rubber seal (6)adhering location) and
along cab frame (8).
6
● Leave a 5 mm margin uncoated along
the black strip adjacent to the clear d
area of the glass.
● When priming paint has been coated, 9
dry it for at least 5 minutes (within 8 ZX215-1006236
A
hours).
Fig. 8-241
C
● Do not use wrong primer.
RI
If wrong glass primer is used, wash it
with unleaded gasoline.
4. Adhere rubber seal (6) (with adhesive tape
E
on both sides) along the inner edge of the
contact surface of the glass.
AM
● Do not detach the waxed paper on the
rubber seal before the window glass is
installed.
N
● Do not touch the cleaned area on the

glass before rubber seal is adhered.
TI
● Be careful not to allow the rubber seal

6
on the corners to peel off. ZXT225-1006245
LA
● When sticking rubber seal (6) along the

Fig. 8-242
window frame, do not overlap the two
ends of the seal. A 5 mm gap (e) be-
tween the two ends of the seal is recom-
NY
mended.
A. Stick rubber seal (6) onto the right cab
window frame as illustrated.
SA
e 6
ZXT225-1006246
Fig. 8-243

● Adhere additional rubber seal (6a) onto the f

right cab window 6a
Position of the additional rubber seal:
(f): 50 mm
h
(f): 90 mm
(h): 250 mm
A
ZXT225-1006247
C
Fig. 8-244
RI
B. Adhere rubber seal (6) on the left cab
E
window as illustrated.
AM 6
N
TI
ZXT225-1006248
LA
Fig. 8-245
C. Adhere rubber seal (6) onto the lower

cab door window as illustrated.
NY
6
SA
ZXT225-1006249
Fig. 8-246

● 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
A
k ZXT225-1006250
C
Fig. 8-247
RI
D. Adhere rubber seal (6) onto the front 6
E
window glass as illustrated.
AM
N
TI
ZX215-1006243
LA
Fig. 8-248
● Different from the rubber seal (6) on

other window, rubber seal (6c) on the
NY
bottom of the front window shall be 6

adhered onto the external edge of the 6c
lower part of the front window frame.
SA
(If it is adhered along the inner edge,

the rubber seal will be seen through the
clear part of the glass.)
ZXT225-1006252
Fig. 8-249

5. Positioning of new window glass

9
A. Check the clearance between the edge
of glass and the cab in 4 directions,
and position the glass. Make sure the n
clearance is even.
B. Put a tape [6] across the glass (9) and [6]
cab (8) and draw a line (n) on it for
alignment.
Adhere tape [6] at 3 points as illustrated
A
for precise alignment of right window 8
C
glass, left rear window glass and cab ZXT215-1006245
door lower window glass. Fig. 8-250
RI
C. Cut the tapes across the glass (9) and
the cab (8) and remove the glass.
E
● Do not remove the tape on the left [6]
side of the glass until the glass is
installed.
AM [6]
8 [6]
N
9
TI
ZX215-1006246
Fig. 8-251
LA
● When positioning front window

glass (4), cover it across the width
of the window frame in the horizon-
NY
P
tal direction.
Set the clearance (p) between the
top edge of the glass and the upper
SA
frame at 3 mm when positioning it in 4

the vertical direction.
ZX225-1006255
Fig. 8-252

6. Adhesive
● Store adhesion agent in dark places 13
where temperature is blow 25℃ .

● Do not heat the adhesive to above 30℃ .
● Before using adhesive that has been un- 12
sealed, remove the hardened part at the
nozzle.
A. Open the aluminum seal (13) on the
A
head of the cylinder (12) and install the
ZX215-1006247
nozzle.
C
Fig. 8-253
Adhesive:
RI
Sunrise MSI SR sealant U90 4463876
E
B. Cut the tip of nozzle as illustrated.
Dimension of the cut: AM 14
(q): 10 mm r
(r): 5 mm
q
N
TI
LA
ZX215-1006248
Fig. 8-254
C. Set the cylinder (12) in the gun [7].

NY
An electrical caulking gun is more ef- 12 [7]

ficient.
SA
ZX215-1006249
Fig. 8-255

4) Remove the waxed paper of the rubber

seal on the surface where adhesive is
15
to be applied.
6
5) Apply adhesive (15) along the external
edge of the rubber seal (6).
A
ZX215-1006250
C
Fig. 8-256
RI
● Adhesive (15) for rubber seal (6) on cab
E
8
(8) shall be applied as illustrated:
AM s
Dimension of (s): 10 mm
Dimension of (t): 15 mm 6
● Adhesive (15) shall be thicker that the t

rubber seal (6). 15
N
● Apply adhesive of the same thickness

TI
evenly.
ZX215-1006251
LA
Fig. 8-257
NY
SA

● Apply adhesive (15) onto the additional

rubber seal of the right window (6a) and 6a
15
additional rubber seal of the cab door low-
er window (6b).
A
ZX215-1006252
C
Fig. 8-258
RI
6b 15
E
AM
N
TI
ZX215-1006253
Fig. 8-259
LA
7. Install window glass

A. Install window glass (9) and align it with
NY
the mark on the cab. (See step 5)

● Since the glass can not be remove
once installed, be very careful when
SA
performing this task.

9
● Install the glass properly within 5 min-
utes after adhesive has been applied.
B. Press the perimeter of the glass (9)
after is has been put in place until it is
ZXT215-1006254
securely stuck to the rubber seal.
Fig. 8-260
● Press the corners of the glass hard.

● After the front window glass has been

installed, fill the clearance between the
glass on area (s) and the center adjust-
ing seal (16) to the dimension of (t) and
(u). Coat primer onto glass (4) on sec- A
tion A-A and apply the adhesive as fill-
ers.
A
● Dimension of (t): 2 mm S
● Dimension of (u): 5 mm
A
● Use a rubber spatula to cover the edge
C
of the glass and trim the adhesive. t
4
RI
● Remove surplus adhesive.
Glass primer：
E
Sunrise MSI Primer 35
AM u
Adhesive：
Sunrise MSI SR Sealant U90 4463876
16
A-A
ZX215-1006255
N
Fig. 8-261
TI
8. Fix the glass

LA
A. After the right window glass (1) has

been adhered to the cab, put position-
ing chips (a) (1 or 2 pcs) beneath the
glass in order to fix it.
NY
1
SA
a
ZXT215-1006256

B. Use foam polystyrene blocks [9] and

[10]
rubber band [10] to fix the glass and
the rubber seal as illustrated.
9. After the glass has been fixed, remove all
the remaining primer and adhesive on the
cab and on the glass.
● Clean the adhesive with unleaded gaso-
line before it is hardened.
● Do not apply impacting force onto the [9]
A
glass when cleaning it.
C
10. Protection of fixed window glass ZX215-1006257
RI
A. Remove the positioning chips, foam Fig. 8-262
polystyrene blocks and the rubber band
after 10 hours.
E
(Condition: Temperature: 20; humidity: AM
60%)
B. Wait for another 14 hours after the
removal of positioning chips, foam
polystyrene blocks and rubber band
N
before operating the machine.

TI
LA
NY
SA

8.33 Front Window AS

Lower the work equipment onto the ground
and shut down the engine.
● The front window assembly must be re-
moved from the cab in order to replace the
front window glass. Disassembling and as-
sembling method of front window assembly
(frame and glass) is illustrated in the fol-
lowing part.
C A
8.33.1 Disassembly
RI
1. Raise the front window assembly to the
roof and secure it with the rear locks (at
both sides).
E
2. Remove left corner plate (1) and right AM
corner plate (2). 2
● Mounting bolt (4) and washer (3) of the 4
3
left corner plate will be used in Step 6 to 1
hang the pull rod.

N
ZX215-1006258
TI
Fig. 8-263
3. Release the rear lock of the cab.

LA
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.
NY
5. Remove roller (5) and (6) from both sides

of the bottom of the front window.
SA
6 5
ZX215-1006259
Fig. 8-264

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
A
7 ZX215-1006260
● A return load of 58.8 N {6 kg}is applied
C
onto the rear of the cab. Be very care-
ful when removing pin (7) to disconnect
RI
pull rod (9).
E
AM 9 8
N
TI
ZX215-1006261
Fig. 8-265
LA
7. Pull out the front window assembly (10)

10
from the opened part of the guide rail and
lower the assembly gradually.
NY
SA
ZX215-1006262
Fig. 8-266

8. Lower the front window assembly (10)

completely.
10
● Be careful not to allow the front window
assembly to damage the machine moni-
tor.
A
ZX215-1006263
C
Fig. 8-267
RI
9. Move the front window assembly (10) to
the right and the left and remove the two
E
upper rollers (11) and (12) from the guide 10
rail. Then, remove the front window as- AM
sembly (10).
N
TI
ZX215-1006264
Fig. 8-268
LA
12 11
NY
SA
10 ZX215-1006265
Fig. 8-269

8.33.2 Assembly
● Reverse the disassembling sequence.
● Adjust the opening and closing of the front

window assembly as per the following in-
struction.
1. Open and close the front window assembly
and check if it interferes with the guide rail.
A
Check if the roller is jammed.
C
2. If the front window can not be opened or
RI
closed properly, loosen the mounting bolt
of the roller adjusting bracket (13) and
adjust the condition of the front window. 13 ZX215-1006266
E
Tighten the mounting bolt after adjusting.
Fig. 8-270
● Make sure bracket (13) is installed with-
out an angle.
AM
Mounting bolt ： 34.3 N·m {3.5
kgf·m}
N
3. Raise the front window assemble and fix it

with rear locks (at both sides).
TI
● Check if the locks at the rear of the cab a

are securely fixed.
LA
4. Install the right corner plate (2).

2
● After the "locked" position is adjusted in
Step 6, tighten the corner plate. a ZX215-1006267
● Install the right corner plate. Clearance Fig. 8-271

NY
(a) between the guide rail and the right

corner plate (2) is 0 – 2.0 mm.
SA
● Install the right corner plate. Keep the

R
surface (R) of the roller without a level
error.
ZX215-1006268
Fig. 8-272

5. Install left corner plate (1)

● After the "locked" position is adjusted in b
Step 6, tighten the corner plate.
● Install left corner plate. Clearance (b)
between the guide rail and the left corner
plate (1) is 0 – 2.0 mm.
● Install left corner plate and keep the sur- b
face (R) of the roller without a level error.
(See the previous illustration).
A
1
C
ZX215-1006269
RI
Fig. 8-273
6. Adjust the "locked" position of the lock of
E
front window assembly as per the following AM
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) 15
N
is pressed closely against the adjusting

seal (19) on the cab.
TI
14
LA
ZX215-1006270
Fig. 8-274
NY
SA

B. Open and close the front window

assembly and check the working condi-
tion of left lock (16) and right lock (17).
● If left lock (16) and right lock (17) do 16 17
not work properly,
a. Loosen the mounting bolt (18) of
the lock and move the lock (16)
forward. Tighten the bolt after that.
Adjust the right lock with the same
A
method. ZX215 1006271
C
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
RI
between the front window assembly
(14) and the adjusting seal (15) on
the cab. (Checked in Step 1)
E
Repeat Step a) and Step b) until the AM
condition of front window glass and
lock (16) and (17) is satisfactory.
Tighten the mounting bolts of the
left and right corner plates.
N
7. After adjustment is finished, flush the front

window glass with abundant water and 16 18
TI
check if any water penetrates into the cab. ZX215-1006272
8. Adjust the "locked" position of the lock of

LA
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.
NY
B. Set the locks of the front window

assembly at the rear of the cab at the
SA
"locked" position, and check the follow- 19 18

ing items:
● Check the conditions of left lock (16)
and right lock (17).
● The front window assembly must con- ZX215-1006273
tact the left and right rubber stopper

(18), and the rubber stoppers must be
pushed backward by 1.5 – 3.0 mm.
● The front window assembly shall push
the limit switch 4 – 7mm backward.

C. Close the front window assembly (10).

D. Loosen the retaining nut (20) at the left
and right side of rubber stopper (18), 18 20
and pull the two rubber stoppers (18)
inward so that they can not contact the
"unlocked" front window assembly.
A
ZX215-1006274
C
Fig. 8-275
RI
E. Adjust the position of latch bolt (21).
Latch bolt(21): M10, Inner diameter of
E
plate (23): ø14.5 mm AM
21
N
23
TI
ZXT225-1006284
Fig. 8-276
LA
F. Adjustment of left and right rubber stop-

per (18)
NY
a. Allow front window assembly (10)

to contact the left and right rubber
stopper (18). (when the lock is
SA
"unlocked")
10 19
17 21
ZX215-1006276
Fig. 8-277

b. Lock front window assembly (10).

c. Turn the left/right rubber stopper
(18) to the left by one and a half
round.
● Turning the rubber stopper (18) left-
ward for one round is equivalent to
pressing it by 1.5 mm.
18
● When front window assembly is
“unlocked”, it must move the left/
A
right rubber stopper (18) by 1.5 – 3.0 ZX215-1006278
C
mm. Fig. 8-278
RI
d. Tighten the retaining nuts (20) at
E
both sides of the rubber stopper
(18). AM 20
18
N
TI
ZX225-1006287
Fig. 8-279
LA
NY
SA

9. Adjust the front window assembly retainer

(24).
A. Adjust and lock both sides of the re-
tainer (24) so that surface (d) of stopper
(D) of front window assembly contacts
surface (c) of retainer (24) when front 24
10
window assembly is raised.
A
D
ZX215-1006279
C
Fig. 8-280
E RI
AM 24
D
d
N
TI
c
ZX215-1006280
Fig. 8-281
LA
10. Check the locking ability of front window

assembly.
A. After the adjustment from Step 6 to
NY
Step 9 is finished, check the locking 16 17

force of left lock (16) and right lock (17).
● Check the locking force at the "locked"
SA
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)

8.34 Monitor - Remove and Install
8.34.1 Removal
NOTICE
3 4
● Always disconnect the cable from nega- 5

tive post of the battery before you pro- 2
A
ceed.
1
C
1. Unscrew the three (3) bolts (4). Remove
RI
the mounting plate and the monitor as-
sembly from the bracket (3).
2. Remove the nut (1) and the gasket (2) to
E
ZX335-1006215
separate the monitor (5) from the mounting Fig. 8-283
AM
plate.
8.34.2 Installation
● Installation is to be performed in the re-
N
verse order of removal.

TI
LA
NY
SA

8.35 Controller AS
8.35.1 Removal
NOTICE 1

tive post of the battery before you pro-
ceed.
A
2
1. Remove the back plates (1) and (2).
C
2. Remove the controller wiring connectors (3)
RI
and (4).
ZXT335-1006216
3. Remove the two(2) bolts. Remove the
Fig. 8-284
E
controller assembly (5).
AM
N
2
TI
3
LA
ZXT335-1006217
NY
Fig. 8-285
8.35.2 Installation
SA

8.36 Radio
8.36.1 Structure
1. Main structure
C A
E RI
AM
N
ZX335-1006218
Fig. 8-286
TI
LA
NY
SA

8-138
2. Wiring
Fig. 8-287
RED — L. SOUND TRACK INPUT
SA
AUDIO INPUT
WHITE — R. SOUND TRACK INPUT

NY
Disassembly and Assembly
RED — ACC IGNITION
YELLOW — BATT POWER SUPPLY

LA
BLACK — GROUND
TI POWER, GROUND AND AUDIO OUTPUT
GRAY — R. SOUND TRACK OUTPUT +

BACK PANEL

N
LIGHT
BLACK
— R. SOUND TRACK OUTPUT –
WHITE — L. SOUND TRACK OUTPUT +

AM
BLACK — L. SOUND TRACK OUTPUT –
E
RADIO ANTENNA
RI
CA
ZX335-1006219
8.36.2 Removal and installation
Console
Removal cover
1. Remove the console cover (1).
NOTICE
● The power must be turned off before re-

Radio
moval.
A
ZX335-1006220
C
Fig. 8-288
RI
2. Remove the radio connector CN-003F.
E
AM
N
TI
Connector CN-003F Cab harness

ZX335-1006221
Fig. 8-289
LA
3. Remove the four(4) screws and the wash-

ers in order to remove the radio and the
radio mounting brackets from the console
NY
cover.
Console
4. Remove the four(4) screws and the wash-
ers in order to remove the radio from the
SA
radio mounting brackets.
Radio
Radio bracket Washer
Screw
ZX335-1006222
Installation Fig. 8-290

8.36.3 Connector model and wiring
1 2 3
1 2 3
20b R+ L+
A
4 5 6 7 0 20b R- L-
C
4 5 6 7
RI
Radio wiring terminals Harness socket terminals
Model: Deutsch DJ7072-3-21
ZX335
E
Fig. 8-291 AM
N
TI
LA
NY
SA

8.37 Battery
8.37.1 Structure
A
2 B
10 J
C
11
C A
6
RI
E
D
E
AM I
G
N
H
TI
F
8 7 5 9 4 3 1
LA
ZX335-1006224
Fig. 8-292
(1) Spinning post (7) Paste (active material)

NY
(2) Charge densimeter (8) "Bag-type" screen

(3) Heat-sealing cover (9) Polar group
(4) PP casing (10) Liquid-gas separator
SA
(5) Central polar ear (11) Central busbar

(6) Forged grid

8.37.2 Removal and installation
NOTICE
● Turn the start switch to the OFF posi-

tion before removal.
● Do not remove the charge densimeter.
Tighten the densimeter clockwise, if it
is loosened, with a suitable tool.
C A
Removal
RI
Bolt Terminal Grounding cable
3. Removal of battery grounding wire
● Open the tarpaulin, unscrew the bolt, and
E
remove the terminal from the battery wiring
post.
AM VART
A
CAUTION Battery
TTER Y
FREE BA
NANGE-
MAINTE
● Battery gas can cause explosion. No

N
sparks or flames are allowed near the ZX335-1006225

TI
battery. Fig. 8-293

LA
2. Disconnect the battery wiring cable and the

Cable
battery breaker cable.
NY
VARTA
VARTA
SA
Battery Breaker cable
ZX335-1006226
Fig. 8-294

3. Remove the four(4) bolts and washers. Battery

Remove the battery assembly from the
bottom plate. Remove the battery.
VAR
TA
TA
VAR
C A
RI
Washer Battery box
Bolt
ZX335-1006227
E
Fig. 8-295
AM
Installation
N
TI
8.37.3 Replacement
There are two 12V batteries with ground-
LA
ing negative (-) posts in the machine. If one

battery fails in the 24V system, it must be re-
placed with one of the same type. Batteries of
different types are probably charged at differ-
NY
ent speeds, which may cause one of them to

fail due to overloading.
SA
NOTICE
● Apply Vaseline, when required during

installation, to battery terminals to pre-
vent corrosion.

8.38 Start Switch

8.38.1 Structure
23 22 20 18 17 15 13 12,11 28 6 10,9,8,7
C A
E RI
AM
25,24 21 1 14 19 16 26 5 4,3,2
N
TI
LA
27
NY
4 5 6
1 2 3
SA
ZX335-1006228
Fig. 8-296
(1) Housing (8) Shield (15) Cover (22) Contact SPR-A

(2) Key (9) Pin (16) Spring (23) Contact B
(3) Ring (10) Spring (17) Ball (24) Terminal
(4) Dial (11) Disc (18) Spring (25) Bolt
(5) Nut (12) Spring (19) Contact SPR-B (26) O-ring seal
(6) Cylinder (13) Plug (20) Contact A (27) Harness AS
(7) Cap (14) Rotor (21) Seat (28) Washer

8.38.2 Removal
1. Unscrew the setscrew to remove the 21
67$5
7 0$
;
console cover.
2))
&.
/2
0,1
Start switch Console cover Setscrew

ZX335-1006229
A
Fig. 8-297
C
2. Remove both setscrews in order to remove
RI
Setscrew Console cover
the mounting plate and the start switch
from the console cover.
E
NOTICE
AM
● Disconnect the power supply of the
start switch before removal.
N
TI
Mounting plate Start switch

LA
ZX335-1006230
Fig. 8-298
3. Remove the nut so as to remove the start

NY
switch from its mounting plate.

SA
Start switch Mounting plate Nut
ZX335-1006231
Fig. 8-299

8.38.3 Working principle
On/off status
Gear
Battery Battery Accessory Preheat plug Start relay
position
(B) relay (BR) (ACC) (C)
(R1) (R2)
3B
OFF
1B
A
2B
ZX335-1006232
C
Fig. 8-300
RI
8.38.4 Wiring
E
AM
1 22 13 3
1 B BR ACC 3
N
4 R1 R2 C 6 4 16 11 6
TI
Harness plug terminal

Start switch wiring terminal Jacket model: Yazaki: 7123-7464-30
LA
Jacket model: Yazaki 7222-7464-30

ZX335-1006233
Fig. 8-301
NY
SA

8.39 Fuse Box
Removal
Cover
1. Remove the cover.
C A
ZX335-1006234
RI
Fig. 8-302
E
2. Remove the bolts and take off the back
Back cover Fuse box cover
cover along with the fuse box. AM
N
TI
LA
Bolt
ZX335-1006235
NY
Fig. 8-303
SA
3. Remove the bolts so as to separate the

Harness
fuse box and harness from the back cover.
Bolts
Back cover
ZX335-1006236
Fig. 8-304

8.40 Wiper
8.40.1 Structure
Wiper blade
Driving mechanism
C A
RI
Wiper arm
E
Wiper motor
AM
Connector
N
Mounting bracket
TI
ZX335-1006237
LA
Fig. 8-305
NY
SA

8.40.2 Working principle
Green (low speed)
A
Yellow (reset)
M
C
Blue (high speed)
RI
Red (power +)
E
AM
Black (power -)
N
ZX335-1006238
Fig. 8-306
TI
LA
NY
SA

8.40.3 Removal
1. Remove the decorative button in order to Decorative button
remove the interior decoration.
Interior decoration
A
ZX335-1006239
Fig. 8-307
C
RI
2. Remove the moving mechanism and the
motor.
● Unscrew the bolts to remove the wiper
E
Bolt
motor and moving mechanism from the
cab.
AM
Moving mechanism
Wiper motor
N
TI
Bolt
LA
ZX335-1006240
Fig. 8-308
NY
3. Remove the arm and the blade.

● Unscrew the nut to remove the wiper
arm and blade from the cab.
SA
Arm bracket
8.40.4 Installation
verse order of removal. Guard
Locknut
Cab
ZX335-1006241
Fig. 8-309

8.40.5 Angle adjustment of wiper arm

● The arm should stops moving when the
Mechanical stopper
blade reaches the stopper.
● If the arm is still working when the blade
reaches the stopper or the arm already
stops working before the blade reaches the Wiper blade
stopper, the moving angle of wiper should
be adjusted to prevent breakdown of the
wiper.
A
● Adjust the wiper in such a way. Loosen the Arm
C
locknut; adjust the arm working angle ac-
cording to actual condition. Make sure that
RI
the wiper motor stops working at the mo-
ment that the blade reaches the mechani-
cal stopper.
E
Locknut
AM
ZX335-1006242
N
Fig. 8-310
TI
LA
NY
SA

8.41 Relays S
8.41.1 Engine relays
1. Starter relay - check B
● Check the conduction and action. Replace

S
the relay in case of any failure. SW L
B 1 SW(-)
AA2A
2 L(-)
ZX335-1006243
A
Fig. 8-311
C
RI
2. Mains relay - check
● Check the conduction and action. Replace 1(+)
2(-)
the relay in case of any failure.
E
AM
3 4
Battery terminal (+)
N
TI
3 4
LA
1(+)
2(-)
ZX335-1006244
NY
Fig. 8-312
3. Heater relay
SA
● Check the conduction and action. Replace 5(-)

1
4. Safety relay 5 1 2 3 4
(-) (+)
● Measure the resistance between terminal
2 and terminal 3.
2 4(+)
Standard Value Approx. 200W Fuse 3
ZX335-1006245
● Check the conduction and action. Replace
Fig. 8-313

8.41.2 Other relays

Function and location
Relay harness
Start control relay Horn relay
Pilot cotnrol relay
A
Headlight relay
C
E RI
AM
N
TI
LA
Parking relay
NY
Work lamp relay

SA
Mounting plate
ZX335-1006246
Fig. 8-314

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
A
C
RI
Relay seat Setscrew Relay
ZX335-1006247
Fig. 8-315
E
8.41.4 Relay connector and wiring AM
5
1 4 2
N
TI
3
LA
Relay wiring terminal
Relay model：HELLA 4RD 007 903-027
Headlight Sart switch Pilot valve Horn Work lamp Shutdown delay
NY
K2 K3 K4 K5 K6 K8
77 ③ 11 ③ 27 ③ 32 ③ 34 ③ 21 ③
SA
① ② ① ② ① ② ① ② ① ② ① ②
④ 0 620 ④ 105 27 ④ 105 31 ④ 0 33 ④ 0 621 ④ 0

74
606
⑤ ⑤ ⑤ ⑤ ⑤ ⑤
73 11a 23 24 15a
Relay socket Jacket 8JA003526-00
Wiring socket terminal

Relay socket model: Jacket 8JA003526-00
ZX335-1006248
Fig. 8-316

8.42 Sensors
1. Water temperature sensor - check

1
● Put the sensor into a vessel containing en-
gine oil.
● Heat the oil to the specified temperature. Sensor body
Stir the oil at the same time.
● Measure the resistance value between the
A
terminal 1 and the sensor body at different
C
temperatures.
ZX335-1006249
RI
50±0.2℃ 80±10Ω
Fig. 8-317
60℃ 56.3Ω(ref.)
Standard 80℃ 29.5Ω(ref.)
E
Value 100℃ 16.5Ω(ref.) AM
106±0.3℃ 14.3±1.0Ω
120℃ 10Ω(ref.)
● Replace the sensor if the measured value

N
exceeds the standard one.

TI
2. Engine speed sensor - check

● Measure the resistance between terminal
LA
1 and terminal 2.
Std. Value(25℃ ) 2.3±0.2kΩ
● Replace the sensor if the measured value

NY
exceeds the standard one.

2 1
ZX335-1006250
SA
NOTICE Fig. 8-318
● Insufficient tightening of the engine

speed sensor may cause signal output
failure. Tighten the sensor to specified
torque.

3. Pressure sensor - check

Pressure joint Body Connector
● Input volt: 4.75~5.25 VDC
● Output volt: 0.5~4.5 V
● Pressure range: 0~50 BAR
Terminal B
Terminal A Terminal C
A
W365813081
C
Fig. 8-319
RI
4. Fuel level sensor - check
E
● Swing the float up and down in order
to measure the effective angle of radial AM
swing, i.e. the line through the float and the Float
turning point will swing 105° .
● Swing the float up and down. The vertical
distance between the upper limit and the
N
Lever
lower limit of the float should be 500 mm.
TI
● Move the float to its upper limit. Measure

the resistance between the sensor terminal
R and ground with a multimeter. The mea- Terminal R
LA
sured resistance should be Ru ≦ 9.6Ω. Shell
● Move the float to its lower limit. Measure

the resistance between the sensor terminal Connector
R and ground with a multimeter. The mea-

NY
sured resistance should be Rd ≧ 86Ω. ZX335-1006252
Fig. 8-320
SA

8.43 Connector Terminals
8.43.1 Insertion
1. Hold tightly a wire terminal at a distance of
about 25 mm from its end.
C A
RI
ZX215-1006320
Fig. 8-321
E
2. Hold the connector. Let the rear seal face
you.
AM
N
TI
LA
ZX215-1006321
Fig. 8-322
NY
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
SA
ensure that the terminal is locked in place.
ZX215-1006322
Fig. 8-323

8.43.2 Removal
1. Hold the connector, with its back end fac-
ing you. Select a suitable tool and clip on
the wire.
C A
ZX215-1006323
RI
Fig. 8-324
2. Push the tool along the wire into the
E
connector so that the tool can expand
the terminal lock shoulder and reach its AM
flanged part.
N
TI
LA
ZX215-1006324
Fig. 8-325
NY
3. Pull out the tool to remove the wire with

terminal.
SA
ZX215-1006325
Fig. 8-326

EA
G RIC
E
PAAM
KNTI
ANLA
BLNY
SA

SY365(B)H-9 Crawler Hydraulic Excavator System Schematics
System Schematics
C A
RI
9 System Schematics
9.1 Diagram of Hydraulic Lines...................................................................................... 9-3
E
9.2 Electrical diagram of chassis ................................................................................... 9-4
AM
9.3 Electrical diagram of control switches...................................................................... 9-5
9.4 Electrical diagram of operator station ...................................................................... 9-6
9.5 Electrical diagram of air conditioner......................................................................... 9-7
9.6 Electrical diagram of monitor ................................................................................... 9-8
N
TI
LA
NY
SA

System Schematics SY365(B)H-9 Crawler Hydraulic Excavator
C A
E RI
AM
N
TI
LA
NY
SA

9.1 Diagram of Hydraulic Lines Swing Arm Bucket Boom Left travel Right travel
SH
PG
D
DB
P
M
GER REG
MB
MB
MA
MA
PB
PA
Transitional block
VB
VB
VA
VA
1
(8) Left swing To XAs
Swing
(4) Right swing To XBs

T
A
4
(3)Arm out To XAa1 lower

P
OUT
XAa2
C
To XBa1
XBa2
IN (10)Arm in PaL Arm hold valve RS1 RS2 P4 (R4) (P4)
RI
Arm
2
R1
R2
1
Bucket (5)Bucket dig To XBc N2 Central

N1
DUMP
Dra
XBp1 swivel
XBp2
PaL HVa
XBp2
joint
E
DIG Aa Dr1
CC0 CCk
(9)Bucket dump To XAc lower (ROD) AaR
T
Ba1
Ba2(HEAD)
3
(HEAD) BaR
Arm 2
XBa1
AM
XBa2
2
(6)Boom down To XBb1 upper

P
UP XBb2 XAa2
PbL Boom hold valve XAa1 LCAT2
Arm 1 Pna1
ARC LCAP2 AcR
Ac(ROD)
DOWN (7)Boom up ToXAb2
XAb1 lower Dr3 LCa
BcR
BoR
PAcs (Bo) Bc(HEAD)
4
Boom (Ao)
AoR
PAcs
Backup
XAo XAc
Bucket
3
Right travel To XBtr lower XBc

XBo
N
Backward LCo LCk Drb
(2)Right travel HVb PbL
Ccb Ab
AbR
(HEAD)
TI
BbR Bb
Forward Dr2 (ROD)
To XAtr upper Boom 2 Boom 1
4
XBb2
T
XBb1
XAb2 Lcb2 LCb XAb1
AtL
P
To XBtL lower Bs cp1

1
BtL
As
Backward Swing XAs XAtL
(1)Left travel Xbs
Left travel
LA
Dr4 LCs XBtL
Pns
Px CP2 CT2 CpG
Btr
Forward To XAtL upper Right travel Atr
XAtr (PTa)
Left travel (PTb)
2
XBtr CT1
CMR1 Pz
Py Φ0.7 CMR2 MR
Φ0.7 Φ0.7
PH P2 front pump PG R3 P1 rear pump

NY
SA
T
PH1 A1 A2 PH2
a1 a2
Psv1 Psv2
(COOLER)
电液比例阀
Travel speed
Front pump
Rear pump
PPC lock
A1 2nd bost
adjuster
adjuster
change
valve
P2
P1
电液控转换
4.5bar
bb
A3
A2
A6
A4
A8
A7
A5
2.5bar
变功率调节 cc
Pf C Pf
dd
Pi1 负压调节 Pi2
B
A4
A
P1 P2
Engine
FRONT REAR
As
DR B1 B3 A3
10μm
10μm
10μm
80~150目
WX365-1309001
9-3
9.2 Electrical diagram of chassis
Air plugging Fuel level Oil press High-temp Low-temp Hydraulic oil
To cab harness CN-502M To cab harness CN-506M Alternator terminals Start motor switch sensor switch switch Temp sensor switch temp sensor
9 T-501 To power supply
CN-501M CN-502F CN-506F CN-113M
T-103 T-116 CN-800F T-102 T-135 CN-103M CN-101F F-301 T-100 F-300 T-101 T-500 grounding wire
0
To cab harness CN-501F 2 3 4 5 6 7 8 9 10 11 12 345678 1 2
15
T-102
42 34 60 14 15 32 0 21 14 60 21 12 103 509 0 508 106 510 66 42 511 T-101 To battery
22 65 50A 64 63 MT- MT+ 507 50 00 57 20
200 T-104 relay KB
1 21
T-120
201
2
202
3 To compressor
203 57
T-107
8 4 clutch
204
5
205
6
206 21 T-134
7 16
T-109
To preheat fuse
207
8
A
208 17 To preheat
9 T-107
resistance
602
10 108A
C
7
108B To rpm sensor
603 CN-125F
11
606 50A 1
13
RI
507 2
607
14 MT- 3 To throttle motor
4 CN-124F
608 00 5
15 MT+ 6
609
16
E
501
6 17 22 1
64
AM
502 2 To parking motor
18 63 3 CN-801F
702 0 4
19 65 5
703 6
20
21 511
22 108A
609 1
108B
23
N
5
0 CN-137F
24 106 2
TI
510
25 606
1
To pilot SV
26 508
0 2 CN-136F
S
27
66
28 608
LA
1
103
4
29 0 CN-133F
2
509
30
32 704
703
1
To R. pump SV
0 CN-134F
NY
2
702
1
To F. pump SV
3 CN-132F
0
2
SA
602
1
0 CN-138F
2
607 1
Hi/Lo travel SV
0
2 2 CN-131F
603
1
0 2 CN-135F
50 00 502 50 00 501 50 00 200 50 00 201 50 00 202 50 00 208 50 00 205 50 00 207 50 00 206 50 00 204 50 00 203
704
A B C A B C A B C A B C A B C A B C A B C A B C A B C A B C A B C 1
Power limit SV
0 2 CN-114F
0 34 32 0# 16 17 21 12 20 CN-116F CN-115F CN-120M CN-121M CN-122M CN-123M CN-124M CN-125M CN-126M CN-128M CN-129M
1
1 2 1 2 1 2 1 2 R. pump main F. pump main Left travel Right travel Arm OUT Swing Bucket DIG Boom DOWN Boom UP Bucket DUMP Arm IN
1 2
pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor pressure sensor
CN-102M F-104 F-103 CN-507M CN-503F CN-504F CN-505M
To work lamp To horn
A B C D E F G H I J K L M N
9-4
9.3 Electrical diagram of control switches
Wrok lamp switch Wiper switch Washer switch

Start switch CN-503F CN-505F CN-507F
HEAT 108B
1
506
OFF 1 3 5 7 1 3 5 7 1 3 5 7 2
50
3
8
ON 33 24 35H 25 35L 36 37 25
61
4
START 62
5
22 62 13 61 11 6
7
8
9
69
A
10
7 73
11
C
74 12
CN-202F
RI
To cab harness CN-202M
E
6
25
AM
1
33
2
35H 3
36
4
37 5
50 506 00 74 73 35L 6
60 14 69 14 60
1 2 3 1 3 5 7
N
5 7
11
8
13
9
TI
14
F-507 F-505 F-508 F-509 10
CN-501F CN-508F 22
11
To fuel control dial Head lamp switch 24 12
LA
CN-203M
4
To cab harness CN-203F
21
Fuse box harness 20
Fuse No. Rated value System 20 13 13 1

F1 20A Start loop 14
NY
2
10A 29 3
F2 Charging indicator
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 42 4
3
F3 5A Horn loop 20 5
15A 20 6
F4
SA
work lamp 22 14 23 24 25 20b 26 38 28 29 42 73 43 27 100 21

7
F5 5A wiper & washer 21 8
F6 10A Radio
10A CN-222F
F7 Cab lamp
F8 20A Air conditioner To cab harness CN-122M
2
F9 5A Access lamp
F10 5A Monitor
F11 20A Controller
F12 15A Head lamp 27 28 38 73 22 100 43 20b 23 24 25 26
F13 10A 1 2 3 4 5 6 7 8 9 10 11 12
Aux. controller
CN-221M
1
F14 10A
Solenoid valve GP
F15 15A Cigarette lighter
To cab harness CN-121F
9-5
9.4 Electrical diagram of operator station
To control switch harness CN-202F To chassis harness CN-502F
Head lamp relay Start control relay Pilot valve relay Horn relay Work lamp relay Shutdown delay relay
25 CN-202M CN-502M
1
9 33 31
2 1 CN-201F
35H 2 3 4 5 6 7 8 9 10 11 12 To horn button
3 1 2 3 4 5 6 10 11 12 23
2
108 B 506 50A 61 62 0 69 73 74 22 65 50A 63 64 MT- MT+ 507 50 00 57 1 2 3 45 1 2 3 45 1 2 3 45 1 2 3 4 5 1 2 3 45 1 2 3 45
36
4
1 2 3 45 1 2 3 45 1 2 3 45 1 2 3 4 5 1 2 3 45 1 2 3 45 13
37 1
5
74 0 77 73 620 105 11 11a 27 0 27 606 31 0 32 23 33 0 34 24 621 0 21 15a
35L 15
CN-203F 6 2
8
60
To control sw- 7 15a
itch harness 1
CN-203M 8 11
13 15 2
9
14
10 37
22 2
A
11 To washer motor
0# 1
24
7
12
C
42 0
3 1 CN-106F
RI
34 105
4 2 To pilot switch
60
CN-506M 5 0 11a 60 68 14
14 0#
6 1 2
E
1 2 3 20b R+ L+ 20b 0# R- L-
1
15 14 66 61 68 0 69 0 62 63 64 65
6
To chassis 7 25
harness To alternator 1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 5 6 7 2
32
AM
To safety relay
CN-506F 8 36
3 CN-110M
CN-181M To preheat relay To parking relay CN-180M CN-003F
200 To radio control panel 35H
1 4 To wiper harness
201 CN-112M
2 C B A 120Ω 35 L 5
202 0-S CAN- CAN+
3 C B A CN-115
CAN- CAN+
203
N
5 4
5 204
57
TI
6 205 1
206 61a
7 4
207 60a
8
208 5
CN-207F
LA
9 0#
4 6 To A/C panel
38
7
606 42 42 0 0 0-S CAN-CAN+ 703 208 502 00 702 501 201 00 00 206 207 205 00 50 00 511 202 00 0 510 204 200 203
13 38 8
607 1 2 3 8 10 11 12 17 18 19 20 22 23 28 29 30 31 7 8 9 10 11 12 19 21 22 23 30 32 33 34 35
14
NY
26
CN-501F 8
CN-141M CN-140M 0#
501
3 To chassis 17 7
harness
502
18
SA
CN-501F 77
702
6
19
703 0# 5
20 CN-150M
511 L-
21 4
L+ To cab radio
22 108 A 3 harness
2 23 108 B R-
2
106 R+
24 1
510
25
508
26
27 28 38 73 22 100 43 20 b 23 24 25 26 13 14 42 20 20 21 21 42 43 100 11 13 607 MT- MT+ 0 0# 620 621 103 106 506 507 508 509 50A 704 60a 61a 108 A 108 B
66 1 2 3 4 5 6 7 8 9 10 11 12 1 2 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 1 2
28
103 CN-114F
1 29 20 12
CN-121F 1 2 CN-113F
30 CN-111M
CN-122M
Access lamp To fuse box harness CN-221M To monitor harness CN-7-113M To monitor harness CN-7-111M To monitor harness CN-7-114M
704 CN-505M
32 To fuse box harness CN-222M To start motor
9-6
9.5 Electrical diagram of air conditioner
Control panel
ACM
10
6
7
21
22
23
26
27
28
29
30
31
32
35
36
4
2
3
8
9
17
18
19
20
24
25
33
34
1
11
12
13
14
15
16
CN-M30 CN-M29
10
4
10
6
2
7
3
11
12
13
14
15
16
4
2
1
8
9
17
18
19
8
9
11
12
13
14
15
16
0.5BrW
0.5BrY
0.5LgR
0.5WY
0.5GO
0.5WO
0.5OW
0.5GW
0.5VR
0.5RY
0.5WR
0.5RW
0.5LO
0.5BG
0.5BW
0.5VW
0.5BR
0.5BL
0.5BY
0.5PB
0.5YB
0.5PG
0.5Sb
0.5R
0.5B
8
0.5LgR
0.5BrW
0.5BrY
0.5BW
0.5WO
0.5OW
0.5GW
0.5WR
0.5VW
0.5WY
0.5RY
0.5GO
0.5BY
0.5LO
0.5YB
0.5BG
0.5RW
0.5PG
0.5VR
0.5BR
0.5PB
0.5BL
0.5Sb
0.5R
0.5B
SWP SWP SWP
4
2
2
6
6
3
8
9
8
9
7
6
7
1
10
12
10
12
13
14
15
16
4
2
3
8
11
11
1
CN-M28 CN-M27 CN-M33
A
4
2
6
3
8
9
7
1
10
12
13
14
15
16
6
7
11
4
2
3
8
4
2
6
3
8
9
7
1
1
10
12
11
7
0.5LgR
0.5BrW
0.5RW
0.5BW
0.5WO
0.5WR
0.5OW
0.5GW
0.5BrY
0.5WY
0.5VW
0.5BG
0.5GO
0.5RY
0.5BY
0.5YB
0.5LO
0.5PG
0.5BR
0.5VR
0.5PB
0.5BL
0.5Sb
C
0.5R
0.5B
RI
Diffuser conversion
servo motor
MV 2
Internal temp sensor
FACE(DEF)
THI
FOOT
GND
E
Vz
Pt
6
2
6
5
3
7
1
CN-M34
2
1
2
6
5
3
7
AM
1
2
1
0.5GW
0.5OW
0.5BW
0.5GO
0.5BR
0.5BR
0.5Sb
050
CN-P15
2 2
1 1
S S 0.5WY FACE
7 7
0.5WR FOOT
6 6
0.5BrW Pt Diffuser conversion
5 5
N
5
4 4
0.5BW
3 3
Vz servo motor
2 2
0.5BR GND
1 1 MV I
TI
CN-A30
2 2 0.5YB FRE
7 7
1 0.5VW
LA
1 6 REC
6
0.5WO Pt
5 5
TH A M 4 4
Fresh air/recirculation
4 0.5BW Vz
3 3 conversion sero motor
2 2
0.5BR GND
1 1
ECC
EC
NY
CN-E06 S 0.5PB
1
Mcool
0.5VR 7 7
CN-M26 Mhot
6 6
1
12 12 0.5BG Pt
5 5
11 11 4 4 A/M servo motor
TO CN-M26-A TO CN-E06-1 0.85W 0.5BW Vz
10 10 3 3
3 9 9 2B 2 2
0.5BR GND
8 8 1 1 MA M
TO CN-M26-7 TO CN-P15-1 0.5BW
7 7
TO CN-M26-7 TO CN-A30-2 0.5RW
6 6
SA
2Br
5 5 1.25R
20A 4 4
TO CN-M26-2 TO CN-P15-2 3 3 0.5RY 5A
2 2
TO CN-M26-1 TO CN-A30-1 0.5BR
1 1
24V 0.5BR
1 1 Low-temp sensor
0.5PG
2 2
1.25G THF
1.25RL 72C 40C 1.25G
2
1.25RL
2G
1.25RL
2RL
0.5BL
2G
2B
0.5BrY
0.85W
0.5LO
0.5R
0.5R
2RL
0.5lgR
2RL
2Br
2Br
0.5BR
0.5BY
2G
0.5B
4
3
1
4
3
1
4
2
3
4
2
2
1
2
1
1
4
2
3
2
4
2
1
1
1
PROTECTION
FOR TEMP.
2
1
1
DRIVING TRANSACTION OF
CIRCUIT INPUT SIGNEL
RL RL VOLTAGE
CORRECTION
R L C C R LB M MB BLC SPH L THW

1 Compressor cltch relay Blower relay Blower motor Hi/Lo pressure switch Coolant temp sensor
9-7
9.6 Electrical diagram of monitor
Cigar lighter Sunlight sensor

CN-7-707M CN-7-706M
1 2 1 2
0# 100 60a 61a
CN-7-113M
A
7 CN-142M
To cab harness
Start signal
CN-113F
C
11
Power-on signal 1
2 13
3 103 42
RI
24V power supply 4 1
42 43
Air block sw sgnl input 5 2
thrttl mtr position fdbck sgnl 6 100
7 507 3
11
8 4
Pwr lmt vlv ctrl sgnl 9 13
5
E
704
6 GND 10
0 607
CAN bus low 11 6
CAN-
RPM sensor signal 12 MT-
7
AM
Coolant temp high switch 13 108A
Eng oil press sw input 14 106 MT+
508 8
RPM sensor GND 15 0
Oil level sensor signal 16 108B 9
17 509 0#
10
Fuel control dial signal 18
506 620 11
Start control signal 19
620
Hi/Lo travel speed ctrl sgnl 20 621
607 12
21
5
N
22
24 V power supply 23
5V power output 24 43
50 A
TI
25
26
27
28
29
GND 30
Motor driving signal + 31 0 CN-7-111F
LA
Motor driving signal - 32 MT+
4 Shutdown delay control 33 MT- To cab harness
621
CAN bus high 34
CAN+
CN-111M
35
103
1
106
2
506
3
NY
507
4
508
5
3 509 6
50 A 7
SA
704 8
60 a
9
61 a 10
108A 108B S CAN+ CAN- 0-S
A B C A B C
2
CN-7-114M
To cab harness CN-7-112F
CN-114F To cab harness
CN-112M
9-8

SM Sy365 (B) H-9 2014-04-16

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www.sanygroup.

com Quailty Changes the World

SANY HEAVY MACHINERY LIMITED

Tel: (86) 21 5700 8518

Documentation No.: ZJSYF0301EN(07-12)-SY55C3/55C9/60C1

Shop Manual - April 2014

1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9

1.3.1.2 Main failures occurring in wiring harness ............................................ 1-10

1.3.1.4 Handling the integrated control monitor .............................................. 1-16

1.3.2.2 Disassembly and maintenance work in the field ................................. 1-18

Shop Manual - April 2014 I

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

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

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

2.3.1 Safe Work Preparations ................................................................................2-11

2.3.5 Safety Partners ............................................................................................ 2-15

2.4.1 Running the Machine ................................................................................... 2-16

II Shop Manual - April 2014

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

3.1 Specific Dimension .................................................................................................. 1-3

3.1.2 Working ranges .............................................................................................. 1-4

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

4 Structure and Functions

Shop Manual - April 2014 III

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

4.4.5 Regulator .................................................................................................... 4-35

4.5.1 Main control valve ........................................................................................ 4-48

4.5.1.2 Main valve structure ............................................................................ 4-50

4.6.2 Swing holding brake..................................................................................... 4-81

4.6.4 Anti-jerk valve............................................................................................... 4-84

IV Shop Manual - April 2014

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

4.8.1 Air conditioner lines .................................................................................... 4-130

4.8.1.2 A/C control panel............................................................................... 4-133

4.8.1.4 Operating principle ............................................................................ 4-136

4.8.1.8 Expansion valve ................................................................................ 4-141

4.8.1.10 Dehydrator ..................................................................................... 4-142

Shop Manual - April 2014 V

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

4.11 Monitoring System ............................................................................................. 4-195

4.11.2 Monitor panel ........................................................................................... 4-197

4.11.2.2 Operation keys ................................................................................ 4-199

4.11.3.3 Main menu ...................................................................................... 4-202

4.11.3.5 Pilot pressure signals ...................................................................... 4-203

VI Shop Manual - April 2014

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

5 Table of Standard Values

6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13

6.5.1 Testing.......................................................................................................... 6-14

6.8 Track Tensioner - Test and Adjust .......................................................................... 6-21

6.8.2 Adjusting ...................................................................................................... 6-22

Shop Manual - April 2014 VII

7.5 Troubleshooting Electrical System (E-Mode)......................................................... 7-49

8 Disassembly and Assembly

8.1 How to Read This Manual ....................................................................................... 8-5

8.3.1 Removal ......................................................................................................... 8-9

8.4 Fuel Injection Pump AS ........................................................................................ 8-10

VIII Shop Manual - April 2014

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

8.12.2 Installation .................................................................................................. 8-43

8.13.1 Disassembly............................................................................................... 8-44

8.14 Idler AS ............................................................................................................... 8-54

8.15.1 Removal ..................................................................................................... 8-58