Shop Manual Sany SY 750H

SY750H
Hydraulic Excavator
Service Manual
• This Service Manual is prepared for experienced technical personnel, and aims to provide the
technical information necessary for maintenance and repair of this machine.
• This Service Manual may involve the working devices and optional equipment which are not available
in your area. You may purchase such components from local authorized dealer of SANY heavy
machinery co., ltd. The materials and technical specifications may be modified without further notice.
SANY Group
Shanghai SANY Heavy Machinery Co., Ltd.
Shanghai SANY Heavy Machinery Co., Ltd. Industrial Park, Ping’an Town,
Fengxian District, Shanghai City, China
Postcode: 201413
http://www.sany.com.cn
Fax: 021-57001222
Sales Hotline: 021-57001111
After-sales Service Hotline: 4008 28 2318
Consultation & Complaints Hotline: 4008 28 2333
Along with the continuous updating of technologies and products, the material and technical specifications
will be changed without further notice. Copyright © 2012 All rights reserved by SANY Group. This Manual
shall not be duplicated, spreaded, sold or modified without the written approval of SANY Group.
SY750H Hydraulic Excavator Table of contents
Table of contents
Page
Preface .......................................................................................................................... 1-1
Safety ............................................................................................................................ 2-1
Technical Specification .................................................................................................. 3-1
Structure, function and maintenance standard .............................................................. 4-1
Standard value of components ...................................................................................... 5-1
Testing and Adjustment ................................................................................................. 6-1
Trouble diagnosis and troubleshooting .......................................................................... 7-1
Disassembling and Assembling ..................................................................................... 8-1
Hydraulic & Electrical Diagram ...................................................................................... 9-1
Service Manual 03-2017 III

Table of contents SY750H Hydraulic Excavator
IV Service Manual 03-2017

SY750H Hydraulic Excavator Preface
Preface
Reading Method of Service Manual ............................................................................................................ 1-2
Explanation on Terms for Maintenance Standards ..................................................................................... 1-4
Handling of Electrical Component and Hydraulic Components .................................................................. 1-6
Notices for handling of electrical components ..................................................................................... 1-6
Precautions when Treating Hydraulic Parts ....................................................................................... 1-13
Pipe joint .................................................................................................................................................... 1-15
Type of Pipe Joint............................................................................................................................... 1-15
Tightening Torque of Pipe Joint ......................................................................................................... 1-16
Connection of O-ring .......................................................................................................................... 1-17
Bolt and nut ............................................................................................................................................... 1-18
Table of Tightening Torque for Bolts and Nuts .................................................................................. 1-18
Type of Bolt ........................................................................................................................................ 1-19
Tightening Sequence of Bolts ............................................................................................................ 1-19
Maintenance of Split Flange ...................................................................................................................... 1-20
Table of Tightening Torque for Split Flange Bolt ............................................................................... 1-20
Conversion Table ...................................................................................................................................... 1-21
Service Manual 03-2017 1-1

Preface SY750H Hydraulic Excavator
Reading Method of Service Manual

● It is likely that some accessories and optional parts mentioned in this Service Manual will not be
transported to specific area. If you need them, please consult with the dealer of SANY heavy
machinery co., ltd.
● The materials and technical specifications may be modified by Sany without further notice owing to
technical advancement. As for the latest relevant technical information, please consult with the
authorized dealer of Sany.
1. Composition of Service Manual

This Service Manual contains the technical information necessary for carrying out maintenance and
repair in workshop. In order to facilitate the understanding, this Manual is divided into the following
parts.
Preface
This Section sets firth the main contents of this Service Manual, the method to use this Service
Manual, the basic principles for repair and other basic information.
Safety
This Section introduces the meaning of safety signs in this Manual and the basic safety information
involved in repair of equipment.
Technical Specification
This Section sets forth the basic data of this machine, such as dimension, excavation range, weight
table and engine curve.
Structure, function and maintenance standard
The contents of this Section are divided into two parts. The Part “Structure and Function” sets forth the
structure and function of every component, and it will not only help you understand the structure, but
also serve as reference material for trouble diagnosis. The Sub-section “Maintenance Standard” sets
forth the standards and measures for disassembling and maintenance.
Standard value of components
This Section sets forth the standard values for new machine as well as the judgment standards for
testing, adjustment and trouble diagnosis, so as to guide the testing, adjustment and troubleshooting.
Testing and Adjustment
This Section sets forth the measuring instruments used for testing and adjustment, the measurement
method, and the method to adjust every part.
Trouble diagnosis and troubleshooting
This Section sets forth the method to identify and repair the parts in trouble. The trouble diagnosis falls
into several trouble modes.
Disassembling and Assembling
This Section sets forth the special tools, procedures and notices for dismantling, installing,
disassembling and assembling every component. In addition, the tightening torque as well as the
quantity and weight of coating, engine oil, lubricating grease and coolant required for operation are
also set forth.
Hydraulic & Electrical Diagram
This part mainly gives the hydraulic oil way diagrams and wiring diagrams
1-2 Service Manual 03-2017

2. Amendment and Issuance

Any supplementation, amendment or change in other notices will be sent to authorized dealers of
SANY heavy machinery co., ltd. Before carrying out any operation, please obtain the latest information.
3. Symbols
The common-used symbols in this Manual are detailed as follows.
Symbols Items Remarks
Safety The special safety notices are required during operation.
This symbol indicates the relevant provisions and notices

Notes
which must be complied with during installation of parts.
Weight of component which must be considered during
Weight selection of lifting steel wirerope or is important for
operation
Tightening Locations where attention shall be paid to tightening torque
Torque during assembling
Locations to which the adhesive must be applied during

Coating
assembling
Lubricant This symbol indicates the lubricant to be used.
Locations where the oil or water must be added, and

Oil and Coolant
capacity thereof
Locations where the oil or water must be drained, and

Emission
quantity thereof
4. Unit
In this Service Manual, the units in SI system are used. The units in gravitational system given in { }
are for reference only.

Explanation on Terms for

Maintenance Standards
The maintenance standards necessary for judging
products and parts are described by using the
following terms.
1. Standard Dimension and Tolerance
● Accurately speaking, the processing dimension
of every part is slightly different.
● In order to specify the processing dimension of
a part, please set a temporary standard
dimension, and point out the permissible
deviation from such dimension.
● The temporarily-set size above is called as
“standard size”, the range of deviation from
standard value is called as “tolerance ”.
● On the right side of standard dimension, the
tolerance with symbol + or – is given.
Example:
Standard dimension Tolerance
-0.022
120
-0.126
● The tolerance may be expressed in the form of

[standard value (upper limit/lower limit of
tolerance)] in text and table. For example: 120
(-0.022/- 0.126)
● Normally, the mutually-matched hole and shaft
have the same standard size and different
Standard
tolerance. The installation tightness will be Dimension +0.060
Tolerance of hole (upper
decided by tolerance. side) +0.046
Standard clearance
● The size relationship between rotating shaft (maximum): 0.122
and hole is as indicated in the figure. Standard clearance
(minimum): 0.030
Tolerance of shaft (lower
side): -0.076
Example: Tolerance of shaft (upper
side): -0.030
Standard Tolerance
dimension Shaft Hole
-0.030 +0.046
Ø60
-0.076 0
Figure 1- 1

2. Standard Clearance and Standard Value 5. Clearance limit

● The clearance appearing when a new part is ● The parts may be used until the clearance
assembled is referred to as “standard between them exceeds a certain limit. The limit
clearance”, and it is expressed by a range from under which these parts may not be used any
minimum clearance to maximum clearance. more is referred to as “clearance limit”.
● As for repair of some parts, normally the ● If the clearance between parts exceeds the
clearance is adjusted to standard clearance. clearance limit, please replace or repair them.
● The performance/function value or equivalent 6. Interference limit
of new product is referred to as “standard
● The maximum permissible interference
value”, and it is expressed by a range or a
between the hole on a part and the shaft of
target value.
another part which is to be assembled is
● During repair of some parts, the referred to as “interference limit”.
performance/function value is set as standard
● The interference limit indicates the repair limit
value.
of part which has the less tolerance.
3. Standard interference
● If the interference between parts exceeds the
● When the dimension of hole is less than interference limit, please replace or repair
dimension of shaft owing to standard value and them.
tolerance, the difference between such
dimensions is referred to as “interference”.
● The interference generated during assembling
of new part is called as “standard interference”,
and it is expressed as an range from minimum
interference to maximum interference.
● After repairing or replacing some parts, please
measure the dimension of their holes and
shafts, and inspect whether the interference is
within the standard range.
4. Repair Limit and Permissible Value
● During use, the size of component may change
owing to wear and deformation. The
permissible limit value for change is called as
“repair limit”.
● If a part is worn to repair limit, please replace or
repair it.
● During use, the performance and function of
component will continuously reduce. The value
below is called as “permissible value”, and
below this value, the product can be used
normally without problem.
● If a product is worn to permissible value, please
inspect or repair it. The permissible value is
estimated on the basis of various testing or
experience in most occasions. However, please
carry out judgment after considering the
operating conditions and needs of customer.

Handling of Electrical Component and Hydraulic Components

After this machine has been used for long time, in order to ensure its operation performance and prevent
the occurrence of troubles and other abnormal situations, please carry out operation, maintenance,
inspection, trouble diagnosis and repair correctly. This Section mainly discusses the correct repair methods
for electrical and mechanical components, aims to improve the repair quality, and is mainly divided into
“handling of electrical components "and “handling of hydraulic components” (especially for gear oil and
hydraulic oil).
Notices for handling of electrical
components
1. Handling of Harness and Connector
A harness is composed of the wires connected
from a component to another component, the
connector used to connect two wires or
disconnect a wire from another wire, and the
shield or pipe used to protect wires.
As compared with other electrical components
which are installed in box, the harness may be
directly affected by rain, water, heat or
vibration. In addition, during inspection and
repair, they may often be dismantled and Figure 1-2
installed again. As a result, they may get
deformed or damaged. Therefore, When
handling any harness, please be extremely
careful.
2. Main Troubles Occurring in Harness
1) Poor contact in connector (poor contact
between electrical plug and electrical socket) The connection is
incorrect
If the electrical plug of connector is not
correctly inserted into electrical socket, or the
connector is deformed and thus the position is
not properly aligned, or the contact surface is
corroded and oxidized, then poor contact may
occur.
Figure 1-3
2) The edge or welded portion of connector is in
trouble
The pins of connector contact with rolled-up Edge portion
terminal or welded portion. However, if the wire
undertakes too much force, the cladding
material on joint will peel off, so that the
connection will be incorrect or break.
Figure 1-4

3) Disconnection of Wire
If the connector is pulled out by holding the
wire, or the connector connected with
component is lifted up by crane, or the wire is
collided by heavy object, then the rolled-up
edge of connector may get separated, or the
welded portion and wire may get damaged.
Figure 1-5
4) The high-pressure water enters into connector

As for water-proof connector, if the high-
pressure water is directly injected onto
connector, on the basis of the injection angle,
the water may enter the connector internal.
Therefore, please be careful not to get the
water splash onto connector. When the water
enters the water-proof connector, it can’t be
drained easily. When water enters into
connector and the pins are short-connected by
water, please immediately blow dry the
connector or take other appropriate measures
before it is powered on.
Figure 1-6
5) Oil or oil sludge sticking to connector

If the connector is stained with oil or lubricating
grease and a layer of oil film is generated on
mating face between pin and hole, then the
current will not be able to pass, so that the
contact trouble will occur. If the connector is
stained with oil or lubricating grease, please
wipe it clean with dry cloth and blow it dry with
compressed air. The compressed air shall be
sprayed by air gun.
When wiping the mating face of connector, be
careful not to use too large force or get the pin
deformed.
If there is oil or water in compressed air, then
the contact may become more dirty. Therefore, Figure 1-7
before using the compressed air to carrying out
cleaning operation, please thoroughly eliminate
the oil and water in compressed air.

3. Dismantle, install and blow dry the connector

and harness
1) Disconnect the connector
● When disconnecting a connector, please hold
it. Press gently when
dismantling
As for the connector fixed with screw, please Locking
fully loosen the screw, hold the concave and reed
convex connectors with two hands and then
separate them. As for the connector equipped
with locking reed, please press down the reed
with thumb and then pull out the connector.
Note: Don’t pull the connector with one hand.
Figure 1-8
● When dismantling a connector from a clip

Both the connector and clip are equipped with
stop block, and when the connector is installed, Both are stop blocks
they are engaged with each other.
Figure 1-9
When dismantling a connector from a clip, please

pull out the connector in the direction parallel to the
clip, so as to remove the stop block.
Note: If a connector is twisted upwards and
downwards or leftwards and rightwards, the casing
may get damaged.
Figure 1-10

● Measures to be taken after a connector is

dismantled
After dismantling any connector, please cover it
with a polythene bag, so as to prevent dust, oil
or water from entering the connector.
If this machine has been in disassembled state
for long time, poor contact may occur.
Therefore, be sure to wrap the connector and
bind up the mouth of bag.
Figure 1-11
2) Connection of Connector
● Visually inspect the connector
Inspect that the pins (mating face) are not
stained with oil or water
Inspect that the pins of connector shall be free
from deformation, contact trouble, rust or
damage.
Inspect that the outside of connector shall be
free from damage or crack.
If there is oil, water or oil sludge on connector,
please wipe it away with a piece of dry cloth. If
water enters into connector, please use a drier
to heat up the inside of wire, but please be
careful not to get it overheated; otherwise short
circuit may be caused.
If the connector is damaged or cracked, please
replace it.
● Fixing of connector
Correctly align the connector and then firmly
insert it. As for the connector equipped with
locking reed, please push in the connector, until
the reed make the sound click. The connector is in
place after chatter
is heard
Figure 1-12

● Correct the situation that the protective cover

bulges and the harness is not aligned.
As for the connector equipped with protective
cover, correct the bulging of protective cover. If
the harness is not aligned, or the thimble is
displaced, please adjust it to the correct
position.
If the connector can’t be corrected easily, then
dismantle clamp, and adjust position.
If the connector clamp has been dismantled, be
sure to restore it to its original position. Please
also inspect whether the clamp is loosened.
Figure 1-13
Figure 1-14
3) Connection of DT Connector
Since the DT8-pin and 12-pin large-power wire
connector has two buttons, please push them
in until the chatter is heard for twice.
● Convex connector: 1
● Concave connector: 2
● Normal locking state (horizontal): a, b, d
● Incomplete locking state (diagonal): c
Figure 1-15

4) Dry up the harness

If there is any oil or stain on harness, please
use a piece of dry cloth to wipe it away. Don’t
use water or steam to clean it up. If it is
necessary to clean up the connector in water,
please don’t apply the high-pressure water or
steam directly onto harness. If the water is
directly applied on connector, please comply
with the following provisions.
● Disconnect the connector and use a piece of
dry cloth to wipe away the water.
The oil contained in air may lead to trouble of
contact. Therefore, before using the
compressed air, please clear away all oil and
water in compressed air. Figure 1-16
● Use a drier to blow dry the inside of connector.
If water enters the connector, please use a
drier to blow dry the connector.
Pay attention to the use time of drier, so as to
prevent the connector or relevant parts from
getting overheated; otherwise the connector
may get deformed or damaged.
● Carry out the conductivity test for connector.
After blowing dry the connector, keep the
harness in disconnected state, and carry out
the conductivity test to inspect whether there is
any short circuit caused by water between pins.
Figure 1-17
T-shaped
Joint
Figure 1-18

4. Handling of Controller
1) The controller contains a micro-computer and
electronic control circuit. They controls all
electronic circuits on this machine. Therefore,
when handling this controller, please be
extremely careful.
2) Don’t place any article on controller.
3) Use a band or polythene bag to cover the
control connector. Please don’t touch any
contact of connector with hand.
4) In rainy days, don’t place a controller in a
position exposed to rain water.
5) Even for short time, don’t place a controller on
any place where there is oil, water, soil or heat. Figure 1-19
(Please place it on an appropriate dry bench)
6) Notices for electric arc welding
When carrying out electric arc welding on body
of machine, please disconnect all harness Toolbox
connectors which are connected to controllers.
Please install an arc weld earth near the
welding point.
5. Matters to be Remembered During Diagnosis

of Trouble in Electric Circuit Figure 1-20
1) Turn off the power supply before disconnecting
or connecting the connector.
2) Inspect whether all the relevant connectors
have been inserted properly before performing
trouble diagnosis.
Disconnect and connect the relevant
connectors by several times for inspection.
3) Connect all the disconnected connectors before
proceeding to the operations in the next step.
It would produce unnecessary abnormal
display if turning on the power supply without
disconnecting the connector.
4) It is necessary to move the relevant wires and
connectors by several times and inspect Figure 1-21
whether the readings of the instrument change
when performing trouble diagnosis for the
electrical circuit (measure voltage, resistance,
connectivity or current).
The contact trouble might exist in the electrical
circuit if the readings change.

Precautions when Treating Hydraulic Parts

As the pressure of hydraulic system increases and the precision of hydraulic components increases, the
impurities in hydraulic oil way are often the most important cause for trouble of hydraulic system. When
filling the hydraulic oil, or when disassembling or assembling the hydraulic components, please be
especially careful.
1. Operating Environment
Avoid filling hydraulic oil, replace the filter or
repair the excavator in the rain or wind or in the
environment with heavy dust.
2. On-site disassembling and maintenance work
The dust might enter the parts if the hydraulic
parts are disassembled and maintain on site. It
would be very difficult to inspect the
performance after repair. Thus, it would be the
best to replace with assembly unit. The
hydraulic parts shall be disassembled and
maintained in the particularly prepared dust-
proof workshop, and the performance shall be
inspected with dedicated test equipment.
Figure 1-22
3. Sealing of Opening
After dismantling any pipe or component,
please use cover, tape or polyethylene bag to
seal up every opening, so as to prevent the
entry by oil sludge or dust. If an opening is kept
open, or is blocked up with a rag, then there is
the risk that the oil sludge will enter or the
surrounding area will be stained by leaking oil.
Therefore, don’t act like that. Don’t simply drain
the oil onto ground. Please collect it and ask
how the customer will handle that.
Figure 1-23
4. During refilling operation, don’t let any oil
sludge or dust in
When refilling in hydraulic oil, be careful to
prevent any greasy filthy or dust entering. Be
sure to keep the engine oil filter core and the
surrounding area clean, and it is necessary to
use clean pump and oil storage container. The
greasy filthy accumulated in the storage
process may be filtered out if the oil cleaning
equipment is used, which is a more effective
method.
Figure 1-24

5. Replace the hydraulic oil at high temperature

It flows easily when hydraulic oil or other oil
temperature is high. Besides, it would be easier
for the sediments to be discharged along with
the oil from the oil way. Therefore, it would be
the best to replace the oil when it is still warm.
When replacing the oil, try to drain the used
hydraulic oil thoroughly (drain oil from hydraulic
oil tank; drain oil from drain plug in the filter and
oil way). If there is any used oil, the impurities
and sediments would mix with the new oil, and
shorten the service life of hydraulic oil.
6. Flushing operation
After disassembling and assembling the
equipment or replacing the oil, it is necessary to
remove the impurities, sediments and the used
oil in the hydraulic oil way with flushing oil. Flushing
Usually it is necessary to flush twice: flush oil
mainly with flushing oil, and use specified
hydraulic oil for auxiliary flushing.
Figure 1-25
7. Cleaning operation
After any hydraulic component (pump, control
valve and etc.) is repaired or When this
machine is running, please clean up the oil, so
as to clear away the deposits or impurities in
hydraulic oil way. The oil cleaning equipment is
used to clear away the fine (about 3μ) particles,
so as to ensure that the filter in hydraulic
component can’t be dismantled. Therefore, it is
a very effective equipment.
Figure 1-26

Pipe joint
The pipe joint is used to connect small-diameter
pipes. The metal sealing faces (4) and (5) of joint
(1) and hose (2) will mate with each other, so as to
seal up the pressure oil.
Attention
● Don’t excessively tighten up the nut (3). Too
large force will act on metal sealing faces (4)
and (5), and thus the joint (1) may get
cracked. Be sure to tighten up the nut (3) in Joint body
accordance with the technical specifications.
● The scratch or other damage on sealing
surface (4) or (5) will lead to oil leakage at
connection. During connect/disconnecting
Figure 1-27
operation, please be careful not to damage
the sealing surface.
Type of Pipe Joint
Concave Convex
Figure 1-28

Tightening Torque of Pipe Joint

Dimension of wrench Dimension of wrench
Tightening torque
Type mm mm
Connecting nut Hose joint N·m(kgf·m,lbf·ft)
19 19 59(6,44)
22 22 98(10,72)
27 27 118(12,87)
36 36 235(24,173)
24°convex type
41 41 295(30,218)
50 50 490(50,361)
60 60 670(68,494)
70 70 980(100,723)
19 17 44(4.5,32)
22 19 59(6,44)
27 22 118(12,87)
24°concave type
36 30, 32 235(24,173)
41 36 295(30,218)
50 46 490(50,361)
Attention
● The torque given in this table is only for common use.
● Under special circumstance that the different torque is given, don’t adopt the torque given in this table.

Connection of O-ring
The end faces of O-ring (6) and joint (7) will mate
with each other, so as to seal up the high-pressure
oil.
Hose joint
Figure 1-29
Attention
● When re-connecting the pipes, be sure to replace the O-ring (6) with a new one.
● Before tightening the nut (9), please make sure that the O-ring (6) has been correctly placed in O-ring
groove (8). During tightening of nut (9), if the O-ring (6) moves, the O-ring (6) may get damaged, and
thus oil leakage may occur.
● Please don’t damage O-ring groove (8) or sealing surface (10). The damaged O-ring (6) may lead to
oil leakage.
● If it is found that the oil leakage is caused by loosing of nut (9), don’t handle the oil leakage by
tightening up the nut (9), but replace the O-ring (6) with a new one, confirm that it is reliably mounted
and then tighten up the nut (9).
Dimension of wrench mm Dimension of wrench mm Tightening torque

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

Bolt and nut

Table of Tightening Torque for Bolts and Nuts
★ Unless otherwise stated, please tighten up the nut and bolt to the torque mentioned below. (when the
torque wrench is used)
Thread Dimension of Hexagonal bolt Inner hexagonal bolt

Class of bolt Dimension hexagonal wrench
specification of wrench
Attention
The following provisions are applicable to fine and coarse thread.
● Please apply the lubricant (namely zinc oxide solved in bobbin oil) onto nuts and bolts, so as to
decrease its friction coefficient. The thrust bolt needs no lubricant.
● The tolerance of torque is ±10%.
● Be sure to use the bolt with correct length. If the bolt is too long, it can’t be properly tightened up,
because the top of bolt will contact the bottom of bolt hole. If the bolt is too short, the fastening force
will insufficient.
● The torque given in the table is only applicable to common purpose. If different torque is given in
special occasion, please don’t use the torque given in the table.
● Before installing any nut or bolt, be sure to ensure that its thread is clean. If there is dirt or rust, please
clear it away.

Type of Bolt
● Please tighten up every nut or bolt to the
specified torque. The type and class of bolt are
indicated in right diagram. Inner
Hexagonal bolt hexagonal bolt
● When assembling this machine or any
component, be sure to use the correct bolts,
and tighten them up correctly.
Figure 1-30
Tightening Sequence of Bolts Tighten them up Tighten them up

alternatively and evenly diagonally
When tightening up two or more bolts, please
tighten them up in turn as indicated in the figure on
right side, so as to ensure that the bolts are evenly
tightened up.
Attention
Tighten them up from
● The tool used shall be suitable for the work center and diagonally
carried out. The temporary use of
inappropriate tools or rules may cause
danger.
● When screwing off or tightening up any nut or
bolt, please use dimension correct tool;
otherwise, the tightening tool may slip, and
thus personal injury may be caused.
Figure 1-31
Figure 1-32

Maintenance of Split Flange

1. Wipe clean the sealing surface and carry out
inspection. Scratch/roughness may lead to
leakage or wear of sealing element. The out-of-
flatness may get the sealing element pushed
out. If these troubles are not properly settled,
the parts must be replaced.
2. Be sure to use the designated O-ring, inspect

whether the O-ring is damaged, and don’t file
the surface of O-ring. When mounting the O-
ring into groove, please use the lubricating
grease to fix its position.
Figure 1-33
3. Please gently tighten up the split flange, locate

the opening at center, make it vertical to oil
port, and use the locking bolt to maintain the
position of part.
Wrong
Figure 1-34
Table of Tightening Torque for Split Flange Bolt

★ Unless otherwise stated, please tighten up the split flange bolt to the following torque value.
Diameter of Thread on
Width across the flats Tightening Torque
Bolt
mm mm N·m kgf·m
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
Using Method of Conversion Table
In this Section, the conversion table is provided, so as to enable the user to carry out the simple
conversion. For example: Use the conversion table to convert the millimeter to inch.
1. Conversion of 55 millimeters into inch
1) Locate the digit 50 in vertical column on left side, mark this position as (A), and then draw a horizontal
line from (A).
2) Locate the digit 5 in horizontal line on top, mark this position as (B), and then draw a vertical line
downwards from (B).
3) Mark the junction of two lines as (C). This point (C) gives the value for conversion from millimeter to
inch. Therefore, 55mm=2.165in.
2. Conversion from 550 millimeters into inch
Since the digit 550 does not appear in the table, please search for the value corresponding to 55mm,
and then multiply it by 10 (namely multiply 2.165in by 10), so as to obtain 550mm=21.65in.
Millimeter to inch (B) 1mm=0.03937in

Length
Millimeter to inch
1mm=0.03937in
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
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.535
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.031 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Weight
Kilogram to pound
1kg=2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 90.39 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 112.43 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 134.48 55.12 57.32 59.52 61.73 63.93
30 66.14 68.34 70.55 72.75 156.53 77.16 79.37 81.57 83.77 85.98
40 88.18 90.39 92.59 94.80 178.57 99.21 101.41 103.62 105.82 108.03
50 110.23 112.43 114.64 116.84 200.62 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 222.66 143.30 145.50 147.71 149.91 152.12
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
90 198.41 200.62 202.82 205.03 288.80 209.44 211.64 213.85 216.05 218.26

Volume
Liter to gallon (USA)
1l=0.2642 U.S.Gal
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
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
40 10.568 10.832 11.096 11.361 11.625 11.889 12.153 12.417 12.682 12.946
50 13.210 13.474 13.738 14.003 14.267 14.531 14.795 15.059 15.324 15.588
60 15.852 16.116 16.380 16.645 16.909 17.173 17.437 17.701 17.966 18.230
70 18.494 18.758 19.022 19.287 19.551 19.815 20.079 20.343 20.608 20.872
80 21.136 21.400 21.664 21.929 22.193 22.457 22.721 22.985 23.250 23.514
90 23.778 24.042 24.306 24.571 24.835 25.099 25.363 25.627 25.892 26.156
Liter to gallon (Britain)

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

Torque
Kilogram meter to foot meter
1 kgf·m=7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
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
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
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
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.6 1048.8 1056.0 1063.3 1070.5 1077.7
150 1085.0 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1229.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.2 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

Pressure
Kilogram/square meter to pound/square inch
1 kgf/cm2=14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.3 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.0 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 996 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 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
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
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
190 2702 2717 2731 2745 2759 2774 2788 2802 2816 2830
200 2845 2859 2873 2887 2902 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3342 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

Temperature
● If you want to convert Fahrenheit temperature into Celsius temperature, please regard the bold-face in
the central column as the Fahrenheit temperature, and read the corresponding Celsius temperature in
left column.
● If you want to convert Celsius temperature into Fahrenheit temperature, please regard the bold-face in
the central column as the Celsius temperature, and read the corresponding Fahrenheit temperature in
right column.
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SY750H Hydraulic Excavator Safety
Safety
Instructions on Safety Signs ........................................................................................................................ 2-3
Safety Signals ...................................................................................................................................... 2-3
Other Signals........................................................................................................................................ 2-3
General Notices ........................................................................................................................................... 2-4
Safety Regulations ............................................................................................................................... 2-4
Keeping the Work Area Tidy and Clean ............................................................................................... 2-5
Storage of Liquid .................................................................................................................................. 2-5
Cleaning of Part.................................................................................................................................... 2-6
Cleaning of this Machine ...................................................................................................................... 2-6
Reasonable Dressing ........................................................................................................................... 2-6
Personal Protective Equipment ............................................................................................................ 2-7
Correct Use of Tools ............................................................................................................................ 2-7
Fire Extinguisher and Emergency Exit ................................................................................................. 2-7
Preparatory Work before Maintenance ....................................................................................................... 2-8
Preparation before Operation ............................................................................................................... 2-8
Warning Signs ...................................................................................................................................... 2-9
Self-preparation .................................................................................................................................. 2-10
Notices for Maintenance/Repair ................................................................................................................ 2-11
Operation during Engine Running ...................................................................................................... 2-11
Dismantlement of Machine Accessories ............................................................................................ 2-12
Operation under Machine ................................................................................................................... 2-12
Adding or Replacement of Oil ............................................................................................................ 2-12
Alignment of Components .................................................................................................................. 2-13
When Using Hammer ......................................................................................................................... 2-13
When Using Compressed Air ............................................................................................................. 2-13
Welding Operation.............................................................................................................................. 2-13
Tensioning Spring .............................................................................................................................. 2-14
Safe Operation of High Pressure Hose .............................................................................................. 2-14
Be Careful for High Pressure Liquid................................................................................................... 2-15
Hot Coolant ........................................................................................................................................ 2-15
Air conditioning system ...................................................................................................................... 2-16
Safe Use of Electricity ........................................................................................................................ 2-16
Interruption of Power Supply for System............................................................................................ 2-16
Handling of Battery ............................................................................................................................. 2-17

Safety SY750H Hydraulic Excavator
Accumulator ........................................................................................................................................ 2-17

Prevent Fire Hazard and Explosion.................................................................................................... 2-18
Correct Disposal of Waste .................................................................................................................. 2-18
Other Notices ............................................................................................................................................. 2-19
Notices for Lifting Operation and Signaling ........................................................................................ 2-19
Notices for Use of Movable Crane ..................................................................................................... 2-21
Notices for Use of Overhead Crane ................................................................................................... 2-21
Selection of Steel Wirerope ................................................................................................................ 2-22

Instructions on Safety Signs

Most of accidents are caused by failure to comply with the basic process and safety rules of maintenance
and repair in the course of operation. In order to enable you to safely maintain and repair this machine,
please read and understand the maintenance and repair technologies stated in this Manual, and some
technologies require the special tools designed by SANY heavy machinery co., ltd. for special purposes.
Safety Signals
The following signals are used to inform you of potential danger which may lead to personal injury or
damage. In this Manual and on signs on this machine, the following signals are used to indicate the
potential degree of danger.
indicates an imminent danger, which, if not avoided, will cause death or serious
Danger injury.
indicates a potential danger, which, if not avoided, may cause death or serious
Warning injury.
Attention indicates a potential danger, which, if not avoided, may cause minor or medium
injury, and is also used to remind the unsafe operation which may cause
personal injury or damage to this machine and environment.
In this Manual, this symbol is used to mark the safety notices. The notices marked with these symbols
shall be implemented carefully. If any dangerous situation occurs or may occur, please firstly consider
safety, and take necessary measures.
It is used in illustrations to warn the users of operation which may not be carried out.
Other Signals
In addition, the following signals indicate the matters which must be comply with for the purpose of
protecting this machine, or provide you with the useful information.
Note It is used to indicate the measures which must be taken to prevent the service life of this machine
from getting shortened.
Remarks It provides very useful information.
Warning
● Incorrect maintenance/repair operation is very dangerous, and may cause serious injury/death
accident.
● Before maintaining or repairing this machine, be sure to read and understand this Manual.
● Never carry out the use or operation which is prohibited by this Manual. If the operation to be carried
out is not expressly prohibited, please ensure the safety of you and others.
● If the fuel oil volume, particle or latitude exceeds the maximum value specified for this model and
application, it might lead to injuries, and such circumstance will not be covered by the quality warranty.
● The machine provided by SANY Heavy Machinery Co., Ltd. to the purchasing country complies with
all the applicable specifications and standards. If the machine is purchased from another country or
from the person of another country, some safety devices and technical requirements may not be
available for your country. Please contact with the authorized agent of SANY Heavy Machinery Co.,
Ltd. before use if you have any doubt about whether the machine meets the local use standards and
specifications.

General Notices
It is very important to formulate the appropriate
safety rules for all persons which enter into or use
the workshop and paste or set up such rules in
conspicuous place. If possible, provide the working
personnel with written safety rules, and discuss with
them over relevant questions or give the answers.
Properly implement of safety rules will ensure the
safety of employees, and provide the most effective
environment for work and study.
Please make it a habit to always keep safety in
mind, and don’t study the safety rules before
carrying out any work and then forget them after the
work is completed. Most of safety accidents are
caused by carelessness, hasty operation or
ignorance of safety rules. Please remember: If you
work carefully and strictly comply with the provisions
in this Manual, the maintenance/repair work will
become safe and pleasant.
Warning
● Incorrect operation is very dangerous. Before
operating this machine, please carefully read
the contents about safety in Service Manual.
Safety Regulations
Before carrying out any lubrication or repair, please
read all safety signs on this machine. As for the
position of safety signs and the detailed explanation
for notices, please refer to the safety manual.
Carefully study and comply with the safety rules
relating to work process. When encountering any Figure 2-1
problem, please seek for help and don’t take risk.
Only the authorized operation personnel may carry
out any operation which requires license or
qualification certificate.
Understand the work that you will carry out.
Maintaining or repairing this machine without
receiving any instruction may lead to serious
mistake. During maintenance/repair, if you can’t
confirm the specific maintenance/repair procedure,
please refer to service manual. If you have any
doubt about operation contents and operation
method, please ask for help from others.
No romping is permitted in workshop. The
temporary “comedy” may lead to lifelong “tragedy”.
The distraction and chatting during
maintenance/repair operation may increase the
possibility of injury.
If you want to smoke, please go to the designated
smoking area. Smoking in operation area is
absolutely prohibited.

Keeping the Work Area Tidy and Clean

The engine oil, lubricating grease, fuel, anti-freezing
fluid and other liquid on ground may make person
skid. If any liquid is found on ground, please clear it
away immediately. No matter who is responsible
therefor, every worker in workshop is obliged to
clear away the oil or liquid splashed onto ground.
Keep the workshop clean. The waste materials and
used parts shall be cleared away in time; it is
prohibited to leave any waste material or used part
on operation platform or in workshop.
After being used, all equipment and tools shall be
stored in original place properly. In order to prevent
the occurrence of any accident, be sure to keep the
workshop tidy and clean.
Please always remember: the good sanitary Figure 2-2
conditions of workshop are extremely important for
creation of safe and comfortable work environment.
Storage of Liquid
The liquid such as fuel, lubricating oil, coolant and
detergent shall be appropriately stored in a place
which is far away from work area. Please keep the
storage place well ventilated.
It is prohibited to randomly place the container of
liquid; otherwise the liquid may overflow and cause
fire. Please carefully read the information about
storage and handling of liquid as stated in label on
container.
Please strictly correctly store and handle the liquid
in accordance with the label on container, and don’t
pour a kind of liquid into the container used to store
another kind of liquid. The improper storage of oil
Figure 2-3
and liquid may lead to damage of equipment, fire or
explosion.
Neither smoking or open flame is permitted near oil;
otherwise fire or explosion may be caused.
When handling any oil or liquid, please put on the
personal protective equipment. Please carefully
handle any oil or liquid.

Cleaning of Part
It is prohibited to use gasoline, diesel oil or and
inflammable liquid clean up part, please use the
specified insoluble solvent to carry out cleaning,
otherwise fire and explosion may be caused. Bang!
Figure 2-4
Cleaning of this Machine

When cleaning up any component of this machine,
please use high-pressure hot water, mild and
nonflammable degreased soap or detergent. Don’t
use any inflammable or corrosive detergent.
It is prohibited to use high-pressure steam to clean
up this machine. Using steam to clean up
equipment may damage the paint, rubber hose and
electrical system of this machine.
Don’t use high pressure to clean up the inside of
cab; otherwise the internal electrical elements may
get damaged.
Figure 2-5
Reasonable Dressing
Improper dressing, loose clothing, leisure clothing,
jewel, unfit shoes and long hair may cause personal
injury.
Please formulate the list of dressing which is
prohibited in workshop; before any operation,
please inspect every operator in accordance with
the list.
Figure 2-6

Personal Protective Equipment

If the operation workshop has clear provisions on
personal protective equipment, please put on the
personal protective equipment in the workshop or
other area where the personal protective equipment
must be put on.
Don’t let any person which has not reasonably put
on personal protective equipment stay in operation
workshop
Always ensure that the personal protective
equipment is in good conditions. If necessary, carry
out replacement in time.
Figure 2-7
Correct Use of Tools

Before carrying out any operation, please fully
inspect the tool, machinery, forklift, crane and
maintenance/repair vehicle required.
Select the correct tool for every work. The use of
any unauthorized, incorrect, defective or damaged
tool may lead to serious personal injury.
Make sure that all tools are in good conditions, and
correctly use them.
Please keep all tools clean. After the operation is
completed, sort out the tools and properly store
them, and make sure that no tool is left on this
machine. Figure 2-8
Fire Extinguisher and Emergency Exit

Before carrying out the operation, spend some time
to understand the workshop, and ensure that you
know the location of emergency exit and fire
extinguisher. If the maintenance/repair operation is
carried out on site, the fire extinguisher shall be
provided.
If you don’t know the using method of fire
extinguisher, please refer to the use instructions on
fire extinguisher.
Figure 2-9

Preparatory Work before Maintenance

Preparation before Operation
Please park this machine on flat and firm ground.
Lower down the working device onto ground and
place it safely and stably.
Put the cushion blocks below the tracks for
preventing the excavator moving.
Turn the throttle control knob to step 1, make the
engine run at low-speed under unloaded state for 5
minutes, and then turn the key switch to the position
OFF so as to stop the engine.
Turn the key switch to the position ON, operate the
control lever to the front, rear, left or right by 2-3
times for releasing the pressure in the system. Figure 2-10
Pull out the key from key switch, and pull the safety
locking rod to locking position.
Make sure that no irrelated person or equipment is
in the operation area; make sure that the operation
personnel can see you (especially when the
maintenance/repair is carried out on site).
Figure 2-11
Figure 2-12

Warning Signs
When an operation is carried out by two or more
persons, before the operation, please reach
consensus on operation process and
communication signal. Before carrying out any
operational step, be sure to inform your colleagues.
Before maintaining the machine, it is necessary to
hang the warning board “Do not Operate” or similar
warning sign on the starting switch or direction
controller to warn that other people are maintaining
the excavator.
If necessary, set up additional warning signs near
this machine. During the maintenance operation, if
any one starts the engine or contacts or operates
any control rod or presses down any pedal, serious Figure 2-13
accident may be caused.
Figure 2-14

Self-preparation
Only the after-sales service personnel certified by
SANY heavy machinery co., ltd. may maintain or
repair this machine. If necessary, an observer may
be appointed.
Wear protective clothing for work and safety shoes.
Please wear rubber apron and rubber gloves when
contacting with corrosive materials. Wear safety
gloves when handling wood material, steel wire
rope or sharp metal.
Wear protective masks when removing the springs
or other elastic parts, or supplementing acid to the
storage battery. Wear safety helmets and protective
goggles when performing welding or cutting Figure 2-15
operations.
Do not perform grinding, flame cutting or welding
operations without breather and ventilation
equipment. Please refer to relevant manual for
proper operation procedures if having to weld on
the excavator.
Figure 2-16

Notices for Maintenance/Repair

Operation during Engine Running
Unless otherwise specified in this Service Manual, it
is prohibited to start this machine during
maintenance/repair. If it is necessary to start up this
machine during operation, please comply with the
following basic rules:
1) The body part might get tangled into the
excavator when operating near the fan, fan belt
or other rotating parts; thus, be particularly
careful.
2) Do not drop or insert the tools or other objects
into the fan or fan belt; otherwise, the parts
would be ruptured or fly out, resulting in
personal injury.
Figure 2-17
3) Move the safety locking lever to the locked
position for preventing the working device
moving accidentally.
4) When carrying out any maintenance/repair
operation under the condition that the engine is
running, make sure that a operator is sitting in
seat in cab and is ready to turn off the engine at
any time, and ensure that all personnel keep in
touch with each other.
5) The operator left in cab may not touch any
control rod. If it is necessary to operate a
control rod, please ensure that the
maintenance/repair personnel can always be
seen clearly, and warn them to go to safe place
before operating the control rod.
6) When this machine is running, the surface of Figure 2-18
most of the components will become hot, and
the surface temperature of some components
may be very high. If necessary, when carrying
out operation near any high-temperature
component, be sure to put on personal
protective equipment, so as to prevent
scalding.
7) When this machine is running, the hydraulic
system, cooling system and fuel system are in
high-temperature and high-pressure state.
When carrying out operation near these
systems, please be very careful.
Figure 2-19

Dismantlement of Machine Accessories

When it is necessary to dismantle any large part
from this machine, be sure to use the correct lifting
equipment, and ensure that the weight of such part
is within the rated lifting capacity of such equipment.
Please properly place the dismantled accessories or
components, and prevent them from dropping down
or moving. Make sure that all articles are placed on
stable plane steadily, and will not block footwalk or
fire passage.
Operation under Machine Figure 2-20

Before repairing or maintaining this machine, please
lower down the working device onto ground. Don’t
carry out maintenance/repair before this machine is
properly supported.
It is necessary to support the excavator or working
device reliably with the cushion block or support
which is strong enough to sustain the weight of
working device and excavator when having to lift up
the excavator or working device for repair or
maintenance; neither support the excavator with
slag brick, pneumatic tires or brackets(They will
collapse under continuous load.); nor support it with
single lifting jack.
It would be very dangerous when working beneath Figure 2-21
the excavator if it is supported only with the working
device when the track shoes are off the ground. The
working device or excavator would drop suddenly,
and it would result in casualty accident if the
hydraulic pipeline is damaged or the control lever is
touched accidentally. Do not work beneath the
excavator unless it has been supported firmly with
cushion block or support.
Adding or Replacement of Oil
When adding or replacing the oil of any system,
please note that these systems may in a high-
temperature and high-pressure state.
When carrying out any operation, please firstly turn
off this machine, wait until the system cools down,
and then screw off the filling port cover; otherwise
serious scalding may occur or oil may spout.
Please slowly loosen the oil filling port cover, drain
plug or pressure-discharging plug, so as to prevent
the oil from spouting.
Figure 2-22

Alignment of Components
When installing or aligning any component, please
be very careful.
When aligning any round hole or mating surface,
please don’t use hand or finger, so as to prevent
your hand or finger from being squeezed or
crushed.
When aligning any component, please use the
appropriate tool, so as to prevent your hand or
finger from being injured.
Figure 2-23
When Using Hammer

The parts and metal fragments might fly out and
cause personal injuries when knocking hard metal
parts with the hammer such as pin, bucket tooth,
blade edge or bearing; thus, it is necessary to wear
protective goggles and gloves, and ensure that
there is no person in the surrounding area.
If possible, don’t use metal hammer to install any
component or pin; otherwise the component or pin
may get damaged. If possible, please use the soft
or nonferrous hammer.
When Using Compressed Air Figure 2-24
The flying particles might cause personal injuries

when cleaning with compressed air. Thus, it is
necessary to wear protective goggles, dust mask,
gloves and other protective articles.
Welding Operation
There exists risks of fire hazard or electric shock in
the welding process; thus, only the competent
welder are allowed to perform welding operations,
and appropriate equipment shall be equipped; the
incompetent personnel shall not weld.
Figure 2-25

Tensioning Spring
When maintaining or repairing the crawler, please
pay attention to the danger which may be caused
by crawler tensioning spring. The crawler tensioning
spring is always in high-pressure state. During
disassembling, the improper operation may make
the spring fly out and cause serious personal injury.
Don’t knock the tensioning springs of crawler,
because these springs under huge pressure may
break explosively and thus cause personal injury.
When dismantling and installing the crawler, please
be very careful. When the main chain link of crawler
is disconnected, the whole crawler may suddenly Figure 2-26
get disconnected and cause personal injury. When
disconnecting the main chain link of crawler, be
sure to evade from the travelling route of crawler.
Safe Operation of High Pressure Hose

If the high pressure hose leaks oil, it would cause
operation trouble, and even fire hazard. If finding
that the bolt on the hose becomes loose, it is
necessary to stop the operation and tighten the bolt
to the specified torque. If finding that the hose is
damaged, it is necessary to stop operation
immediately and replace the hose in time.
1) The hydraulic pipe connector is damaged or
leaks.
2) The cladding layer is worn out or broken, or the
steel wires of reinforcement are exposed.
3) Some positions of cladding layer are swelled.
Figure 2-27
4) The cladding layer contains impurities.
5) The movable part is twisted or crushed.

Be Careful for High Pressure Liquid

The hydraulic system always contains pressure.
When inspecting or replacing the pipeline, it is
necessary to inspect whether the pressure in the
hydraulic pipeline has been released. If there is still
pressure in the oil way, it would lead to serious
accident. Thus, it is necessary to operate according
to the following provisions:
1) Before maintaining the hydraulic system,
please press the air bleeding button on
breather valve, so as to release the pressure in
system.
2) Do not use open flame around the hydraulic
system. It is necessary to clean the splashed
hydraulic oil immediately.
3) The diesel oil or pressurized hydraulic oil could
penetrate the skin or the eyes, resulting in
serious injuries, blindness or death. It is very
difficult to judge by naked eyes whether the
hydraulic oil leaks; it is necessary to seek the
leakage with a piece of paperboard or wood
chip but it is not allowed to touch the leaking
liquid directly; it is necessary to wear masks or
protective goggles to protect the eyes. If the
liquid penetrates the skin, it is necessary to
wash with clean water and go to a doctor as
early as possible.
4) The fuel pipeline will contain high pressure
when the engine is running. When inspecting or Figure 2-28
maintaining the fuel pipeline system, it is
necessary to turn off the engine by at least 30s
to let the internal pressure reduce before
operating.
Hot Coolant
When the engine temperature increases, the
pressure of cooling system will increase. Before
taking down the radiator cover, it is necessary to
stop the engine, cool down the system and then
take down the radiator cap after the coolant
temperature reduces.
Figure 2-29

Air conditioning system

● Keep away from fire when repairing and
maintaining the air conditioning system.
● When adding the refrigerant, please correctly
use the refrigerant. The refrigerant is R134a,
and no other refrigerant may be used;
otherwise the A/C system may get damaged;
● It would cause blindness if the refrigerant
enters the eyes; it would cause cold injury if it is
splashed on the skin.
● It is strictly prohibited to discharge the
refrigerant directly into the atmosphere when
using the recovery and circulation system. Figure 2-30
Attention
● R134a refrigerant is nontoxic gas under
normal temperature but would become highly
toxic gas after encountering the fire.
Safe Use of Electricity

When testing the electric circuit of this machine, be
sure to understand the elements to be tested in the
system. Both high pressure and heavy current may
cause damage of equipment, or cause electrical
spark, explosion or even fire.
Before maintaining, repairing or testing the electrical
system, please understand the voltage of such
system. Before carrying out any maintenance/repair
operation, be sure to inspect the electric circuit and
ensure that the electric circuit is in disconnected
state.
When carrying out any operation near inflammable
liquid or explosive system, please only use the Figure 2-31
specified explosion-proof lighting lamp. The use of
unauthorized lighting equipment may cause
explosion or fire.
Interruption of Power Supply for System
Before carrying out any maintenance/repair
operation, please disconnect the wire of battery, or
turn off the main power switch (if equipped).
When disconnecting the battery, please firstly
disconnect the negative (-) joint, and then
disconnect the positive (+) joint.
When connecting the battery, please firstly ensure
that all switches of electrical system are turned off,
and then respectively connect the positive (+) joint
and negative (-) joint.
Figure 2-32

Handling of Battery
Carrying out operation near battery involves certain
danger, especially when the battery has been used
for a while. The following are the notices for
maintenance of battery or operation near battery:
1) When carrying out any operation near battery,
be sure to put on personal protective
equipment.
2) The gas emitted by battery is very explosive.
After opening the battery box, please leave
sufficient time to let the gas in box escape, and
then carry out the maintenance operation.
3) When handling the battery, be sure to select a Figure 2-33
well-ventilated place.
4) If the battery is corroded, please use the
mixture of sodium bicarbonate and warm water
to clean it up.
5) Once the electrolyte of battery splashes onto
your skin or into your eyes, please immediately
flush skin or eyes with a lot of fresh water, and
see a doctor as soon as possible.
Figure 2-34
Accumulator
The accumulator is charged with high pressure
nitrogen. Improper operation of accumulator would
cause explosion, resulting in serious accident.
Therefore, it is necessary to observe the following
precautions:
1) Do not disassemble the accumulator.
2) Keep the accumulator away from the fire and
do not expose it in the flame.
3) Do not drill holes, weld or apply cutting etc. on
the accumulator.
4) Do not collide or roll the accumulator, or subject
the accumulator to any impact.
Figure 2-35
5) When disposing the accumulator, it is
necessary to bleed the air; please contact with
the authorized agent of SANY Heavy
Machinery Co., Ltd. for this operation.

Prevent Fire Hazard and Explosion

It is necessary to stop the engine and turn off the
electrical equipment when filling oil into the oil tank;
be particularly careful and prevent any sparks
around the grounded nozzle when supplementing
fuel to the hot engine.
Treat all solvent and dry chemicals in the well-
ventilated environment according to the steps
indicated on the container.
Clean all the dust and residue on the excavator. Do
not put any greasy duster cloth or other flammable
materials on the excavator.
When cleaning the parts, please use non-flammable
solvent and do not use gasoline, diesel oil or other Figure 2-36
flammable liquid.
Store the flammable liquid and materials in the
appropriate containers according to the safety
regulations.
Inspect and maintain regularly to ensure the fire
extinguisher is readily available.
Correct Disposal of Waste
It would cause harm to the environment and
ecology if the wastes have not been treated
properly. Consult with the local recycling center or
the authorized agent of SANY Heavy Machinery
Co., Ltd. for the recycling or treatment methods for
wastes.
1) The potential hazardous wastes existing in the
equipment of SANY Heavy Machinery Co., Ltd.
include hydraulic oil, fuel oil, coolant, Figure 2-37
refrigerant, filter and storage battery etc.
2) When draining the liquid, it is necessary to use
leak-proof container but it is not allowed to use
containers for food or drinks; otherwise, it may
be taken in by mistake.
3) Don’t pour the waste liquid onto ground, into
sewer or into any water source;
4) The A/C refrigerant would damage the
atmosphere if it leaks. It is necessary to recycle
or regenerate the refrigerant according to the
relevant regulations.
Figure 2-38

Other Notices
Notices for Lifting Operation and Signaling
1) Only a designated worker may send the signal,
and all personnel involved in operation shall
communicate with each other frequently. The
designated signaler shall stay at such a
Lifting weight (kN (kg))

position that the driver and signaler can clearly
see the operation, and clearly send the
specified signal. The signaler shall stand in
front of the load, and safely instruct the driver.
● Don’t stand under the load.
● Don’t step on the load.
2) Before carrying out any lifting operation, please
inspect the sling. Lifting angle (Degree)
3) During the lifting operation, please always wear

the gloves. (If any, please wear leather gloves.) Figure 2-39
4) Visually measure the weight of load and inspect
its center of gravity.
5) In light of the weight of load and the lifting
method used, use the appropriate sling. If too
thick steel wireropes are used to lift up any light
load, then the load may slide down or fall off.
6) Don’t separately use one steel wirerope to lift
up any load; otherwise the load will rotate and
may slide off from steel wirerope. Please
symmetrically use two or more steel wireropes.
7) Normally, the limit of lifting angle is 60°. Don’t
lift up any heavy load with large lifting angle.
When using two or more steel wireropes to lift
up a load, the force borne by every steel
wirerope may increase as the lifting angle
increases. The table below indicates the
change in permissible load expressed in kN
under various lifting angles when two steel
wireropes are used to carry out lifting and the
permissible maximum vertical lifting load of
every steel wirerope is 9.8kN{1,000kg}. When
two steel wireropes are used to vertically lift up
a load, the maximum total weight which can be
supported is 19.6kN{2,000kg}. When the lifting
angle of two steel wireropes is 120°, this weight
is reduced to 9.8kN{1,000kg}. If two steel
wireropes are used to lift up the load of which
the weight is 19.6kN{2,000kg} when the lifting
angle is 150°, then the force borne by every
steel wirerope is 39.2kN{4,000kg}.

8) When installing the steel wirerope onto a load

with sharp corner, please use pad so as to
protect the steel wirerope. If the load is smooth,
please use the appropriate material to prevent
the steel wirerope from falling off.
9) Use the specified eye bolt and U-shaped ring
with pin to fix the steel wirerope or lifting chain.
10) Install the steel wirerope at the middle of lifting
hook.
● During any lifting operation, when the sling
is too close to top end of lifting hook, the
steel wirerope may slide off from lifting
hook. The middle portion of lifting hook has
the maximum strength.
Figure 2-40
11) Don’t use any twisted steel wirerope.
12) When lifting a load, please comply with the
following provisions.
● Slowly lift up the load, until the steel
wirerope is tightened. When handling the
steel wireropes with hand, don’t hold them;
otherwise your finger may get crushed.
● After the steel wirerope is extended,
please stop the crane and inspect the
conditions of lifted load, steel wirerope and
backer.
● If the load is unstable or the steel wirerope
or lifting chain is twisted, please lower
down the load and then lift it up again.
● Don’t slantwise lift up the load.
13) When lowering down a load, please comply Figure 2-41
with the following provisions.
● When lowering down a load, please
suspend the operation for a while after the
load is 30cm away from ground, and then
lower it down slowly.
● Inspect whether the load is stable, and
then dismantle the sling.
● Eliminate the twisting and oil sludge on
steel wireropes and lifting chains used for
lifting operation, and store them in
designated place.

Notices for Use of Movable Crane
Warning
● Please carefully read the operation & maintenance manual of crane in advance, and safely operate
the crane.
Notices for Use of Overhead Crane

1) Before carrying out any operation, please inspect steel wirerope, brake, clutch, controller, track, stop
device, anti-electric-shock earth leakage circuit breaker, anti-collision device of crane and warning
lamp, and carry out safety inspection.
2) Observe the signals given for lifting operation.
3) Operate the crane at a safe point.
4) Be sure to inspect the direction of indication plate (east, west, south and north) and the direction of
control.
5) Don’t slantwise lift up the load. When the load lifted rotates, don’t move the crane.
6) When the crane laterally or longitudinally moves, don’t lift up or lower down the load.
7) Don’t drag the sling.
8) When lifting up a load, please lift it up only after it leaves the ground and inspect whether it is safe.
9) Consider the travelling route in advance, and lift up the load to a safe height.
10) Place the control switch at the position where it will not become the obstacle for operation and
passage.
11) After operating the crane, don’t turn the control switch.
12) Please keep in mind the position of main switch, so that you can immediately turn off the power supply
in case of emergency.
13) If the crane stops owing to power failure, then turn the power switch to the position OFF. When turning
on the switch which has been turned off by anti-electric-shock earth leakage circuit breaker, please
inspect whether the device related to switch is not working.
14) If any obstacle is found near the crane, please stop the operation.
15) After the operation is completed, stop the care at the specified position, and lift up the lifting hook until
it is at least 2m away from ground. Don’t leave the sling mounted on lifting hook.

Selection of Steel Wirerope

In light of the weight of the part to be lifted, select the appropriate steel wirerope. Please refer to the table
below.
Steel wire rope

(“Z” or “S”-twisted steel rope, ungalvanized)
Nominal Diameter of Steel
Allowable load
Wirerope
mm kN t
10 9.8 1.0
11.5 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.5 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
Attention
● The permissible load is 1/6 of breaking force of used steel wirerope. (safety coefficient: 6)

SY750H Hydraulic Excavator Technical Specification
Specified size .............................................................................................................................................. 3-2
Overall Dimensions .............................................................................................................................. 3-2
Operation range ................................................................................................................................... 3-3
Technical Specification ................................................................................................................................ 3-4
Table of Weight ........................................................................................................................................... 3-6
Engine oil, fuel and coolant ......................................................................................................................... 3-7
Feature curve of engine............................................................................................................................... 3-8

Technical Specification SY750H Hydraulic Excavator
Specified size
Overall Dimensions
Unit: mm
Items SY750H
A Total length (transportation posture) 12865
B Total width 4030/3430
C Total height (transportation posture) 4855
D Width of upper portion (including walking platform) 4290
E Total height (top of cab) 3800
F Std. track shoe width 650
G Track gauge 3380/2780
H Minimum ground clearance 875
I Tail swing radius 4220
J Length to centers of rollers 4650
K Track length 5865
L Ground clearance of upper frame 1538
Explanation: B and G respectively include extended width and retracted width

Operation range
Unit: mm
Name SY750H
a Max. digging height 11055
b Max. loading height 7210
c Max. digging depth 7630
d Maximum vertical excavation depth 4300
e Max. digging reach 12050
f Min. swing radius 5515
g Maximum height at minimum swing radius 9775

Excavator model SY750H
Total weight kg 76200
Bucket capacity m3 4.2

Travel speed (High/ Low ) km/h 4.5/2.9
Performance of Swing speed rpm 7.3
excavator
Gradeability Degree 35
Ground pressure kPa 110
Maximum excavation force of bucket kN 402
Maximum excavation force of bucket arm kN 345
Isuzu
Model
AH-6WG1
6-cylinder, 4-stroke, water-cooled,
Type electrically-controlled, turbocharging,
Number of cylinders – bore × stroke mm and air-air intercooled
Total displacement L 6-Φ147×154
15.681
Rated power kW/rpm 377/1800 (calibration)
Engine
Maximum torque N·m/rpm 2138/1500 (calibration)
Maximum speed under
Perform
unloaded condition rpm 1800±20
ance
Minimum speed under
unloaded condition rpm 850±30
Minimum fuel consumption g/kWh 216
Starting motor 24V/7kW
Alternator 24V/90A
Sprocket (single side) Piece 3

Lower body of
Supporting wheel (single side) Piece 8
machine
Number of crawler plats (single side) Piece 47


Kawaski (variable swashplate
Type
plunger type double pump)
Pressure of main safety
Hydraulic pump MPa 34.3
valve
Maximum flowrate of
L/min 2×486
main pump
Type × quantity KMX36N×1
Control valve
Control method Hydraulic type
KYB MSF-340VP-FH7
Running Motor
(Braking valve, parking brake)
Hydraulic Hydraulic motor
Kawaski oblique shaft type plunger
system Slewing motor motor
(Slewing stop controller)
Type Reciprocating plunger type
Boom cylinder mm Φ190×Φ130×1790×2520
Hydraulic cylinder
Bucket rod cylinder mm Φ215×Φ150×2140×3030
Bucket cylinder mm Φ200×Φ140×1455×2210
Hydraulic oil tank Closed type

Hydraulic oil filter Oil return side of oil tank
Hydraulic oil cooler Air cooled

Table of Weight Unit: kg

Engine 1165
Radiator assembly 165
Hydraulic oil tank assembly (excluding hydraulic oil) 1162
Fuel tank assembly (excluding fuel) 485
Slewing platform 7497
Cab 757
Cab seat and control box 16
Counterweight 1100
Hydraulic pump 300
Multi-way valve 380
Back slewing reducer assembly 425×2
Travelling retarder assembly 860×2
Slewing connector 8.3
Running frame 3022×2
Main frame 5522
Slewing bearing 899
Guide wheel 890×2
Tensioning device 530×2
Sprocket wheel 53×6
Supporting wheel 178×16
Boom assembly 5556
Bucket arm assembly 1026
Bucket assembly 4682
Boom cylinder assembly 602×2
Bucket arm cylinder assembly 1026
Bucket cylinder assembly 629
Connecting rod 336
Rocker 89X2
Oil disperser assembly (including motor and fan) 180
Note: This table of weight only provides reference for operation or transportation of components.

Engine oil, fuel and coolant

Ambient temperature
Liquid
Container -22 -4 14 32 50 68 86 104 122°F
variety
-30 -20 -10 0 10 20 30 40 50℃
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
Slewing
mechanism
box Engine oil
Guide wheel
SAE 30
Supporting
wheel
Carrying wheel
SAE 10W
SAE 10W-30
SAE 15W-40
Hydraulic
system
L-HV32 low-temperature anti-
wear hydraulic oil
Hydraulic
oil L-HM46 anti-wear hydraulic oil
L-HM68 anti-wear hydraulic oil
ASTM D 975 No.2
Fuel tank Diesel oil GB252 premium grade - #20 diesel oil
GB252 premium grade - #35 diesel oil
Lubricating
Grease nozzle NLGI No.2
grease
Cooling
Coolant Fill in anti-freezing solution
system
● Engine oil recommended by Sany Heavy Machinery: above API CF-4and no lower than API CD.
● Gear oil recommended by SANY heavy machinery co., ltd.: GL-5.
● Please purchase the genuine oil of Sany from authorized dealer of SANY heavy machinery co., ltd., so
as to ensure the quality of oil.

Feature curve of engine

6WG1X
Testing conditions:
1) Under the condition that the temperature is 25℃, the atmospheric pressure is a standard atmospheric
pressure, and there is no fan;
Figure 3-3

SY750H Hydraulic Excavator Structure, function and maintenance standard
Structure, function and

maintenance standard
Engine and Cooling System ........................................................................................................................ 4-4
Engine-related parts ............................................................................................................................. 4-4
Radiator and intercooler ....................................................................................................................... 4-5
Transmission Train ...................................................................................................................................... 4-6
Transmission Train ............................................................................................................................... 4-6
Travelling retarder assembly ................................................................................................................ 4-7
Back slewing reducer ........................................................................................................................... 4-9
Slewing bearing .................................................................................................................................. 4-11
Lower travelling device .............................................................................................................................. 4-13
Crawler carrier and tensioning mechanism ........................................................................................ 4-13
Guide wheel ....................................................................................................................................... 4-14
Driving wheel ...................................................................................................................................... 4-15
Supporting wheel................................................................................................................................ 4-16
Carrying wheel ................................................................................................................................... 4-17
Track................................................................................................................................................... 4-18
Hydraulic system (Part 1) .......................................................................................................................... 4-20
Arrangement diagram of hydraulic parts ............................................................................................ 4-20
Hydraulic oil tank and filter ................................................................................................................. 4-22
Hydraulic pump (SY750H) ................................................................................................................. 4-23
User Manual for Kawaski Swashplate-type K3V/K5V Axial Plunger Pump K3V280DTH .......... 4-25
Pilot pump ................................................................................................................................... 4-37
Regulator..................................................................................................................................... 4-38
Function principle ........................................................................................................................ 4-41
Adjustment of regulator ............................................................................................................... 4-42
Hydraulic system, Part 2............................................................................................................................ 4-50
Control valve ...................................................................................................................................... 4-50
Wiring diagram of hydraulic system ................................................................................................... 4-57
Hydraulic system, Part 3............................................................................................................................ 4-81
Slewing motor ..................................................................................................................................... 4-81
Overflow valve section ................................................................................................................ 4-87

Structure, function and maintenance standard SY750H Hydraulic Excavator
Anti-swing valve .......................................................................................................................... 4-88

Central slewing connector ......................................................................................................................... 4-90
Running Motor ........................................................................................................................................... 4-91
Double balance valve ......................................................................................................................... 4-94
Operation of parking brake ................................................................................................................. 4-98
Operation of brake valve .................................................................................................................... 4-99
Control system ......................................................................................................................................... 4-107
Leading valve ........................................................................................................................................... 4-108
Manual pilot valve ............................................................................................................................. 4-108
Traveling leading valve ..................................................................................................................... 4-112
Electromagnetic valve.............................................................................................................................. 4-116
Accumulator ............................................................................................................................................. 4-117
Pilot oil filter ............................................................................................................................................. 4-118
Working Device ........................................................................................................................................ 4-119
Size of component ............................................................................................................................ 4-119
Dimension of bucket arm .................................................................................................................. 4-121
Dimension of bucket ......................................................................................................................... 4-123
Air conditioning system ............................................................................................................................ 4-125
Arrangement diagram of A/C elements ............................................................................................ 4-126
A/C control panel .............................................................................................................................. 4-127
Schematic diagram for circuit ........................................................................................................... 4-128
Principle for refrigeration .................................................................................................................. 4-130
Compressor ...................................................................................................................................... 4-131
Clutch................................................................................................................................................ 4-133
Condenser ........................................................................................................................................ 4-134
Expansion valve ............................................................................................................................... 4-135
Evaporator ........................................................................................................................................ 4-135
Drier .................................................................................................................................................. 4-136
Pressure switch ................................................................................................................................ 4-137
Refrigerant ........................................................................................................................................ 4-138
Compressor oil ................................................................................................................................. 4-151
Engine control .......................................................................................................................................... 4-152
Operation of system ......................................................................................................................... 4-153
Components of system ..................................................................................................................... 4-154
Fuel control knob ....................................................................................................................... 4-154
Engine control unit (ECU) ......................................................................................................... 4-156
Electrical Control System......................................................................................................................... 4-159
Control function ................................................................................................................................ 4-159
Control system diagram of this machine ................................................................................... 4-160
Engine — pump combined control function .............................................................................. 4-162
Valve Control Function .............................................................................................................. 4-164
Warning and protection for too low engine oil pressure ............................................................ 4-166
Warning and protection for too high engine water temperature ................................................ 4-167
Control on engine preheating .................................................................................................... 4-168
System components ................................................................................................................................ 4-169

Pump pressure sensor ..................................................................................................................... 4-169

Leading pressure sensor .................................................................................................................. 4-170
Fuel oil level sensor.......................................................................................................................... 4-171
Display system ........................................................................................................................................ 4-172
Displayer .......................................................................................................................................... 4-173
Display panel............................................................................................................................. 4-174
Display the page operation method for every page .................................................................. 4-177

Engine and Cooling System

Engine-related parts
Figure 4-1
1. Muffler Technical Specification
2. Flywheel Capacity of engine oil: 52L
3. Rubber vibration damper assembly
4. Radiator assembly

Radiator and intercooler
Figure 4-2
1. Intercooler Technical Specification
2. A/C radiator Radiator assembly:
3. Water inlet pipe ZH1150×450×1390-S180Z45Q/SY015028
4. Fuel radiator Coolant used:
5. Water tank 36L+24L=60L (among which 36L is the capacity of
6. Water radiator engine, and 24L is the capacity of radiator)
7. Water outlet pipe

Transmission Train
Transmission Train
Figure 4-3
1. Slewing motor 6. Accumulator
2. Back slewing reducer 7. Multi-way valve
3. Slewing bearing 8. Retarder assembly
4. Guide wheel 9. Plunger pump
5. Slewing connector 10. Engine

Travelling retarder assembly
Figure 4-4
Figure 4-5

1. Plunger cylinder subassembly 9. Sun gear 2

2. Shaft 10. Planet gear 2
3. Gear hub 11. Sealing ring
4. Planet carrier 2 12. Running Motor
5. Planet carrier 1 13. Oil filling port
6. Planet gear 1 14. Inspection port
7. Sun gear 1 15. Oil discharge port
8. End cover
Reduction ratio: 87
S/N Inspection Item Standard Measures
Backlash between sun gear 2 Standard clearance Clearance limit

16 Replacement
and planet gear 2 0.13 ～ 0.47 1.00
Backlash between planet gear
17 0.17 ～ 0.57 1.10
1 and gear hub
Backlash between sun gear 1
18 0.14 ～ 0.46 1.00
and planet gear 1
Replacement
Backlash between planet gear
19 0.16 ～ 0.56 1.10
2 and gear hub
Backlash between planet
20 0.38 ～ 0.66 1.00
carrier 1 and sun gear 2

Back slewing reducer
Figure 4-6

1. Plug 11. Planet wheel subassembly 2

2. Oil seal 12. Planet gear 2 (number of teeth: 17)
3. Automatic aligning bearing 13. Elastic pin
4. Tooth ring (number of teeth: 52) 14. Slewing retarder screw plug
5. Planet carrier 2 15. Grease nozzle
6. Planet carrier 1 16. Automatic aligning bearing
7. Sun gear 2 (number of teeth: 16) 17. Bearing sealing element
8. Sun gear 1 (number of teeth: 14) 18. Back slewing small gear
9. Slewing motor 19. Oil dipstick
10. Planet gear 1 (number of teeth: 18) 20. Oil filling pipe
Reduction ratio: (14+52)/14× (21.78+52)/16=21.74

Standard
Backlash between slewing motor shaft Clearance limit
21 clearance Replacement
and sun gear 1
0.18～ 0.28 —
Backlash between sun gear 1 and planet
22 0.16～ 0.50 1.00
gear 1
Backlash between planet gear 1 and
23 0.18～ 0.59 1.10
toothed ring
Backlash between planet carrier 1 and
24 0.39～ 0.71 1.20
sun gear 2
Backlash between sun gear 2 and planet
25 0.16～ 0.50 0.90 Replacement
gear 2
Backlash between planet gear 2 and
26 0.18～ 0.59 1.00
toothed ring
Backlash between planet carrier 2 and
27 0.07～ 0.23 —
slewing pinion
Backlash between slewing pinion and
28 0.22～ 1.32 2.00
slewing support

Slewing bearing
Figure 4-7

1. Steel ball Technical Specification

2. Outer race of back slewing bearing Reduction ratio: 90/13
3. Inner race of slewing support (number of teeth: 90) Capacity of lubricating grease: 60 Kg
a. Position “S” on soft area of inner race
b. Position “S” on soft area of outer race
Unit: mm
Inspection Item Standard Measures
Axial clearance of bearing Standard clearance Clearance limit

(Installed on chassis) 0.5 ～ 1.2 3 Replacement

Lower travelling device

Crawler carrier and tensioning mechanism
Figure 4-8
1. Guide wheel ● The size and number of supporting wheels will
2. Supporting wheel vary from model to model, but the basic
3. Carrying wheel structure is same.
4. Track ● Number of supporting wheels
5. Driving wheel Model Number (one side)
6. Tensioning device SY750H 9

Guide wheel
Figure 4-9
SY750H Unit: mm
Standard
S/N Inspection Item Measures
Standard
Repair limit
dimension
Carry out welding or
1 A 810 790
replacement
2 B 855 /
3 C 22.5 32.5
replacement
4 D 270 /
5 E 126 /
6 F (bushing) 130 131 (reference) Replacement
7 G (shaft) 130 129 (reference) Replacement

Driving wheel
SY750H Unit: mm
Standard Measures
S/N Inspection Item
Standard dimension Repair limit
1 A 442.5 437.5
replacement
2 B 397.5 392.5
replacement
3 C 114 / /
4 D (pitch) 260.35 / /

Supporting wheel
Figure 4-10
SY750H Unit: mm
Standard Measures
S/N Inspection Item
1 A 260 240
replacement
2 B (shaft) 110 109 (reference) Replacement
3 C 26 / /
4 D (bushing) 110 111 (reference) Replacement

Carrying wheel
Figure 4-11
SY750H Unit: mm
Standard Measures
S/N Inspection Item
Carry out welding
1 A 175 155
or replacement
2 B 265 / /
3 C 121 / /
4 D (shaft) 59.8 / /

Track
Figure 4-12
SY750H Unit: mm
Standard
S/N Inspection Item Measures
1 A 151 146 Replacement
2 B 1 61 Replacement
3 C 260.35 / /
4 D (shaft) 57.5 /
5 E 5 10
6 F (Bolt) M27×2 / /

Three-tooth crawler plate
Figure 4-13
SY750H
Unit: mm

1 Height
36 21
2 Thickness 16
3 33
Length of base
4 26 Carry out bead
welding or
5 25 replacement
6 Length of top 20
7 22
8 Thickness
52 15

Hydraulic system (Part 1)

Arrangement diagram of hydraulic parts
1. Bucket cylinder
2. Bucket rod cylinder
3. Boom cylinder
4. Hydraulic oil tank
5. Hydraulic oil filter
6. Multi-way valve
7. Plunger pump
8. Radiator
9. Accumulator
10. Left travelling motor
11. Right travelling motor
12. Slewing motor
13. Safety Locking Lever
14. Left pilot valve
15. Central back slewing joint
16. Right pilot valve
17. Traveling leading valve
18. Electromagnetic valve assembly
Figure 4-14

Figure 4-15

Hydraulic oil tank and filter
Figure 4-16
1. Oil discharge filter element Technical Specification
2. Oil return filter core Capacity of oil tank: 700L
3. Hydraulic oil tank Effective capacity: 630L
4. Liquid level meter Breather valve
5. Oil suction filter core Filtration precision: 10μm
6. Breather valve Ambient temperature: -30℃～100℃
7. Oil suction cover Pressure setting: Air suction side → 0.004MPa(at 1L/min)
8. Oil return cover Air exhaust side → 0.017MPa(at 1L/min)

Hydraulic pump (SY750H)

Type: K3V280DTH1GZR
Directi
on A
Figure 4-17 SY750-17011501

Overview
● This pump is composed of two variable swashplate-type plunger pumps, two regulators and one pilot
gear pump.
a1: Mounting hole of front pump A3: Oil output port of pilot gear 1: Front pump
pressure sensor pump 2: Rear pump
a2: Mounting hole of rear pump Psv1: Control port of front pump 3: Pilot gear pump
pressure sensor regulator 4: Front pump
a3: Front pump regulator pressure Psv2: Control port of rear pump regulator
testing port regulator 5: Rear pump
a4: Pressure testing port on rear Dr1: Oil discharge port of front regulator
pump regulator pump
a5: Pilot gear pump output Dr2: Oil discharge port of rear
pressure testing port pump
A1: Oil transfer port of front pump Dr3: Oil discharge port of front
A2: Rear pump
Dr4: Oil discharge port of rear
pump
B1: Oil suction port of pump
B3: Oil suction port of pilot
pump

User Manual for Kawaski Swashplate-type K3V/K5V Axial Plunger Pump K3V280DTH
Model representation
Type-0 sealing ring
Model of regulator:
As for detailed
explanation, please refer
to the user manual for
regulator
Rotating direction
R: Right rotation (viewed from
shaft side)
L: Left rotation (viewed from
shaft side)
Design no.
H: With turbocharger
DT: Tandem-type double pump
Specification (displacement: cm3/rev)
K3V pump

Specification
Model K3V280
Displacement (cm3/rev) 280
Rated 34.3
Pressure (MPa)
Maximum 37.2
Maximum 1800
*Speed min-1
Self-suction maximum 1800
Mass kg 300
Type Anti-wear hydraulic working oil
Temperature range -20℃～+95℃
Working oil Viscosity range 10-1000cst (mm2/s)
Nominal value of oil return circuit:10μm
Recommended oil filter
Oil suction circuit 80-150 mesh
*It can be used only when the pressure at oil-suction flange disc is higher than 0.01mpa
Structure and action principle

This pump is parallel equipped with 2 pumps, and adopts the structure whereby it is connected with driving
gear (191) and driven gear (192) and transmits the rotation of prime mover to driven shaft (113) and drives
2 pumps via driving shaft (111), driving gear (191) and driven gear (192). The pilot gear pump can be
th th
installed behind driven shaft (113), and the 4 pump can be installed behind driving shaft (111), and the 5
pump can be installed on PTO via driving gear.
This pump can be divided into: the rotation mechanism will make the main body of pump rotate; the
swashplate mechanism which changes the output flowrate; the oil distribution cover mechanism which
achieves the changeover between oil suction and oil drainage, and the structure which takes power from
th
PTO mechanism for driving the 5 pump.
(1) Rotation mechanism

The rotation mechanism is composed of driving shaft (111, 113), cylinder body (012), plunger, sliding shoe
(151, 152), return disc (153), sphere bushing (156) and return spring (157). The driving shaft is riveted onto
the head of plunger (151) via bearing (123, 124) and sliding shoe (152) on both sides, so as to form the
ball joint and reduce the thrust generated by axis via load pressure. In order to reduce the friction between
sliding shoe (152) and sliding shoe disc (211) and achieve the smooth sliding, the annular oil groove where
the pressure is balanced (static pressure) is adopted on sliding shoe. On the other hand, in order to ensure
that the plunger and sliding shoe subassembly (151, 152) can smoothly slide on sliding shoe disc (211),
the return disc (153) and ball bushing (156) will be pressed against the sliding shoe disc (211) by return
spring (157). This end of cylinder body (012) on the other side will also be pressed against the oil
distribution disc (313, 314) by return spring (157).

(2) Swashplate mechanism

The swashplate mechanism is composed of swashplate (212), sliding shoe disc (211), swashplate
supporting table (251), inclined bushing (214), inclined pin (531) and servo piston (532). The swashplate
(212) is supported on swashplate supporting table (251) on the side opposite to sliding face of sliding shoe.
The pressure oil controlled by regulator control will be led into oil chambers on two ends of servo piston
(532), so that the servo piston (532) will move leftwards, and the ball on inclined pin (531) will make the
swashplate (212) swing on swashplate supporting table (251), so as to change the inclination of
swashplate.
(3) Oil distribution cover mechanism
The oil distribution cover mechanism is composed of oil distribution cover (311, 312), turbocharging wheel
(310), spline coupling (114), oil distribution disc (313, 314) and oil distribution disc pin (885). The spline
coupling (114) is located between oil distribution covers F (311) and R (312), is connected with
transmission shaft F and transmission shaft R, and transmits the torque. The turbocharging wheel (130) is
connected to spline coupling (114), and in order to increase the suction ability of pump, it will pressurize
the pressure sucked through centrifugal force. The oil distribution disc (313, 314) equipped with two arc-
shaped oil distribution ports is installed on oil distribution cover (311, 312), and carries out the changeover
for oil supply to cylinder body (012). The oil transferred by oil distribution disc (313, 314) will flow to
external pipe via oil distribution cover (311, 312).
When the transmission shaft (111) is driven by prime mover (motor, engine and etc.), it will rotate together
with spline coupling (012). If the swashplate (212) is inclined, the plunger subassembly (151, 152) in
cylinder body (012) will rotate together with cylinder body (012) and also carry out the reciprocating
movement in relation to cylinder body (012). In other words, as for a plunger pair (151, 152), during the
period when the cylinder body (012) rotates for a round, the plunger pair (151, 152) will move away from oil
distribution disc (313, 314) (oil suction stroke) for 180°, and in the remaining 180°, it will move towards the
oil distribution disc (313, 314) (oil discharge stroke). When the inclination angle (α) of swashplate (212) is
zero, the stroke of plungers (151, 152) will not change, so that no oil will be discharged.
(4) PTO mechanism
nd rd
The PTO mechanism is composed of 2 gear and 3 gear. It will use the driving gear to transmit the
th
rotation to every gear, so as to drive the 5 gear.
When the driving shaft (111) is driven by prime mover (motor, engine and etc.), it will rotate together with
cylinder body (141) owing to spline connection. Owing to driving gear (191), the driven gear (192) will
make the driven shaft (113) rotate together with cylinder body (141). When the swashplate (212) is inclined,
the plunger pair (151, 152) installed in cylinder body (141) will rotate together with cylinder body (141) and
also carry out the reciprocating movement in relation to cylinder body (141). In other words, taking one
plunger pair (151, 152) for example, during the period when the cylinder body (141) rotates for one round,
the plunger pair (151, 152) will move away from oil distribution disc (313, 314) (oil suction stroke) for 180°,
and in the remaining 180°, it will move towards the oil distribution disc (313, 314) (oil discharge stroke).
When the inclination angle (α) of swashplate is zero, the plunger pair (151, 152) will not move, so that no
oil will be discharged.
Meanwhile, the rotation of driven shaft (113) will be transmitted to pilot gear pump (04) via spline, and just
th th
like driven shaft (113), the rotation of driving shaft (111) will also be transmitted to 4 pump and 5 pump
th th
via spline, so as to respectively drive the 4 pump and 5 pump of pilot gear pump (04).

Notices for use

1. Installation
S/N Items Notices

In principle, when installing the pump motor, please install the drive shaft
1 Installation direction
horizontally.
In principle, don’t externally apply radial or axial load onto shaft end of pump.
External load on If it is necessary to apply the above-mentioned load such as belt pulley,
2
shaft end please comply with the technical instructions given by this Company
, and further consult with this Company.
Since the spline on shaft end is applied with antirust coating, please clear it
away with detergent before use. Please apply the lubricant such as
Clearing of antirust
3 molybdenum disulfide onto spline, and then install it with coupling.
coating
In addition, when using the detergent, please be careful not o splash the
detergent onto oil seal.
When the driving shaft if pump is connected with the shaft of engine, in
Connection and
4 principle, please use the elastic coupling. The error in alignment between
alignment of pump
coupling and transmission shaft shall be less than 0.03mm.
As for the tightening torque for fixing bolts of pump, please refer to the
Tightening of fixing
5 attached table 1 “Specifications and Tightening Torque for Bolts” in this
bolts of pump
Manual.
2. Notices for pipes
S/N Items Notices

Rotation direction ① Rotation direction: rightwards as viewed from shaft end
1 and ② Position of oil suction/drain ports: Please refer to the diagram of
oil suction port appearance and dimension.
The oil suction/drain pipes and oil tank shall be fully acid-washed and
2 Cleaning of pipes
flushed. The oil suction pipes shall be cleaned up thoroughly.
When installing a pipe, please don’t forcibly install the pipe on oil suction port
Installation of oil
3 or oil drain port of pump, and don’t sharply bend the pipe. As for tightening
suction/drain pipes
torque for fixing bolts, please refer to the attached table.
① The oil leakage pipe shall be higher than the pump as indicated in the
figure below, and then return to the oil tank.
4 Oil leakage pipe
② It is advised to set up the oil filter in leakage oil way.

When the permissible pressure in this pump is in stable state, please control
5 Oil leakage pressure
it below 0.1mpa.

3. About oil filter

In order to prevent pump and other hydraulic parts from getting damaged and prolong their service life, the
key is to properly manage the contamination of working oil. Therefore, it is necessary to set up the 10μm
oil filter in the circuit.
S/N Items Notices
Please set up the 10μ oil filter in oil return circuit of actuation
element, as indicated in the figure below. In addition, please also
set up the 80-150 mesh oil strainer on oil suction side.
1 Oil filter
Air
150 mesh
150 mesh
Example for setting of oil filter

The relationship between contamination and service life of pump is
very complicated, and varies greatly depending on type and nature
of dirt and impurities. The intrusion of sand and dust may obviously
2 Contamination shorten the service life of pump.
Under the precondition that neither sand nor dust will intrude, it is
advised to use the NAS9. If the fine-hole contamination method is
adopted, then the range 2-4mg/100cc shall be adopted.

4. Working oil and temperature range
S/N Items Notices

Generally, please use the mineral-type hydraulic working oil which has
1 Type of oil high viscosity index and to which the high-pressure lubricating additive,
foam inhibitor, antioxidant and anticorrosive agent are added.
As for opened-type circuit, the recommended viscosity is 10-200cst. As
for closed-type circuit or use in motor, though the viscosity of 10-
1000cst can be adopted, in consideration of optimal efficiency, it is
advised to select the viscosity of 10 -200cst. In addition, the
temperature range is restricted by the -20℃- 80℃ operating
temperature of oil seal and O-ring. In consideration of the factors such
as deterioration of working oil and sealing element, it is advised that the
operating temperature shall be lower than 65℃.
Critical value of high viscosity
Critical value of suction

port of pump
low temperature
Critical value of
Critical value of
temperature
Viscosity
high
Viscosity
Optimal use
Optimal viscosity and
2 temperature of working
oil
Range
Critical
value of low
viscosity
Appropriate viscosity and

temperature range
If the working oil such as organic phosphate, monoethylene glycol or

fatty acid ester is used, please consult with this Company in advance.

5. Notices for use
Items Notices
If possible, don’t set aside pump or motor for long time (more than 1 year).
During the storage period, please start it for short time even once.
Long-term storage In addition, even if a part is stored, it is still effective to rotate the shaft end
with hand. If it has been stored for too long time, please disassemble and
inspect it.
Modification of rotating Please note that the rotating direction of pump is rightward when being
direction viewed from shaft end.
6. Oil filling and air bleeding
Items Notices
The housing of pump shall be filled with oil. Since there are high-speed
rotating parts such as bearing, plunger, sliding shoe, sphere bushing and
Fill in oil gear in pump, if the housing is not filled with oil, these parts may get
heated or damaged.
Therefore, be sure to fully fill the oil.
If air exists in circuit and pump, the action will be abnormal and the parts
Bleed off the air
may get damaged. Therefore, please fully bleed the air.
7. Notices for operation

1) Please inspect whether the pipe is fully installed.
2) Please inspect whether the rotating direction, oil suction direction and oil discharge direction are
correct.
3) Before the engine is started, please confirm that no load is applied onto pump.
4) After starting up the engine, please make it run under unloaded condition for a while, so as to fully
bleed the air from circuit.
5) Please confirm whether there is oil leakage or abnormal vibration.
6) When the gear box pump is equipped, please inspect whether the specified gear oil is filled into gear
box by reference to table of oil level.

Cause of trouble and corresponding handling

1. General Notices
The handling method to be adopted for abnormal situation in use of axial plunger pump and motor is
detailed as follows. General notices:
(1) Matters to be considered before elimination of abnormal situation
Before carrying out the operation, please carefully judge the nature of abnormal situation. Please judge
whether the cause of trouble is located in circuit or regulator or auxiliary valve. Please consider again
whether that is really the cause for trouble of pump motor.
(2) Before the dismantlement, please carefully read the service manual, and carry out dismantlement and
installation in accordance with the correct procedures.
(3) Even if only a part is dismantled, please be careful not to get dust enter such part.
(4) Most of the components are precisely manufactured. Therefore, please be careful not to get any part
damaged during installation.
2. Inspection method for abnormal pump body

In many cases, the pump is equipped with regulator, auxiliary valve and auxiliary pump. Though it is very
difficult to identify the cause of trouble, if the following inspection items are carried out, the abnormal
component can be identified.
(1) Inspect the oil filter and oil leakage
Please inspect the oil filter element. Confirm whether a lot of abnormal impurities are discharged.
Since the sliding shoe and cylinder body may discharge the worn powder, it is avoidable that a little of
metal powder will enter into oil filter. However, if there is a lot of metal powder in oil filter, maybe the sliding
shoe is in trouble. In addition, please inspect the pump housing for internal oil leakage.
(2) Is there any abnormal vibration or abnormal noise?
Please inspect whether there is abnormal vibration or abnormal noise on pump body. Please inspect
whether there is vibration on regulator and whether there is regular vibration when the auxiliary valve is
overflowing. When there is abnormal vibration, maybe the cavitation occurs or the inside of pump is
damaged.
(3) When 2 pumps are used
When the motor uses the parallel-installed two pumps, please interchange the pipes of every pump, and
then inspect whether the pipes are correct. On the basis of this result, judge whether the pump is in trouble
or the circuit behind pump is in trouble.
(4) Carry out the pressure testing for every component
When any control problem occurs, don’t randomly dismantle the components and carry out inspection, but
carry out the pressure testing for every component so as to identify the abnormal component.

3. Overloading of prime mover
Causes Handling Notices

1) Carry out setting in
1) Is the speed or pressure
accordance with the design
higher than design value?
value.
2) Is the torque of regulator set 2) Inspect the setting of 2) Please refer to the instructions
too high? regulator again. of regulator.
3) The internal component of 3) Inspect the oil filter and oil.
3) Replace the damaged
pump is overheated and Please confirm whether there is
components.
damaged. abnormal worn powder.
4) Wrong installation of pipes 4) Correctly install the pipes of
of regulator regulator
4. When the flowrate of pump excessively reduces, and the output pressure can’t increase

1) Please refer to the instructions
1) Trouble of regulator 1) Repair the regulator.
for regulator.
2) The internal component of
2) Replace the damaged 2) Confirm the oil filter and oil
pump is overheated and
components. leakage.
damaged.
3) Replace the damaged 3) Please inspect the coupling after
3) Trouble of auxiliary pump.
components. dismantling the auxiliary pump.
4) Trouble of auxiliary valve 4) Replace the auxiliary valve
for auxiliary valve
5) Wrong installation of pipes 5) Correctly connect the pipes
of regulator for regulator.
6) Damage of gear 6) Replace the gear.
5. Abnormal noise and abnormal vibration

1-1) The turbocharging (suction)
pressure is too low.
1) Prevent the cavitation.
1-2) Trouble of auxiliary pump.
Please inspect whether self
1) Cavitation 1-3) Air is sucked from oil suction
turbidity occurs to the
pipe.
working oil.
1-4) The oil-suction resistance is too
high.
2) Replace the components
2) The riveted portion of sliding
such as plunger, sliding
shoe is damaged.
shoe and sliding shoe disc.
3) The cylinder body is
3) Replace the cylinder body.
cracked.
4) The pump is installed
4) Correctly install it.
incorrectly.
5) Vibration of regulator 5) Repair the regulator.
for regulator.
6) Vibration of overflow valve in 6) Please refer to the instructions
6) Replace the auxiliary valve.
auxiliary valve for auxiliary valve.
7) Damage of gear 7) Replace the gear.

Attached Table 1: Checklist of pump install torque
Installation torque
Part name Specification B(mm) Name of Tool
(N˙m)
M8 34 6
Inner hexagonal bolt
M12 98 10 Hexagonal spanner
(material SCM435)
M22 630 17
Flange seat type bolt

(Bolt with washer) M10 33 8 Hexagonal spanner
(material SCM435)
Hexagonal nut
M10 240 Monkey spanner
(material SS400)
G1/8 17 5
RO/ROH oil plug
G1/4 36 6
Material (G1/8, G1/4: S45C Hexagonal spanner
G3/4 170 12
G3/4, G1-1/4: SCM435)
G1-1/4 270 17

Attached figure 1
Attached Figure 2 is in 9-20 (Page 531)

Reference diagram
Less than
C0.2
Guiding bolt (used for installation/dismantlement of

oil distribution cover)
Less than
C0.2
Guiding bolt (used for installation/dismantlement of

front housing)
(Note) R and C are 0.1-

(Note) R and C are 0.1-
0.5mm.
0.5mm.
Driving-side resin cover (used for Driven-side resin cover (used for
needle bearing) needle bearing)

Pilot pump
Figure 4-55
307: Valve rod 361: Body

308: Valve seat 433: Screw
309: Retainer ring 434: Screw
310: Spring 435: Screw
311: Adjusting screw 466: Plug
312: Nut 700: Washer
351: Body 710: O-ring
353: Gear shaft 725: O-ring
354: Gear shaft 732: O-ring
355: Filter core 850: Washer
Functions
● The engine will drive the driving shafts of main pump and pilot pump via gearbox, and then drive the
pilot pump through engagement of gear.

Regulator
Type: KR3D-OE82-V
Figure 4-27
SY750 main
pump regulator

S/N Part name Material Quantity Code of material Remarks

4 Gear pump Steel 1 60015495 2902440-3244A
2 Regulator Steel 2 60335190 29150918-2062
11 Plunger assembly Steel 2 60015828 2924530-0468
30 Swash plate Steel 2 60335193 2953802832
111 Driving axle Steel 1 60335194 2924250-0104
113 Driving axle Steel 1 60335195 2924250-0237
114 Spline sleeve Steel 1 60335196 2924290-0010
123 Bearing Steel 2 60335197 PNUP311RC3
124 Bearing Steel 2 60335198 PAJ50480A-HSC
127 Adjusting pad Steel 4 60335199 38C00-127A
130 Turbocharger Steel 1 60335200 2924170-0001
153 Supporting plate Steel 2 60335201 2924110-0037
156 Sphere bushing Steel 2 60015816 2924610-0014
157 Spring Steel 18 60335202 2953802351
211 Sliding plate Steel 2 60015758 372A00AA-124
251 Casing Steel 2 60335203 2923330-0639
253 Gasket Steel 8 60335204 2903710-0088
261 End cover Steel 1 60335205 2923150-1819
263 End cover Steel 1 60335206 2923150-0261
271 Casing Steel 2 60335207 2923250-0828
311 End cover Steel 1 60335208 2923110-1139
312 End cover Steel 1 60335209 2923110-1140
401 Inner hexagonal screw Steel 4 60335210 2953802570
402 Inner hexagonal screw Steel 4 60335927 2903620-0042
406 Inner hexagonal bolt Steel 4 60039371 0SBM820
407 Inner hexagonal screw Steel 4 60335211 0SBM830
465 Screw plug Steel 5 60038487 0R0H18
466 Oil plug Steel 2 60038654 0VP14
468 Oil plug Steel 4 60039400 0VP34
491 Orifice Steel 4 60335214 0TRS116A06
497 Blind plug Steel 31 60225354 0MHM7
530 Inclined pin Steel 2 60335215 2925130-0034A
532 Plunger Steel 2 60335216 2924490-0051
534 Screw plug Steel 2 60335217 2953802576
535 Screw plug Steel 2 60335218 2953802575

S/N Part name Material Quantity Code of material Remarks

702 O-ring Rubber 2 60082182 00RBG45W
717 O-ring Rubber 4 60335220 PCPP195V
718 O-ring Rubber 1 60335221 PCPP185V
723 O-ring Rubber 5 60038716 00RBP8W
724 Square sealing ring Rubber 19 60342215 P0RKP8W
774 Shaft seal Steel, rubber 1 60357966 PSD65887F
789 Retainer ring Steel 2 60335223 PT2SP22
792 Retainer ring Steel 2 60335224 PT2SG45
808 Hexagonal nut Steel 4 60039359 0RNM20
824 Snap ring Steel 2 60318724 0SR55
885 Pin Steel 2 60314907 PJR1014
887 Spring pin Steel 5 60038261 0SPV620
901 Lifting ring Steel 2 60335225 0EBM16
953 Bolt Steel 2 60335226 PSSSM2050
954 Bolt Steel 2 60319629 2903300-0014
956 Screw Steel 8 60318855 PSSSM810-2471
981 Nameplate Steel 1 60100511 PNPA-2550C
983 Pin Steel 2 60038620 0SK2548
Repair kit for
999 Rubber 1 60355199 K3V280DTH-OE82
plunger pump

Function principle
● The regulator controls the flowrate of main
pump on the basis of various command signals,
so as to ensure that the driving power of pump
will not exceed the power transmitted by the
engine to main pump.
● The front pump and rear pump are respectively
equipped with a regulator. The main parts of
regulator are electromagnetic proportional
pressure-reducing valve (1), positive flowrate
regulator (2), servo piston (3), and servo
changeover valve (4). On the basis of various
command signal, the regulator will open or
close the oil way of servo piston (3) and change
the inclination of swashplate, so as to control
the flowrate of pump.
Current control: in normal state
● The inclination angle (output flowrate) of
swashplate of pump can be freely controlled by
changing the command current value I flowing
into electromagnetic proportional pressure- Figure 4-20
reducing valve. This regulator adopts the
positive flowrate control (positive control)
method, and as the command current value I
increases, the output flowrate Q will also
increase. The current for flowrate necessary for
operation can be input via this mechanism. As
a result, the pump will only transmit the
necessary flowrate, and the power will not be
wasted.
Hydraulic power control: for emergency use
● In the hydraulic power control state, the
inclination angle (output flowrate) of swashplate
of pump will be automatically reduced as the
output pressure Pd of pump increases, so as to
control the input torque below a certain value.
(When the speed is constant, the input power
will become the constant power.)
● When the power control is carried out, the
regulator of every pump will be controlled to the
same inclination angle (output flowrate).
Therefore, the state of power control is not
related to load of two pumps, and will
automatically prevent the prime mover from
getting overloaded.
● With this mechanism, the pump will obtain the
optimal power during operation.
● Though the regulator has the above-mentioned
2 control mechanisms, when various controls
jointly act, the mechanical calculation
mentioned below will give priority to the small
inclination angle (small flowrate) command.

Adjustment of regulator
Figure 4-21
531: Inclined pin

532: Servo piston
548: Feedback pin
807: Fixing nut
808: Fixing nut
953: Minimum flowrate adjusting screw
954: Maximum flowrate adjusting screw
● The maximum flowrate and minimum flowrate

can be adjusted by using the adjusting screws
(953, 954) on pump body side; the power
control features can be adjusted by using the
adjusting screw (C) (628) and adjusting wheel
(C) (627) on this regulator; the flowrate control
features can be adjusted by using the
hexagonal locating screw (924).
Figure 4-22

Adjustment of maximum flowrate (pump body side)

● Loosen the hexagonal nut (808), and screw in
(or screw off) the hexagonal locating screw
Output flowrate Q
(954). Other control features will remain
unchanged, and only the maximum flowrate will
change.
Command current value I
Figure 4-23
Adjustment of minimum flowrate (pump body side)

● Loosen the hexagonal nut (806), and screw in
Output flowrate Q
(or screw off) the hexagonal locating screw

(953). Though the adjustment is as same as
the adjustment of maximum flowrate and other
control features remain unchanged, if the screw
is excessively tightened, at the maximum
output pressure (overflow), the power required
will increase.
Figure 4-24

Input power
Output flowrate Q
Adjustment of external spring
● After loosening the hexagonal nut (630), please
screw in (or screw off) the adjusting screw (C)
(628) to carry out adjustment. If the adjusting
screw (C) (628) is screwed in, the control curve
will move rightwards as indicated in the right
figure, and the input power will increase.
Furthermore, if the adjusting screw (C) (628)
has been screwed in for N rounds, since the
internal spring (626) will also rotate, its set
value will also change. Therefore, please turn
Output pressure (Pd1)
the adjusting screw (C) (627) in reversed
direction for N×A.
(As for value of A, please refer to the attached Figure 4-25
table)
Adjustment of internal spring

Output flowrate Q
● After loosening the hexagonal nut (802), please

screw in (or screw off) the adjusting screw (C)
(627) to carry out adjustment. When the
adjusting screw (C) (627) is screwed in, the
flowrate will increase as indicated in the right
figure, and the input power will also increase.
Figure 4-26
Adjustment of flowrate control features

Output flowrate Q
● After loosening the hexangonal nut (801),

please screw in (or screw off) the hexangonal
locating screw (924) so as to carry out
adjustment. When srcewing in the hexangonal
locating screw (924), please make sure that
the line moves rightwards as indicated in the
right figure.
Figure 4-27

Explanation on action
Displacement Q of pump
● As indicated in the right figure, the output
flowrate of pump can be controlled in a stepless
manner through command current value I
(When the speed of pump is fixed).
Figure 4-28
1) During electrical control The mouthpiece C1 is
connected with large diameter
Flowrate increase head of servo piston
● When the command current value I increases,
the secondary pressure P2 of electromagnetic
proportional pressure-reducing valve will
increase, so that the pilot plunger (643) will
move towards A until P2 is balanced with the
force of pilot spring (646). The movement of
pilot plunger will be transmitted to deflector rod
(2) (613) via pin (875), and the deflector rod (2)
(613) will rotate in the direction of arrow around
point B. The rotation of deflector rod (2) will
also be transmitted to feedback rod (611) via
axis pin (897), and the feedback rod (611) will
rotate together with B in the same direction
around point C. Meanwhile, the valve core
(652) connected with feedback rod will move Figure 4-29
towards D. When the valve core is moving
towards D, the mouthpiece C1 will be
connected with mouthpiece of oil tank, so that
the pressure in large-diameter chamber of
servo piston will be released. As a result, the
output pressure Pd1 flowing through the small-
diameter chamber will move the servo piston
(532) towards E, and thus the flowrate will
increase. Since the feedback rod is connected
with servo piston and valve core, if the servo
piston moves towards E, the feedback rod will
rotate around the point F, so that the valve core
will move to its original position. Owing to this
movement, the opening between slide valve
and valve body will be closed slowly, and the
servo piston will stop when such opening is
fully closed.
Figure 4-30

Reduction of flowrate The mouthpiece C1 is

connected with large
● When the command current value I decreases, diameter head of servo
the secondary pressure P2 of electromagnetic piston
proportional pressure-reducing valve will
decrease, so that the pilot plunger (643) will
move towards G until P2 is balanced with the
force of pilot spring (646). The movement of
pilot plunger will be transmitted to feedback rod
(611) via axis pin (897), and the feedback rod
(611) will rotate together with H in the direction
of arrow around point I. Meanwhile, the valve
core (652) connected with feedback rod will
move towards J. When the valve core is
moving towards J, the output pressure Pd1 will
be led into large-diameter chamber of servo
piston via valve core and mouthpiece C1. On
the other hand, the output pressure Pd1 will be
always led into the small-diameter chamber of Figure 4-31
servo piston, and owing to area difference, the
servo piston will move towards K, so that the
inclination angle will reduce and the flowrate
will reduce. Since the feedback rod is
connected with servo piston and valve core, if
the servo piston moves towards K, the
feedback rod will rotate around the point L, so
that the valve core will move to its original
position. Owing to this movement, the opening
between valve core and valve body will be
closed slowly, and the servo piston will stop
when such opening is fully closed.
2) During hydraulic control

Output flowrate Q
Power control (for emergency use)

● As indicated in the right figure, when the load
pressure increases, the inclination angle of its
pump will reduce, so as to prevent the prime
mover from getting overloaded.
● The control on power is as same as control on
flowrate, and is described briefly as follows.
Figure 4-32

Prevention of overloading (For emergency

use)
● When the output pressure Pd1 of pump
increases, since the output pressure Pd1 acts The mouthpiece C1 is
on step portion of compensation plunger (621), head of servo piston
the compensation rod (623) will move towards
M until the output pressure Pd1 is balanced
with the force of external spring (625) and
internal spring (626). The movement of
compensation rod will be transmitted to
deflector rod (1) (612) via pin (875), and the
deflector rod (1) (612) will rotate in the direction
of arrow around point N. The rotation of
deflector rod (1) will also be transmitted to
feedback rod (611) via axis pin (897), and the
feedback rod (611) will rotate in reversed
direction of N point O. Meanwhile, the valve
core (652) connected with feedback rod will
move towards P. When the valve core is Figure 4-34
moving towards P, the output pressure Pd1 will
be led into large-diameter chamber of servo
piston via valve core and mouthpiece C1. The
output pressure Pd1 will be always led into the
small-diameter chamber of servo piston, and
owing to area difference, the servo piston will
move towards Q, so that the inclination angle
will reduce and the flowrate will also reduce.
Since the feedback rod is connected with servo
piston and valve core, if the servo piston moves
towards Q, the feedback rod will rotate around
the point R, so that the valve core will move to
its original position. Owing to this movement,
the opening between valve core and valve
body will be closed slowly, and the servo piston
will stop when such opening is fully closed.

Resumption of flowrate (For emergency

use)
● When the output pressure Pd1 of pump
decreases, under the action of external spring The mouthpiece C1 is
(625) and internal spring (626), the head of servo piston
compensation rod (623) will move towards S
until the output pressure Pd1 is balanced with
the force of external spring (625) and internal
spring (626). The movement of compensation
rod (623) will be transmitted to deflector rod (1)
(612) via pin (875), and the deflector rod (1)
(612) will rotate in the direction of arrow around
point T. The rotation of deflector rod (1) will
also be transmitted to feedback rod (611) via
axis pin (897), and the feedback rod (611) will
rotate in reversed direction of N point U.
Meanwhile, the valve core (652) connected with
feedback rod will move towards V. When the
valve core is moving towards V, the
mouthpiece C1 will be connected with the
mouthpiece of oil tank, and thus the pressure in
large-diameter chamber of servo piston will be
released. As a result, the output pressure Pd1
flowing through small-diameter chamber of
servo piston (532) will move towards W, so that
the flowrate will increase. Since the feedback
rod is connected with servo piston and valve
core, if the servo piston moves towards W, the
feedback rod will rotate around the point X, so
that the valve core will move to its original
position. As a result, the opening between
valve core and valve body will be closed slowly,
and the servo plunger will stop when such
opening is fully closed.
Priority mechanism for small inclination angle (small flowrate) command

● As mentioned above, the tilting command for flowrate control and the tilting command for power
control will be transmit ted to feedback rod (611) and valve core (652) via large-hole portion of
deflector rod 2 (613) and large-hole portion of deflector rod 1 (612). However, since the pin (φ5) on
large hole (φ9) extrudes, only contacts with the rod and pin on the side with less tilting and does not
contact with the φ9 hole and- axis pin (897) on rod on the side with more titling, the flowrate will be
controlled, and the tilting command for power control will be prior.

Attached Table: Checklist for adjustment of regulator
Model of regulator KR3S-9T1L-V

-1
Rotary speed (min ) 2100
Tightening amount (rotation) of
Adjustment of maximum +/4
adjusting screw (954)
flowrate
Change in flowrate (L/min) 6
Adjustment of minimum +1/4
flowrate
+1/4
Start pressure of compensation control
Adjustment of 16
(kgf/cm²)
external spring
Adjustment Change in input torque (kgf·m) 4.3
of input A 1.8
horsepower
+1/4
Adjustment of
internal spring Change in flowrate (L/min) 10
Change in input torque (kgf·m) 4.2
+1/4
Adjustment of flowrate Change in start pressure for flowrate
control features 1.5
control (kgf/cm²)

Hydraulic system, Part 2

Control valve
Appearance diagram of main valve
Figure 4-66

: Slewing logic control valve pilot

P1 : Pump mouthpiece (P1 side) Pns
mouthpiece
P2 : Pump mouthpiece (P2 side) PG : Pilot pressure source mouthpiece
: Bucket arm cylinder piston rod chamber
Aa PH : Pilot pressure source mouthpiece
mouthpiece (extension)
: Bucket arm cylinder piston head chamber : Pilot pressure for pressure rise for main
Ba1 Pz
mouthpiece (retraction) overflow valve
: Bucket arm cylinder piston head chamber : Locking valve pilot mouthpiece (bucket
(Ba2) PaL
mouthpiece (retraction) arm piston rod side)
: Boom cylinder piston head chamber : Locking valve pilot mouthpiece (boom
Ab PbL
mouthpiece (lifting) piston head side)
: Boom cylinder piston rod chamber
Bb Px : Signal mouthpiece for working device
mouthpiece (lowering)
: Bucket cylinder piston rod chamber
Ac Py : Travelling signal mouthpiece
mouthpiece (unloading)
: Bucket cylinder piston head chamber
Bc Drl : Oil discharge mouthpiece
mouthpiece (excavation)
Atr : Right travelling motor mouthpiece Dr2 : Oil discharge mouthpiece
Btr : Right travelling motor mouthpiece Dr3 : Oil discharge mouthpiece
AtL : Left travelling motor mouthpiece Dr4 : Oil discharge mouthpiece
BtL : Left travelling motor mouthpiece Dra : Oil discharge mouthpiece
As : Slewing motor mouthpiece Drb : Oil discharge mouthpiece
Bs : Slewing motor mouthpiece R1 : Oil return mouthpiece
XAtr : Right travelling pilot mouthpiece (R2) : Oil return mouthpiece
XBtr : Right travelling pilot mouthpiece R3 : Oil return mouthpiece
XAtL : Left travelling pilot mouthpiece Rs1 : Oil filling mouthpiece
XBtL : Left travelling pilot mouthpiece Rs2 : Oil filling mouthpiece
XAs : Slewing pilot mouthpiece (Ao) : Standby mouthpiece
XBs : Slewing pilot mouthpiece (Bo) : Standby mouthpiece
XBb1 : Boom 1 (lowering) pilot mouthpiece (XAo) : (Standby pilot mouthpiece )
XAb1 : Boom 1 (lifting) pilot mouthpiece (XBo) : (Standby pilot mouthpiece )
: Boom interflow (reduce/lower) pilot
XBb2 (PTa)
mouthpiece
XAb2 : Boom interflow (lifting) pilot mouthpiece (PTb)
XBa1 : Bucket arm 1 (retraction) pilot mouthpiece (N1)
XAa1 : Bucket arm 1 (extension) pilot mouthpiece (N2)
XBa2 : Bucket arm 2 (retraction) pilot mouthpiece (P3)
XAa2 : Bucket arm 2 (extension) pilot mouthpiece (P4)
XAc : Bucket (unloading) pilot mouthpiece (R4)
XBc : Bucket (excavation) pilot mouthpiece
: Bypass cut-off valve core pilot mouthpiece
XBp1
(P1 side)
: Bypass cut-off valve core pilot mouthpiece
XBp2
(P2 side)
PAcs : Bucket (excavation) stroke pilot mouthpiece
: Bucket arm 1 logic control valve pilot
Pna1
mouthpiece

Figure 4-67

Cross-section C-C
Figure 4-68

Cross-section D-D
Cross-section N-N
Figure 4-69

Cross-section Q-Q
Cross-section K-K
Cross-section E-E
Figure 4-70

Installation Quan Installation

S/N Part name Quantity S/N Part name
torque (N.m) tity torque (N.m)
101 Valve body A 1 305 Slewing valve core 1
102 Valve body B 1 306 Bucket arm 2 valve core 1
103 Valve body C 1 307 Boom 2 valve core 1
Straight travelling valve
151 Oil plug 6 13~17 308 1
core subassembly
152 Oil plug 2 34~39 309 Standby 1
153 Oil plug 10 69~78 310 Bypass cut-off valve core 2
161 O-ring 4 323 Spring 2
163 O-ring 9 331 Spring seat 4
165 O-ring 4 333 Bolt with gasket 2 16~18
166 O-ring 12 334 Block 2
167 O-ring 6 336 Bolt with gasket 10 37~41
168 O-ring 3 337 Block 10
169 O-ring 10 341 Oil plug 1 34~39
201 Spring cover 9 342 Piston 1
202 Spring cover 2 351 Orifice plug (φ0.7) 3 7.8~9.8
203 Valve core cover 9 371 Spring 8
204 Spring cover 1 372 Spring 1
205 Valve core cover 1 375 Spring 1
211 Plate 1 511 Cone valve 10
213 Flange disc 2 512 Cone valve 2
214 One-way valve plate 1 513 Cone valve 2
Cover plate without
275 1 514 Cone valve 1
pipe mouth
Cover plate without
216 1 515 Cone valve 2
pipe mouth
Locking valve selection
252 2 9.8~14 521 Spring 12
subassembly
Bucket arm 1 logic
253 1 522 Spring 3
valve component
Slewing logic valve
254 1 523 Spring 2
component
255 Logic control valve 2 52~62 531 Spring seat 1
Bucket arm
257 regeneration cut-off 1 120~140 541 Steel ball 1
valve subassembly
263 O-ring 9 551 Oil plug 17 370~410
264 O-ring 3 552 Oil plug 2 230~260
265 O-ring 1 553 Oil plug 2 370~410
266 O-ring 1 554 Oil plug 1 25~29
267 O-ring 1 555 Oil plug 1 220~260
271 Inner hexagonal bolt 40 52~62 561 O-ring 19
275 Inner hexagonal bolt 12 140~180 601 Main overflow valve 1 120~140
276 Inner hexagonal bolt 4 25~34 602 Mouthpiece overflow valve 6 120~140
277 Inner hexagonal bolt 4 83~110 605 Mouthpiece overflow valve 2 120~140
301 Travelling valve core 2 971 Inner hexagonal bolt 12 390~470
Bucket arm 1valve core
302 1 991 Nameplate 1
subassembly
Boom 1valve core
303 1 992 Rivet 2
subassembly
304 Bucket valve core 1 W 365V130707
Figure 4-71

Wiring diagram of hydraulic system
Traveling
Straight
RIGHT
travelling
Traveling
LEFT
Back swing
Boom 2
Boom 1
Standby
Bucket
Bucket 2
Bucket 1
Bypass
cutoff
Figure 4-72

Operating principle
(1) When the valve cores are at middle position
(Main circuit)
● When all valve cores are at the middle position, the working oil supplied by hydraulic pump (front) will
flow from mouthpiece P1 of pump, be led into main oil way (1), flow into middle position bypass (2) of
valve core of straight travelling (308), left travelling (301), boom 1 (303), bucket (304) and bucket arm
2 (306) (performance of M-shaped slide valve at middle position), and return to working oil tank from
oil return mouthpieces R1 and R3.
● The working oil supplied by hydraulic pump (rear) will flow into via mouthpiece P2 of pump, will be led
into main oil way (3), will flow through middle position bypass (4) of valve core of right travelling (301),
slewing (305), boom 2 (307), standby (309) and bucket arm 1 (302) (performance of M-shaped slide
valve at middle position), and will return to the working oil tank via mouthpieces R1 and R3 of oil tank.

Figure 4-73

(2) Traveling
(Pilot circuit)
● If the left travelling valve core or right travelling valve core is switched, the side oil way will be closed,
and thus the pressure of mouthpiece Pie (signal mouthpiece for travelling) will increase.
(Main circuit)
● When the pilot mouthpiece xbtl used for left travelling valve core (301) is pressurized, the middle
position bypass (2) on the boom 1side will be closed, and the working oil supplied by hydraulic pump
(front) will be supplied into left travelling motor from mouthpiece btl.
● Similarly, when the pilot mouthpiece xbtr used for right travelling valve core (301) is pressurized, the
middle position bypass (2) on bucket arm 1 side will be closed, and thus the working oil supplied by
hydraulic pump (rear) will be supplied into right travelling motor from mouthpiece Btr.
● On the other hand, the oil returning from left/right travelling motor will pass the left travelling (right
travelling) valve core from mouthpiece atl (Atr), and then return to the working oil tank from oil return
mouthpieces R1 and R3.
● When the travelling on the opposite side is carried out (when the pilot mouthpieces xatr and xatl are
pressurized), the situation will be as same as the above-mentioned.
Running Motor

(3) Bucket rod

When the bucket arm is being extended
(Pilot circuit)
● If the valve core (302) of bucket arm 1 is switched, the side oil way will be closed, and thus the
pressure of mouthpiece Px (signal mouthpiece for working device) will increase.
(Main circuit)
● When the bucket arm is being extended, the pilot pressure oil will be supplied into mouthpiece
xaal/xaa2. When the pilot pressure oil is applied to both sides of mouthpiece xaal/xaa2, the bucket
arm 1/bucket arm 2valve core will be switched to the left side as indicated in Figure 4-51. As a result,
the working oil from mouthpiece P2 will pass the main oil way (3) and be led into middle position
bypass (4). By switching the bucket arm 1valve core (302), the middle position bypass will be cut off.
As a result, the working oil flowing into parallel oil way will push open the cone valve (253)of logic
valve, and then flow into bucket arm 1valve core (302) via U-shaped oil way. Thereafter, the oil from
bucket arm 1valve core (302) will be supplied into piston rod chamber (R) of bucket arm cylinder.
● On the other hand, the working oil flowing in from mouthpiece P1 will be led to middle position bypass
(2) via main oil way (1). By switching the bucket arm 2 valve core (306), the middle position bypass
will be cut off. As a result, the working oil from parallel oil way will push open the cone valve (514) of
one-way valve, and the working oil from middle position will push open the cone valve (511) of one-
way valve and flow into bucket arm 2 valve core (306) from U-shaped oil way. And then, the oil way
from bucket arm 2 valve core (306) will interflow with mouthpiece Aa, and the oil will be supplied into
piston rod chamber (R) of bucket arm cylinder.
● The oil returning from piston chamber (H) of bucket arm cylinder via mouthpiece Bal will flow into oil
tank oil way of bucket arm 1/bucket arm 2, and return to the working oil tank from oil tank mouthpiece
R1/ R3.

Figure 4-74

When the bucket arm is being retracted

(Pilot circuit)
● If the bucket arm 1valve core (302) is switched, the side oil way will be closed. As a result, the
pressure of Px mouthpiece (signal mouthpiece for working device) will increase. Meanwhile, the
pressure oil will be supplied into mouthpiece pal, and the release signal will be sent to the locking
valve selection subassembly (252).
(Main circuit)
● When the bucket arm is being retracted, the pilot pressure oil will be supplied into mouthpieces xbal
and xba2. When the pilot pressure oil is applied onto mouthpieces xbal and xba2, the bucket arm 1
and bucket arm 2 valve cores will respectively change over to right side as indicated in Figure 4-52. As
a result, the working oil flowing in from mouthpiece P2 will be led into middle position bypass (4) via
main oil way (3). By switching the valve core (302) of bucket arm 1, the middle position bypass will be
cut off. As a result, flow into the working oil flowing into parallel oil way will push open the cone valve
(253) of logic valve, and flow into bucket arm 1 valve core (302) from U-shaped oil way. And then, the
oil will flow into circumference of bucket arm 1valve core (302), and
Will be supplied into piston head chamber (H) of bucket arm cylinder from mouthpiece Ba1.
● On one hand, the working oil flowing in from mouthpiece P1 will be led into middle position bypass (2)
via main oil way (1). By switching the bucket arm 2 valve core (306), the middle position bypass will be
cut off. As a result, the working oil flowing in from parallel oil way will push open the cone valve (514)
of bucket arm 2 one-way valve, and the working oil from middle position bypass will push open the
cone valve (511) in one-way valve and will flow into bucket arm 2 valve core (306) via U-shaped oil
way. And then, the oil from bucket arm 2 valve core (306) will interflow with the oil from mouthpiece
Bal, and will be supplied into piston head chamber (H) of bucket arm cylinder.
● On the other hand, owing to dead weight of bucket arm, the oil returning from piston rod chamber (R)
of bucket arm cylinder will get its pressure increase and return to the mouthpiece Aa. The working oil
returning to mouthpiece Aa will flow into valve core from hole (a) on circumference of bucket arm 1
valve core (302), push open the cone valve (302-317) in valve core only when the load is small, and
interflow with mouthpiece Bal mouthpiece from hole (b) on circumference. This is called as the
regeneration function of bucket arm.
● If the pressure in piston head chamber of bucket arm cylinder and U-shaped oil way increases, the
bucket arm regeneration cut-off valve core (257-103) will pushed to left side as indicated in Figure 4-
53, and will be closed owing to backpressure of cone valve (302-317) in valve core. As a result, the
bucket arm regeneration function will be released, the oil returning from piston rod chamber (R) of
bucket arm cylinder will flow into valve core via hole (a) on circumference of bucket arm 1 valve core
(302), flow into bucket arm regeneration cut-off valve (257) via hole (c) on circumference of bucket
arm 1 valve core (302), and return to the working oil tank via mouthpieces Rl and R3 of oil tank.

● When the load is small
Dead weight of
bucket arm
Figure 4-75

● When the pressure of piston head chamber (H) of bucket arm cylinder increases
Figure 4-76

(4) Boom
When the boom is being lifted
(Pilot circuit)
● When the valve core (307) of boom 2 is switched, the side oil way will be closed, and thus the
pressure of mouthpiece Px (signal mouthpiece for working device) will increase.
(Main circuit)
● When the boom is being lifted, the mouthpiece xab1 will be supplied with pilot pressure oil, and thus
the boom 1 valve core (303) will move to left side as indicated in Figure 4-54. The working oil flowing
in from mouthpiece Pl will be led into middle position bypass (2) via main oil way (1). By switching the
boom 1 valve core (303), the middle position bypass will be cut off. As a result, flow to working oil
flowing to parallel oil way will push open the cone valve (511) of one-way valve, and flow into boom 1
valve core (303) from U-shaped oil way. And then, the oil will flow into circumference of boom 1 valve
core (303), and will be supplied into piston head chamber (H) of boom cylinder from mouthpiece Ab.
● Meanwhile, the pilot pressure oil will also be supplied into mouthpiece xab2, and the boom 2 valve
core (307) will move leftwards as indicated in Figure 4-54. The working oil flowing in from mouthpiece
P2 will flow through boom 2 valve core (307), and the middle position bypass will be cut off. Therefore,
the working oil flowing into parallel oil way will flow into boom 2 valve core (307) via U-shaped oil way,
push open the cone valve (511) of one-way valve, interflow with the oil from mouthpiece Ab, and be
supplied into piston head chamber (H) of boom cylinder. (This is called as “boom interflow function”)
● On the other hand, the oil returning from piston rod chamber (R) of boom cylinder will flow in via
mouthpiece Bb, flow into circumference of boom 1 valve core (303), and return to the working oil tank
via mouthpieces R1 and R3 of oil tank.

Figure 4-77

When the boom is being lowered

(Pilot circuit)
● When the valve core (307) of boom 2 is switched, the side oil way will be closed, and thus the
pressure of mouthpiece Px (signal mouthpiece for working device) will increase. Meanwhile, the
mouthpiece pbl will be supplied with pressure oil, and the release signal will be sent to the locking
valve selection subassembly (252).
(Main circuit)
● When the boom is being lowered, the mouthpiece xbb1 will be supplied with pilot pressure oil, and
thus the boom 1 valve core (303) will move to right side as indicated in Figure 4-55. The working oil
flowing in from mouthpiece P1 will be led into middle position bypass (2) via main oil way (1). By
switching the valve core (303) of boom 1, the middle position bypass will be cut off. As a result, the
working oil flowing into parallel oil way will push open the cone valve (511) of one-way valve, and flow
to boom 1 valve core (303) from U-shaped oil way. And then, the oil will flow into circumference of
boom 1 valve core (303), and will be supplied into piston rod chamber (R) of boom cylinder from
mouthpiece Bb.
● On the other hand, the oil returning from piston head chamber (H) of boom cylinder will flow through
the hole (a) and circumference of boom 1 valve core (303).
● Owing to the dead weight of boom, the pressure of return oil will increase, and the oil will flow through
oil way in valve core under high pressure, the cone valve (303-317) in valve core will be pushed open
as indicated in Figure 4-55, and the oil will flow out of valve core. This pressure oil, as the working oil
for lowering of boom, will once again be supplied into piston rod chamber (R) of boom cylinder (this is
called as boom regeneration function). A part of the return oil flowing into internal oil way of valve core
from hole (a) will return to working oil tank via hole (b).

Figure 4-78

(5) Bucket
When the bucket is carrying out excavation
(Pilot circuit)
● When the bucket valve core (304) is switched, the side oil way will be closed, and thus the pressure of
mouthpiece Px (signal mouthpiece for working device) will increase. Meanwhile, the mouthpiece xbp2
will also be supplied with pressure oil.
(Main circuit)
● When the bucket is carrying out excavation, the mouthpiece XBc will be supplied with the pilot
pressure oil, and thus the bucket valve core (304) will move to left side as indicated in Figure 4-56.
The working oil flowing in from mouthpiece P1 will be led into middle position bypass (2) via main oil
way (1). By switching the bucket valve core (304), the middle position bypass will be cut off. As a
result, the working oil flowing into parallel oil way will push open the cone valve (511) of one-way valve,
and flow into bucket valve core (304) from U-shaped oil way. And then, the oil will flow into the
circumference of bucket valve core (304), and will be supplied into piston head chamber (H) of bucket
cylinder from mouthpiece Bc.
● On the other hand, the return oil from piston rod chamber (R) of bucket cylinder will flow in from
mouthpiece Ac, and flow to mouthpieces R1 and R3 of oil tank along circumference of valve core, so
as to return to the working oil tank.
● When the boom is being lifted and the bucket is carrying out excavation at the same time, the
mouthpiece PAcs will be supplied with pilot pressure oil, and thus the stroke of bucket valve core will
not be limited to end of stroke, but be limited in middle position. As a result, the oil way of bucket
cylinder will be throttled, the working oil from bucket valve core (304) will also flow into boom 1 valve
core (303), so as to make the boom lifting prior.
Interflow
Figure 4-70

When the bucket is being unloaded

(Pilot circuit)
● When the bucket valve core (304) is switched, the side oil way will be closed, and thus the pressure at
mouthpiece Px (signal mouthpiece for working device) will increase. Meanwhile, the mouthpiece xbp2
will also be supplied with pilot pressure oil.
(Main circuit)
● When the bucket is being unloaded, the mouthpiece xac will be supplied with pilot pressure oil, the
bucket valve core (304) will move to right side as indicated in Figure 4-57. The working oil flowing in
from mouthpiece P1 will be led into middle position bypass (2) via main oil way (1). By switching the
bucket valve core (304), the middle position bypass will be cut off. As a result, the working oil flowing
into parallel oil way will push open the cone valve (511) of one-way valve, flow into bucket valve core
(304) via U-shaped oil way, flow to circumference of bucket valve core (304), and then be supplied
into the piston rod chamber (R) of bucket cylinder from mouthpiece Ac.
● On the other hand, the oil will return from piston head chamber (H) in bucket cylinder, flow through
mouthpiece Bc, and then flow into mouthpieces R1 and R2 of oil tank from circumference of valve
core, so as to return to the working oil tank.
Interflow
Figure 4-80
Bucket interflow
● When the excavation or unloading of bucket is being carried out, the mouthpiece xbp2 will also be
supplied with pilot pressure oil, and the bypass cut-off valve core (310) will be switched. The working
oil supplied from mouthpiece P2 will be led into middle position bypass (4) via main oil way (3). By
switching the bypass valve core (310), the middle position bypass will be cut off. As a result, the
working oil will push open the one-way valve (515), and interflow with bucket valve core (304) via
internal oil way and U-shaped oil way.

(6) Back swing

When slewing is being separately carried out
(Pilot circuit)
● When the slewing valve core (305) is switched, the side oil way will be closed, and thus the pressure
of mouthpiece Px (signal mouthpiece for working device) will increase.
(Main circuit)
● When slewing is being separately carried out, the mouthpiece xas (or mouthpiece xbs) will be supplied
with pilot pressure oil, so as to switch the slewing valve core (305). The working oil from mouthpiece
P2 will be led into the middle position bypass (4) via main oil way (3). By switching the slewing valve
core (305), the middle position bypass will be cut off. As a result, the working oil flowing into parallel oil
way will push open the logic cone valve (254-101) of slewing logic valve component, flow into slewing
valve core (305) via U-shaped oil way, flow to circumference of slewing valve core (305), and be
supplied into slewing motor from mouthpiece As (or mouthpiece Bs).
● On the other hand, the oil returning from slewing motor will flow in from mouthpiece Bs (or mouthpiece
As), and then flow into mouthpieces R1 and R2 of oil tank from circumference of valve core, so as to
return to the working oil tank.
Slewing motor
Figure 4-81

(7) Priority function

● This is to ensure that, when the retraction of bucket arm and the slewing are carried out at the same
time, the working oil from mouthpiece P will fully flow into the large-load working device, so as to
improve the operability.
● The priority of slewing in relation to retraction of bucket arm is detailed as follows.
(Main circuit)
● When the mouthpiece Pna1 of logic control valve (255) is supplied with the pressure oil, the piston
(255-356) and valve core (253-107) will move upwards, and thus the lifting amount of cone valve (253-
101) will be limited. As a result, the oil way from parallel oil way to U-shaped oil way will be throttled,
and the oil from valve core of bucket arm 1 will firstly flow to slewing valve core, so that the slewing will
be prior.
● Similarly, when the mouthpiece Pns of logic control valve (255) is supplied with the pressure oil, the
lifting amount of cone valve (254-101) will be limited, so that the lifting of boom will be prior in relation
to slewing.
Figure 4-82

(8) Standby
The standby valve core is used to control the additional devices such as hydraulic scissors.
Operation standby
(Pilot circuit)
● When the standby valve core (309) is switched, the side oil way will be closed, and thus the pressure
of mouthpiece Px (signal mouthpiece for working device) will increase.
(Main circuit)
● During operation standby, the mouthpiece XAo (or mouthpiece xbo) will be supplied with pilot pressure
oil, so as to switch the standby valve core (309). The working oil from mouthpiece P2 will be led into
middle position bypass (4) via main oil way (3). By switching the standby valve core (309), the middle
position bypass will be cut off. As a result, the working oil flowing into parallel oil way will push open
the cone valve (511) of one-way valve, and flow into standby valve core (309) via U-shaped oil way.
● And then, the oil will flow to circumference of standby valve core (309), and will be supplied into
additional device from mouthpiece Ao (or mouthpiece Bo).
● On the other hand, the oil returning from additional working device will flow into via mouthpiece Bo (or
mouthpiece Ao), flow into mouthpieces R1 and R2 of oil tank from circumference of valve core, and
return to the working oil tank.
Interflow
Figure 4-83
Standby interflow
In order the achieve the standby interflow, the mouthpiece xbp1 will also be supplied with pilot pressure oil,
so as to switch the bypass cut-off valve core (310). The working oil from mouthpiece P1 will be led into
middle position bypass (2) via main oil way (1). By switching the bypass cut-off valve core (310), the
middle position bypass will be cut off. As a result, the working oil will push open the cone valve (515) of
one-way valve, and interflow with standby valve core (309) via internal oil way and U-shaped oil way.

(9) Straight travelling

When the travelling valve core (301) and other valve core are simultaneously operated
The situation that the travelling valve core (301) and slewing valve core (305) are operated at the
same time is discussed as follows.
(When the mouthpieces xatl, xatr and xas are supplied with pilot pressure oil.)
(Pilot circuit)
● The side oil way of right travelling/left travelling valve core (301) will be closed, the side oil way of
slewing valve core on downstream will be closed, and the pilot pressure oil from mouthpiece PG will
be supplied into the pta mouthpiece, so as to switch the straight travelling valve core (308).
(Main circuit)
● When the straight travelling valve core (308) is switched, the mouthpiece P2 will be firstly connected
with the right travelling/left travelling valve core (301), and then the mouthpiece P1 will be connected
with the oil way of standby bucket arm 1 of slewing boom 2/oil way of bucket arm 2 of boom 1. As a
result, the working oil supplied from mouthpiece P2 will mainly flow into mouthpiece atl and
mouthpiece Atr, and will be evenly supplied to two travelling motors.
● On the other hand, the working oil from mouthpiece p1will be supplied into slewing motor via
mouthpiece As.
● When the pressure at mouthpiece P2 is lower than the pressure at mouthpiece P1, a part of the
working oil from mouthpiece P1 will be supplied into P2 side. In this way, the sudden drop of travelling
speed can be prevented.
Figure 4-84

(10) Function of locking valve

● The locking valve selection subassembly (252) is installed between piston rod chamber (R) of bucket
arm cylinder and bucket arm 1 valve core (302) and bucket arm 2valve core (306), so as to reduce the
leakage in valve core caused by pressure of cylinder.
● Similarly, the locking valve selection subassembly (252) is also installed between piston head
chamber (H) of boom cylinder and valve core (303) of boom 1 or valve core (307) of boom 2, so as to
reduce the leakage in valve core caused by pressure of cylinder.
● The situation that the piston head chamber (H) of boom cylinder is supplied with oil is detailed as
follows. (The situation that the piston rod chamber (R) of bucket arm cylinder is supplied with oil is the
same.)
Middle position state of valve core
● When the valve core (303) of boom 1 or valve core (307) is at middle position, the valve core (252-511)
in locking valve selection subassembly will be maintained at the position as indicated in Figure 4-62 by
the pre-tightening force of spring (252-512), and will be pressed against the valve set of valve body
(252-101) of locking valve selection subassembly.
● At this position, the working oil in piston head chamber (H) of boom cylinder will flow in from hole (a),
flow along the circumference of valve core (252- 511) in subassembly as selected by locking valve,
and will be pressed onto the valve seat via hole (b) and cone valve (513). As a result, the internal
leakage volume will be reduced.
Figure 4-85

When the boom is being lowered

● When the boom is being lowered, the mouthpieces pbl, xbb1 and xbb2 will be supplied with pilot
pressure oil. The valve core (252-511) in pilot pressure oil locking valve selection subassembly will
move upwards as indicated in Figure 4-63. Owing to the movement of valve core (252-511) in locking
valve selection subassembly, firstly the hole (a) will be cut off, and the working oil from piston head
chamber (H) of boom cylinder will not flow into spring chamber (RH). In addition, the oil in spring
chamber (RH) will flow into oil leakage circuit via hole (b). As a result, the cone valve (513) will be
pushed open by pressure in piston head chamber (H) of boom cylinder, and thus the function of
locking valve selection subassembly (252) will be deactivated.
Figure 4-86
When the boom is being lifted
● When the boom is being lifted, the mouthpieces xab1 and xab2 will be supplied with pilot pressure oil.
The pressure oil flowing in from boom 1 valve core (303) and boom 2 valve core (307) will push open
the cone valve (513), so that the working oil will flow into mouthpiece Ab.

(11) Function of main overflow valve

The main overflow valve is installed on valve body A (101). Its function is indicated as follows.
● The working oil will be filled into chamber (a) via oil way (P) and through hole on valve rod housing
(601-101) and valve rod (601-511). As a result, the valve rod (601-511) will be pressed onto valve rod
housing (601-101) and form the reliable seal.
● When the pressure in oil way (P) exceeds the set pre-tightening force of spring (601-521), the cone
valve (601-401) will be opened. As a result the working oil will, along the periphery of cone valve (601-
401) and through the gap between valve rod housing (601-101) and valve sleeve (601-102), flow to
the low-pressure oil way (R).
● Since the cone valve (601-401) is opened, the pressure in chamber (a) will reduce, and thus the valve
rod (601-511) will be opened. As a result, the working oil in oil way (P) will directly flow to low-pressure
oil way (R).
● When the mouthpiece Pz is supplied with the pressure oil of which the pressure is higher than 3mpa,
the pressure oil will push open the plunger (601-302) and move leftwards, so that the pre-tightening
force of spring (601-512) will increase. At that moment, the state will change to pressure rise state.
Figure 4-87

(12) Function of mouthpiece overflow valve

The mouthpiece overflow valve is installed between cylinder mouthpiece and low-pressure oil way. In
addition to the function as overflow valve, it has the function oil-replenishing one-way valve to prevent
cavitation. Its function is indicated as follows.
Function to act as overflow valve
● The working oil will be filled into chamber (B) via hole (A) on plunger (301). As a result, the valve rod
(511) will be pressed onto valve seat (541), and the valve seat (541) will be pressed onto valve seat
and form the reliable seal.
Figure 4-88
● When the pressure in oil way (P) exceeds the pre-tightening force of spring (621), the cone valve (611)
will be opened. As a result, the working oil will, along the periphery of cone valve (611) and through
the hole (C), flow to the low-pressure oil way (R).
Figure 4-89

● Since the cone valve (611) is opened, the pressure in chamber (B) will reduce. As a result, the valve
rod (511) will be opened, and thus the working oil in oil way (P) will directly flow into low-pressure oil
way (R).
Figure 4-90
Function to act as oil-replenishing one-way valve for preventing cavitation
● When the negative pressure is generated in oil way (P), the working oil will be supplied from oil way
(R). When the pressure in oil way (R) is higher than the pressure in oil way (P), the valve seat (541)
will move rightwards. As a result, the working oil from oil way (R) will, along the periphery of valve seat
(541), flow into the oil way (P), so as to prevent cavitation.
Figure 4-91

Hydraulic system, Part 3

Slewing motor
Figure 4-92

A: Main oil port PG: Release port of brake

B: Main oil port SH: Command port of brake
M: Oil filling port L: Level rod
PA: Pressure testing port IP: Gear oil filling port
PB: Pressure testing port 1. Safety valve
DB: Oil port 2. Anti-swing valve
SY750H
Model M5X180CHB-10A-8PA/290-RG20D22G17-140
Theoretical displacement 180.1 cm3/rev
Set pressure of safety valve 28.5 MPa
Rated engine speed 1350
Braking releasing pressure 2.7-4.9 MPa

Cross-section view of slewing motor
Anti-swing
valve
Port PG
Oil filling
port
Overflow
valve
Port SH

Figure 4-93
1. Spacing sleeve 6. One-way valve spring 11. Plate
2. Casing 7. One-way valve 12. Piston
3. Disc 8. Oil distribution disc 13. Driving axle
4. Brake spring 9. Cylinder bore
5. Housing 10. Brake piston

Schematic diagram for slewing motor
Braking cylinder
Middle position
braking delay
valve
Slewing braking
oil replenishing
valve
Slewing anti-
swing valve

Overflow valve section

Structure
● The overflow valve is composed of overflow valve (1) and (2), one-way valve (3) and (4). Functions
● When this machine is in the slewing holding mode, the control valve (5) will close the outlet oil way of
motor, but owing to the inertial force, the motor will continue to run. Therefore, the output of motor will
increase abnormally, so that the motor may get damaged.
● In order to prevent the motor from getting damaged, the overflow valve will overflow the abnormally-
high pressure from outlet side (high-pressure side) of motor to oil port (M).
Operations From oil port M
1. When the slewing commences (It is assumed

that the high-pressure oil flows into port A)
● When the slewing control rod is operated for
right slewing, the pressure oil from pump will be
provided to oil port (A) via control valve (5).
● The pressure at oil port (A) will increase, the
start torque will be generated in motor, and the
motor will begin to rotate.
● The pressure oil from motor outlet will return to
the oil tank via oil port (B) and control valve (5).
Figure 4-94
2. When the slewing stops From oil port M
● When the slewing control rod returns to the

middle position, the supply of pressure oil from
pump to oil port (A) will be cut off.
● Since the oil return way from control valve (5)
to oil tank will be closed, the pressure oil from
outlet of motor can’t return to oil tank, so that
the pressure at oil port (B) will increase.
● The slewing resistance will be generated on
motor, and the brake will begin to work.
● When the pressure at oil port (B) increases to
the set value for pressure of overflow valve (2),
the overflow will occur.
● The large braking torque will act on motor, to Figure 4-95
stop the motor.
● When the overflow valve (2) acts, the
overflowing pressure oil and the pressure oil
from oil port (M) will be provided to oil port (B)
via one-way valve (4).
● In this way, the cavitation at oil port (B) will be
prevented.

Overflow valve section

Structure
● The overflow valve is composed of overflow valve (1) and (2), one-way valve (3) and (4). Functions
● When this machine is in the slewing holding mode, the control valve (5) will close the outlet oil way of
motor, but owing to the inertial force, the motor will continue to run. Therefore, the output of motor will
increase abnormally, so that the motor may get damaged.
● In order to prevent the motor from getting damaged, the overflow valve will overflow the abnormally-
high pressure from outlet side (high-pressure side) of motor to oil port (M).
Operations From oil port M
1. When the slewing commences (It is assumed

that the high-pressure oil flows into port A)
● When the slewing control rod is operated for
right slewing, the pressure oil from pump will be
provided to oil port (A) via control valve (5).
● The pressure at oil port (A) will increase, the
start torque will be generated in motor, and the
motor will begin to rotate.
● The pressure oil from motor outlet will return to
the oil tank via oil port (B) and control valve (5).
Figure 4-94
2. When the slewing stops From oil port M
● When the slewing control rod returns to the

middle position, the supply of pressure oil from
pump to oil port (A) will be cut off.
● Since the oil return way from control valve (5)
to oil tank will be closed, the pressure oil from
outlet of motor can’t return to oil tank, so that
the pressure at oil port (B) will increase.
● The slewing resistance will be generated on
motor, and the brake will begin to work.
● When the pressure at oil port (B) increases to
the set value for pressure of overflow valve (2),
the overflow will occur.
● The large braking torque will act on motor, to Figure 4-95
stop the motor.
● When the overflow valve (2) acts, the
overflowing pressure oil and the pressure oil
from oil port (M) will be provided to oil port (B)
via one-way valve (4).
● In this way, the cavitation at oil port (B) will be
prevented.

Anti-swing valve
Work diagram
1. Valve body
2. Slide valve (Aside)
3. Spring (A side)
4. Plug
5. Slide valve (B side)
6. Spring (B side)
7. Plug
Slewing
motor
Back slewing control valve
Figure 4-96
Effect diagram
With anti-swing valve
Without anti-swing valve

Reversing pressure
Pressure MA
Restraining
Reversing pressure
pressure
Pressure MB
First reversing
Second reversing
Motor speed
Start Brake Reversing
Figure 4-97

Overview
● Owing to the factors such as the inertia of
slewing body, the reactive thrust and rigidity of
mechanical system and the compressibility of
hydraulic oil, this machine may swing during
slewing. The anti-swing valve can effectively
reduce this situation, and can effectively
prevent the overflow of load in bucket when the
slewing stops and reduce the circulation time (It
has good locating performance, and can move
quickly, so as to carry out the next operation.)
Figure 4-99
Operations
1. When the braking pressure is generated at oil
port (B)
● The pressure MB will enter the oil chamber d
through gap, and the valve core (5) will, in
accordance with the area difference (D1>D2),
push the spring (6) leftwards, and B will be
connected with e. At that moment, the pressure
A will be lower than the set pressure of spring
(3), so that the slide valve (2) will not move,
and the hydraulic oil will be cutoff by slide valve
(2), so that the brake will be maintained.
Figure 4-100
2. After the motor stops

● Since the closing pressure is generated in oil
port B, the motor will rotate in reversed
direction (first reversed rotation). When this
situation occurs, the reversion pressure will be
generated at oil port A. The pressure A will
enter the oil chamber a, so that the slide valve
(2) will push the spring (3) rightwards, and A
will be connected with B. At that moment, b will
be connected with f via orifice on valve core (5),
so that the reversion pressure of oil port A will
flow to oil port T, so as to prevent the second
revised rotation.
Figure 4-101

Central slewing connector
Figure 4-81
1. Slewing shaft A: From main valve BL
2. Dust proof ring B: From main valve BR
3. O-ring C: From main valve AL
4. Slewing body D: From main valve AR
5. Rotating seal A1: To left travelling motor oil port (P1)
6. Gasket B2: To right travelling motor oil port (P2)
7. Retainer ring φ90 C3: To left travelling motor oil port (P2)
8. Plug (ZG3/4) D4: To right travelling motor oil port (P1)
9. Plug (ZG3/4) E: From oil discharge pipe of travelling motor retarder assembly
10. Cover E1: To oil tank
F: To high/low speed changeover port (P) of travelling motor retarder
F1: From port P of electromagnetic valve group

Running Motor
Figure 4-103
Ps: 2-speed pilot pipes A. Installation face with driving wheel
PmA: Pressure testing port B. Installation face with undercarriage
PmB: Pressure testing port 1. Installation hole with driving wheel
Dr: Oil discharge port 2. Installation hole with undercarriage
PA: Main oil port
PB: Main oil port

● Technical specification of motor
Equivalent displacement cm3/rev q×i

Motor Large displacement q1 cm3/rev 304.8
displacement
q Small displacement q2 cm3/rev 190.6
Reduction ratio i 74.3
2-speed
Low speed to high speed Mpa More than 1.5
changeover
pilot
High speed to low speed Mpa Less than 0.4
pressure
Parking braking torque N•m 644×i
Operating flowrate L/min 300
Operating pressure Mpa Less than 34.3
Peak pressure Mpa Less than 44.1
Action times under pressure higher than
Times Less than 1.2 million
34.3Mpa and lower than 44.1Mpa
At large
rpm
capacity
Motor shaft
At small
rpm Less than 2500
capacity
Swing speed
At large
rpm
capacity
Retarder
At small
rpm Less than 60
capacity
Output torque KN•m Less than 63.036
Normal PS
Input power Less than 210 (within 30 consecutive
Maximum PS
seconds)
Oil discharge Normal Mpa Less than 0.2
pressure Instant maximum Mpa Less than 0.5 (less than 300khz)
Weight kg 430

Connected with
driving wheel
Fixed on
undercarriage
Plunger motor shaft
Figure 4-104

Double balance valve

Function:
● The function to control the speed of motor speed and prevent over speeding when the speed of
plunger motor increases in relation to flowrate owing to external load (hereinafter referred to as
“pumping effect”)
● The function to constitute the braking circuit with overloading overflow valve, and apply the braking
force on rotation of plunger motor, so as to brake the motor gradually.
● In order to enable the parking brake to be released by its own pressure, the shuttle valve function is
selected as high pressure.
● The structure of standard double balance valve is as indicated in the figure below. The operating
principle is described as follows by taking the standard double balance valve as an example.
A. Stop state
● When the main valve is in neutral state (the motor stops), since there is no pressure at ports p1and P2,
the ports m1and M2 will be locked up by valve core (1) and one-way valve (2) (the oil ports will be
closed), and the motor will not run.
Oil way B
Oil way C2
Oil way C1
Orifice D3
Orifice D1
Damping chamber A2
Damping chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
Figure 4-105

B. When the motor is started

● When the hydraulic oil of main pump output enters via the port P1 of double balance valve, the one-
way valve (2-1) will push leftwards the spring (3), the oil way C1 will be opened, and the hydraulic oil
will enter the plunger motor via port M1 and try to make the motor rotate. Meanwhile, the oil returning
from plunger motor will flow back to double balance valve via port M2, but will be blocked by one-way
valve (2-2), so that the output pressure of main pump will increase. Therefore, the pressure on port P1
side will increase, the hydraulic oil will act on spring chamber 1 and damping chamber A1 via orifice
(4-1) and one-way valve (5-1), the force in proportion to pressure will be generated and push the
spring (7-2) on opposite side, and then push the plunger (1) rightwards. At that moment, the oil
returning from port M2 will generate back pressure on port M2 via oil way B on gap around plunger (1),
flow through port P2 and main valve and return to oil tank, so that the motor will begin to slewing.
Oil way B
Oil way C2
Oil way C1
Orifice D3
Orifice D1
Damping chamber A2
Damping chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
Figure 4-106
C. Balancing function
● When the motor is forced by external load to swivel at excessively-high speed during operation, the
pumping effect of plunger motor will occur, and then the motor will become out of control. At that
moment, the port P1 will act as the suction side of pumping effect, so that the pressure will reduce.
Meanwhile, the pressure of spring chamber 1 and damping chamber A1 will also reduce, and thus the
plunger (1) will move leftwards under the action of spring (7-2), so as to close the oil way B and the oil
way on suction side. After the oil way B is closed, the pressure on port P1 side will increase sharply
owing to hydraulic oil supplied by main pump, so that the plunger (1) will move rightwards again. As a
result, when the pumping effect is caused by external load, the slight movement of plunger (1) will
ensure that the oil way B maintains a certain opening area. Therefore, the swiveling speed of motor
will be maintained at the level corresponding to the flowrate of main pump, so as to prevent the
situation that the motor becomes out of control owing to vacuum in hydraulic oil way.

D. Braking of motor
● The double balance valve and the overloading overflow valve constitute the braking circuit. When the
main valve returns to neutral position, the hydraulic oil of main pump output will be cut off, and the
pressure at ports P1 and P2 will be the same. Therefore, the plunger (1) will move towards neutral
position move, and the opening area of oil way B will reduce. Meanwhile, under the action of inertial
force of external load, motor will still try to run (pumping effect), so that the pressure at port M2 will
increase and act as the braking force for rotation of motor. When the pressure at port M2 reaches the
set pressure of overflow valve (8), the cone valve (8-1) at port M1 will overcome the force of spring (8-
2) and move leftwards, so that the hydraulic oil will flow to port M1 side. In this way, the impact
generated by inertial energy on port M2 side will be controlled, and the generation of vacuum will be
prevented on port M1 side.
Oil way B
Oil way C2
Oil way C1
Orifice D3
Orifice D1
Damping chamber A2
Damping chamber
A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
Figure 4-107

E. Shuttle valve function used for selection of high pressure

● The double balance valve has the shuttle valve function to select high pressure, and can be used to
release the parking brake. When the hydraulic oil is supplied to port P1 side, the plunger (1) move
rightwards. At that moment, the oil discharge way F in motor housing will be closed, the oil way D
leading to cylinder chamber E of parking brake will be opened, and the hydraulic oil will flow to oil way
G via orifice and finally enter the cylinder chamber E of parking brake, so as to release the parking
brake. In addition, when the motor stops, the plunger (1) will return to neutral state, the oil way D will
be closed, and the oil discharge way F in motor housing will be opened, so that the hydraulic oil in
parking brake cylinder E will be led into oil discharge way in motor housing, and the parking braking
function will work.
Oil way D
Oil way D
Oil way F
Orifice
Oil way F
Oil way D Oil way G Oil way G Cylinder
chamber E
Figure 4-108

Operation of parking brake

1) When Travelling Begins
● When the travelling control rod is operated, the
pressure oil from pump will open the slide valve
(10) in backpressure valve, open the oil way to
parking brake, and flow into chamber A of
brake piston (12). The pressure oil will
overcome the force of spring (11), and push the
piston (12) leftwards in the direction of arrow.
● When the above-mentioned situation occurs, Travelling
the force which pushes the pad (13) and disc control valve
(14) together will disappear. As a result, the
pad (13) will be separated from disc (14), and
thus the braking will be released.
Figure 4-109
2) When Travelling Stops

● When the travelling control rod is at the middle
position, the slide valve (10) of backpressure
valve will return to the middle position and the
oil way to parking brake will be closed. The
pressure oil in chamber A of brake piston (12)
will be charged into housing from orifice in
brake piston, and the brake piston (12) will be
pushed to right side by spring (11) in the
direction of arrow. Therefore, the plate (13) and Travelling
disc (14) will be pushed together, so as to apply control valve
the brake. When the brake piston returns to
original position, the pressure oil will flow
through a throttle valve in slow return valve (22)
and provide a delay, so as to ensure that the
brake will still be effective after this machine Figure 4-110
stops.

Operation of brake valve

● The brake valve is composed of a safety oil- Travelling
suction valve (8A) and a balance valve (18), as control valve
indicated in the right figure. The function and
operation of every part are introduced as
follows.
Figure 4-111
1) Balance valve and one-way valve

Functions
● When this machine is travelling down a slope,
the weight of this machine will try to make the
speed of this machine higher than the speed of
motor. Therefore, if this machine travels under
the circumstance that the engine is running at
low speed, the motor will rotate under unloaded
condition, and this machine will become out of
control. This is very dangerous. In order to
prevent this situation, the valve will act, so as to
make this machine travel in accordance with
the engine speed (pump flowrate).
Operation during Supply of Pressure Oil Travelling

control valve
pressure oil from control valve will be
transmitted to oil port PA. The pressure oil will
push open the safety oil-suction valve (8A) and
flow into oil outlet port MB of motor from oil inlet
port MA of motor. However, the oil transfer port
of motor will be closed by safety oil-suction
valve (8B) and slide valve (19), so that the
pressure on oil supply side will increase (as
indicated in right figure).
Figure 4-112

● The pressure oil on oil supply side will flow into Travelling
chamber S1 from orifices E1 and E2 in slide control valve
valve (19). When the pressure in chamber S1 is
higher than the changeover pressure of slide
valve, the slide valve (19) will be pushed
rightwards in the direction of arrow. Therefore,
the oil port MB and oil port PB will be
connected, the oil outlet port of motor will be
opened, and the motor will begin to rotate (as
Figure 4-113
Operation of Brake when Machine Travels down a Travelling

Slope control valve
● When travelling down a slope, if this machine is

out of control, the motor will run under
unloaded condition, the pressure at oil inlet of
motor will reduce, and the pressure in chamber
S1 will also reduce via orifices E1 and E2.
When the pressure in chamber S1 reduces to
the level which is lower than the changeover
pressure of slide valve, the slide valve (19) will
be pushed by spring (20) to left side as
indicated by arrow, and the oil outlet port MB
will be throttled. Therefore, the pressure on oil
outlet port side will increase, and the resistance
for rotation of motor will be generated, to
prevent this machine from getting out of control. Figure 4-114
On the other hand, the slide valve will move to
the position where the pressure at oil outlet port
MB is balanced with the pressure at oil inlet
port, and then the weight of this machine will
generate a force. It will throttle the oil way of oil
outlet port and control the travelling speed on
the basis of the flowrate of pump (as indicated
in right figure).

2) Safety valve
Functions
● When the travelling stops (or this machine is travelling down a slope), the oil way of oil inlet/outlet port
of motor will be closed via balance valve, but the motor will still rotate owing to inertia, so that the
pressure at oil outlet port of motor will be abnormally high and may damage the motor or pipe. The
safety valve will release this abnormal pressure and transmit it to oil-inlet side of motor, so as to
prevent the equipment from getting damaged.
Operations Travelling
control valve
a) When the travelling stops (or during travelling
down a slope or turning right)
● When the pressure at oil inlet port of motor
(pressure PA) reduces, the pressure in
chamber S1 will also reduce. When the
pressure is lower than the changeover pressure
of slide valve, the slide valve will return to the
left side via spring (20), and the oil way B1 of
oil outlet port will be throttled. When such
situation occurs, the motor will still rotate under
the action of inertia, so that the pressure at oil
outlet port (pressure MB) will increase (as
Figure 4-115
• If this pressure is higher than the set pressure

of safety oil-suction valve (8A), the valve core
will be opened. The oil will flow through the
large-groove port A1 in slide valve (19) of
balance valve, and flow into the chamber MA in
opposite oil way (as indicated in the right
figure).
Valve core
Figure 4-116

When the travelling commences (or during normal Travelling

travelling) control valve

pressure oil from pump will move the slide
valve (19) of balance valve to right side. When
such situation occurs, the oil way to safety oil-
suction valve will become the oil way which
passes through small-groove port B2 in slide
valve of balance valve. Therefore, a high
pressure difference will be generated, and the
pump pressure will increase so as to provide a
high traction force (as indicated in right figure).
Figure 4-117
3) Overloading overflow valve
● The structure of overflow valve is indicated in
the right figure. This overflow valve is an area
difference type direct-action overflow valve, and
has the damping function to reduce the impact
generated when the engine is started and the
brake is applied.
Figure 4-118
A. Action principle and function of overflow valve
● When the main valve acts and thus the motor
begins to run or stops and the pressure in front
of cone valve (2-9-2) exceeds the set pressure,
the force of spring (2-9-5) will be overcomed,
the cone valve (2-9-2) will move rightwards and
leave the valve seat (2-9-3), and the high-
pressure oil in front of cone valve (2-9-2) will
flow to low-pressure side. As a result, the
impact generated by inertial energy on high-
pressure side will be controlled, and the
generation of vacuum will be prevented on low-
pressure side.
Figure 4-119

B. Damping function
● When the overflow valve begins to act, the Area S2
damping piston (2-9-9) will move to left side,
and thus the low pressure can be maintained in
spring chamber D. At that moment, the
pressurized area S1 of cone valve (2-9-2) will
be much higher than the pressurized area (S1-
S2) set for overflow valve in normal state.
Therefore, When the damping piston (2-9-9) is
moving, the action pressure of overflow valve
will be maintained at about 1/3 of set pressure Area S1 Spring
in normal state, to absorb the impact caused by chamber D
inertial energy on high-pressure oil way side.
After the movement of damping piston is
completed, the pressure in spring chamber D
will increase, the pressure in front and behind Figure 4-120
cone valve (2-9-2) will be equal, and the
overflow valve will work at the set pressure for
normal state. As mentioned above, the overflow
valve will use the 2-phase action to reduce the
impact generated when the motor starts and
brakes, to provide the good operability.
Pressure
Damping mode Time
Figure 4-121

● Repair reference for motor parts

Applicable Location inspected and
Permissible critical value Key points for repair • handling
parts tested
If the sliding face of sliding
Roughness 0.8a: The surface is rough, shoe has been ground, or the
1. Sliding face of sliding
and there is any scratch of which the scratch can’t be repaired,
shoe
depth exceeds 0.02mm. please replace the 4 cylinder
body assemblies.
Roughness 1.2a: The surface is rough,
2. Outside diameter of
1-4-2 Plunger and there is any scratch of which the
plunger
assembly depth exceeds 0.02mm..
3. Outside diameter of
Replace the 4 cylinder body
plunger and cylinder
Clearance 0.060. assemblies.
body 4-1
Inner diameter
4. Clearance of ball head
Clearance 0.4.
of sliding shoe
If the sliding face of sliding
Roughness 0.8a: The surface is rough, shoe has been ground, or the
1. Valve plate and sliding
and there is any scratch of which the scratch can’t be repaired,
face
depth exceeds 0.02mm.. please replace the 4 cylinder
body assemblies.
Roughness 1.6a: The surface is rough,
2. Inside diameter of shaft
and there is any scratch of which the
hole
1-4-1 Cylinder depth exceeds 0.02mm..
body 3. Inside diameter of shaft
hole and plunger 4-2
Clearance 0.060. Replace the 4 cylinder body
Outside diameter of
assemblies.
assembly
The span of round bar is less than 38.749
4. Spline on mating portion (diameter of pin used in testing: φ
of shaft 3.333(V1=2.80)) or is broken or
damaged.
32 If the sliding face is ground,
1-21 Oil Roughness 0.8a: There is scratch of
or the scratch can’t be
distribution 1. Sliding face which the depth exceeds 0.02mm on
repaired, please replace the
disc sliding face, or the sliding face is burnt.
22 valve plates.
1-4-3
Mounting
Roughness 0.8a: There is scratch of Replace the mounting plate,
plate
1. Sliding face which the depth exceeds 0.02mm on and fix the retaining
1-4-4
sliding face, or the sliding face is burnt. mechanism.
Retaining
mechanism
1-4-1 If the sliding face is
Roughness 0.8a: The sliding face is
ground, or the scratch can’t be
1. Sliding face abnormally worn or there is scratch of
repaired, please replace 22
which the depth exceeds 0.02mm.
valve plates.
1-5 Roughness 1.6a.
swashplate 2. Assemble the hole on There is scratch of which the depth is
steel ball more than 0.02m on sphere or the
Replace the swashplate.
surface is rough.
3. Assemble the hole on
Depth of sphere 14.5.
steel ball
Roughness 1.6a: There is sliding mark on
1. Outside diameter of lip of oil seal, there is any scratch of
Replace the swashplate.
sliding portion of oil seal which the depth exceeds 0.02mm, or the
surface is rough.
1-3 shaft 2. Mating spline of cylinder
(diameter of pin used in testing: φ3.00) or
body
is broken or damaged.
Replace the shaft.
3. Connection of driving
(diameter of pin used in testing: φ3.33) or
gear
is broken or damaged.

Applicable Key points for repair •

Location inspected and tested Permissible critical value
parts handling
1. Appearance and dimension Height 38.2
2. Sliding face Roughness 2.5a
1-15 Brake
There is any scratch of which the Replace the brake plunger.
plunger
3. Appearance depth exceeds 0.02mm or the
surface is rough.
1. Appearance and dimension Thickness 3.2
There is relatively deep scratch on
1-13 Disc plate Replace the disc plate.
2. Appearance sliding face or the friction material
peels off.
1-8 Ball The situation such as peeling or
1. Rolling face
bearing fracture happens.
Replace the ball bearing.
1-9 Ball The rotation is abnormal (abnormal
2. Action
bearing noise • uneven rotation)
If the sliding face has been
Roughness 1.6a: The surface is
ground or the scratch thereon
1. Sliding face of sliding shoe rough, or there is any scratch of
can’t be repaired, please
which the depth exceeds 0.02mm.
replace the flange disc.
The roughness is 1.2a, the surface
1-7 Plunger 2. Outside diameter of plunger is rough, and there is any scratch of
assembly which the depth exceeds 0.02mm.
3. Outside diameter of plunger
Replace the flange disc.
and inside diameter of flange Clearance 0.040.
disc component
4. Clearance of ball head of
Clearance: 1.0.
sliding shoe
Roughness 0.8a: there is any
1. Outside diameter of plunger scratch of which the depth exceeds
1-2-2 Plunger 0.02mm, or the surface is rough. Replace the valve plate
assembly 2. Outside diameter of plunger subassembly.
and inside diameter of valve Clearance 0.060.
plate
Roughness 0.8a: There is any
1. Assemble the plunger
scratch of which the depth exceeds
assembly
0.02mm, or the surface is rough.
2. Inside diameter of valve plate
and outside diameter of Clearance 0.060
plunger
1-2-1 Valve 3. Install the slide valve core Replace the valve plate
plate assembly subassembly.
0.02mm, or the surface is rough.
4. Inside diameter of slide valve
plate and outside diameter of Clearance 0.060.
valve core
5. Sliding portion of movable There is the scratch of which the
plunger and valve set of depth exceeds 0.02mm, or the
overflow valve assembly surface is rough.
1. Outside diameter of valve
1-2-9 Slide core
0.02mm, or the surface is rough. Replace the accessories of
valve core
2. Outside diameter of slide valve plate.
assembly
valve core and inside Clearance 0.060.
diameter of valve plate
1-2-7-9 There is the scratch of which the
1. Sliding portion of valve plate
Movable depth exceeds 0.02mm, or the
and valve seat
plunger surface is rough. Replace the overflow valve
There is the scratch of which the assembly.
1-2-7-1 1. Sliding portion of movable
depth exceeds 0.02mm, or the
housing plunger (outside diameter)
surface is rough.
1-4-7 spring 1. Appearance and dimension Free length 61.0
It is deformed or the surface of steel
2. Appearance
wire is damaged

Applicable Key points for repair •

Location inspected and tested Permissible critical value
parts handling
1-18 spring 1. Appearance and dimension Free length 39.0
It is deformed or the surface of steel wire
2. Appearance
is damaged
1-20 spring 1. Appearance and dimension Free length 41.5
2. Appearance
is damaged
2. Appearance
is damaged
2. Appearance
is damaged
Every O-ring Replace every O -ring and
During dismantlement
and oil seal oil seal

Control system
Figure 4-102
1. Travelling PPC valve 8. Hydraulic pump
2. Left Running Control Lever 9. Main control valve
3. Right Running Control Lever 10. Electromagnetic valve
4. Right PPC valve 11. Left working device control rod
5. Right working device control rod
6. Accumulator
7. Transition block

Leading valve
Manual pilot valve
Figure 4-123
P: From overflow valve of pilot pump
P1 : Left hand pilot valve: extension of bucket arm/right pilot valve: lowering of boom
P2 : Left pilot valve: bucket arm retraction /right pilot valve: boom lifting
P3 : Left pilot valve: left slewing/right pilot valve: inward folding of bucket
P4 : Left pilot valve: right slewing/right pilot valve: outward unfolding of bucket
T: To oil tank

Figure 4-124
1. Valve rod 7. Joint
2. Adjusting spring 8. Plate
3. Central spring 9. Locator
4. Piston 10. Valve body
5. Disc
6. Nut (used for connection of control rod)

Operations
1. At middle position
● The oil ports (A) and (B) of control valve as well
as the oil ports (P1) and (P2) of PPC valve will
be connected with discharge chamber (D) via
flow-through groove (f) of valve rod (1).
Pilot
pump
2. During the fine control (middle position →fine

control)
Control valve
● When the piston (4) is pushed by disc (5), the
locator (9) will be pushed, and the valve rod (1)
will also be pushed by adjusting spring (2) and
move downwards. Figure 4-125
● The flow-through groove (f) will be cut off from
discharge chamber (D), and will be connected
with pump pressure chamber (PP) almost at
the same time. The pilot pressure oil of control
pump will be led to oil port (A) from oil port (P1)
via flow-through groove (f). When the pressure
at oil port (P1) becomes relatively high, the
valve rod (1) will be pushed back, and the flow-
through groove (f) will be cut off from pump
pressure chamber (PP). Meanwhile, it will be
connected with the discharge chamber (D), so
as to release the pressure at oil port (P1). As a
result, the valve rod (1) will move upwards and
downwards, until the force of adjusting spring
(2) is balanced with the pressure at oil port
(P1).
● The position relationship between valve rod (1) Pilot
and valve body (10) [The fine control hole (f) is pump
located in middle between discharge chamber
(D) and pump pressure chamber (PP)] will
remain unchanged before the locator (9)
contacts the valve rod (1).The adjusting spring
Control valve
(2) will contract in proportion to the stroke of
control rod. The pressure at oil port (P1) will
also increase in proportion to the stroke of
control rod. As a result, the control valve rod Figure 4-126
will move to the position where the pressure of
chamber (A) (as same as the pressure at oil
port (P1)) is balanced with the force of return
spring in control valve rod.

3. Fine control (when the control rod returns)

● When the disc (5) begins to return, the valve
rod (1) will be pushed upwards by the force of
central spring (3) and the pressure at oil port
(P1).
● Therefore, the flow-through groove (f) will be
connected with the discharge chamber (D), and
the pressure oil at oil port (P1) will be released.
● If the pressure at oil port (P1) excessively
reduces, the valve rod (1) will be pushed
downwards by the adjusting spring (2).
● The flow-through groove (f) will be cut off from
the same time. Before the pressure at oil port Pilot
(P1) resumes to the level equivalent to that pump
indicated by position of control rod, the
pressure will be provided.
● When the valve rod of control valve returns, the
oil in discharge chamber (D) will flow in through Control valve
the from flow-through groove (f) in valve on
nonworking side. This oil will flow through oil
port (P2) and enter the (B) chamber, so as to fill
this chamber with pressure oil. Figure 4-127
4. At full stroke
● The disc (5) will push downwards the piston (4),
and the locator (9) will push downwards the
valve rod (1).
● The flow-through groove (f) will be cutoff at the
with the pump pressure chamber (PP).
● Therefore, the pressure oil from self-pressure-
reducing valve will flow into (A) chamber from
oil port (P1) via flow-through groove (f), so as to
push the control valve rod.
● The oil returning from chamber (B) will flow to
discharge chamber (D) from oil port (P2) via
flow-through groove (f).
Pilot
pump
Control valve
Figure 4-128

Traveling leading valve
Figure 4-129
P: From pilot pump P4: Right forward travelling

P1: Left backward travelling P5: Travelling signal
P2: Left forward travelling P6: Travelling signal
P3: Right backward travelling T: To oil tank

Figure 4-130
1. Baffle
2. Valve body
3. Piston
4. Protective ring
5. Central spring
6. Adjusting spring
7. Valve

Work Process
Operations
1) At middle position
● The oil ports (A) and (B) of control valve as well
as the oil ports (P1) and (P2) of PPC valve will
be connected with discharge chamber (D) via
fine control hole (f) of valve rod (1).
Pilot pump
2) Fine-tuning control (middle position →fine-

tuning control) Control valve
● When the piston (4) is pushed by control rod

(5), the locator (9) and the valve rod (1) will
also be pushed by adjusting spring (2) and Figure 4-131
move downwards.
● When the fine control hole (f) is cut off from
discharge chamber (D), it will be connected
the same time.
● The pilot pressure oil of control pump will be led
into oil port (A) from oil port (P1) via fine control
hole (f).
● When the pressure at oil port (P1) becomes
relatively high, the valve rod (1) will be pushed
back, and the fine control hole will be cut off
from pump pressure chamber (PP). Meanwhile,
it will be connected with discharge chamber
(D), so as to release the pressure at oil port
Pilot pump
(P1).
● As a result, before the force of adjusting valve
rod (2) is balanced with the pressure at oil port
(P1), the valve rod (1) will move upwards and Control valve
downwards.
● The position relationship between valve rod (1) Figure 4-132
and valve body (10) [The fine control hole (f) is
located in middle between discharge chamber
(D) and pump pressure chamber (PP)] will
remain unchanged before the locator (9)
contacts the valve rod (1).
● The adjusting spring (2) will contract in
proportion to the stroke of control rod.
● The pressure at oil port (P1) will also increase
in proportion to the stroke of control rod.
● In this way, the valve rod of control valve will
move to the position where the pressure of
chamber (A) (as same as the pressure at oil
port (P1)) is balanced with the force of return
spring in rod of control valve.

3) Fine control (when the control rod returns)

● When the disc (5) begins to return, the valve
rod (1) will be pushed upwards by the force of
central spring (3) and the pressure at oil port
(P1).
● Therefore, the fine control hole (f) will be
connected with the discharge chamber (D), and
the pressure oil at oil port (P1) will be
discharged.
● If the pressure at oil port (P1) excessively
reduces, the valve rod (1) will be pushed
downwards by the adjusting spring (2).
Pilot pump
● The fine control hole (f) will be cut off from
discharge chamber (D), and be connected with
pump pressure chamber (PP).
● Before the pressure at oil port (P1) resumes to Control valve
the level equivalent to that indicated by position

of control rod, the pressure will be provided.
Figure 4-133
● When the valve rod of control valve returns, the
oil in discharge chamber (D) will flow in from
the fine control hole (f) in valve at nonworking
side. This oil will flow through oil port (P2) and
enter the (B) chamber, so as to fill this chamber
with pressure oil.
4) At full stroke
● The disc (5) will push downwards the piston (4),
and the locator (9) will push downwards the
valve rod (1).
● The fine control hole (f) will be cut off from
with pump pressure chamber (PP).
● Therefore, the pressure oil from self-pressure-
reducing valve will flow into (A) chamber via
fine control hole (f) and oil port (P1), so as to
push the control valve rod.
● The oil returning from chamber (B) will flow to Pilot pump
discharge chamber (D) from oil port (P2) via
fine control hole (f).
Control valve
Figure 4-134

Electromagnetic valve
Pilot valve locking, bucket interflow, travelling speed
Figure 4-135
A1 Pilot locking electromagnetic valve

A2 High/low speed change-over electromagnetic valve
A3 Boom-slewing priority electromagnetic valve
A4 Boom lifting control electromagnetic valve
A5 Interflow electromagnetic valve of boom 2
A6 Boom-bucket priority electromagnetic valve

Accumulator
1. Air plug
2. Casing
3. Seat valve core
4. Retaining bracket
5. Leather reservoir
6. Oil port
Gas capacity: 500 cc (for PPC)
Figure 4-136

Pilot oil filter
Model
Pressure
Precision
Figure 4-137
1. Nameplate Technical Specification
2. Top cover Maximum flowrate :40 L/min
3. O-ring Filtration precision :10 um
4. Seal ring Operating pressure :20 Mpa
5. Filter Maximum operating pressure :40 Mpa
6. Casing Pressure loss :0.05 Mpa
Maximum permissible differential pressure :1 Mpa
Specification of O-ring of oil inlet/outlet port: 30×3.1

Working Device
Size of component
Figure 4-138

SY750H
Unit: mm
Tolerance
Standard Standard Clearance
Number Inspection Item Hole/before Hole/after clearance Measures
dimension Shaft limit
pressed pressed
Clearance between
axis pin which
-0.043 +0.584 +0.433 0.334～
1 connects boom 140 1.0
-0.083 +0.521 +0.291 0.516
with slewing table
and bushing
Clearance between
axis pin which
-0.043 +0.584 +0.426 0.331～
2 connects boom 140 1.0
-0.083 +0.521 +0.288 0.509
with bucket arm
and bushing
Clearance between
axis pin which
-0.036 +0.524 +0.399 0.301～
3 connects bucket 114 1.0
-0.071 +0.461 +0.265 0.470
arm with rocker Replace
and bushing the axle
Clearance between sleeve or
axis pin which axis pin
-0.043 +0.584 +0.426 0.326～
4 connects bucket 130 1.0
-0.083 +0.521 +0.283 0.509
arm with bucket
and bushing
Clearance between
axis pin which
-0.043 +0.584 +0.432 0.334～
5 connects 130 1.0
-0.083 +0.521 +0.291 0.515
connecting rod with
bucket and bushing
Clearance between
axis pin which
-0.043 +0.584 +0.428 0.329～
6 connects rocker 130 1.0
-0.083 +0.521 +0.286 0.511
with connecting rod
and bushing
Clearance (a) of Adjusting
7 1.0-1.5
bucket gasket

Dimension of bucket arm
Figure 4-139

SY750H Unit: mm
Number Standard dimension Tolerance
+1.0
1 162
+0.5
+0.1
2 Φ140
0
+1.0
3 157
+0.5
+0.1
4 Φ130
0
+0.5
5 522
0
+0.063
6 Φ140
0
+0.5
7 551 0
+0.2
8 Φ130
+0.1
0
9 520
-0.5
+0.159
10 Φ100
+0.072
0
11 520
-0.5
+0.185
12 Φ130
+0.085
+1.5
13 550
+1.0
+0.148
14 Φ130
+0.085
15 3000 ±3
16 2235 —
17 680 ±0.5
18 765 ±0.5
19 900 ±0.5
Minimum 2210
20
Maximum 3665

Dimension of bucket

SY750H Unit: mm
Number Standard dimension Tolerance
1 680 ±0.5
2 2235 —
3 210 —
4 210 —
5 104 0 —
+0.5
6 576
0
+1.5
7 550
+1.0
+0.269
8 Φ130
+0.122
+0.063
9 Φ150
0
10 644 ±1.0
+1.5
11 550
+1.0
12 780 ±1.0
+0.148
13 Φ130
+0.085

Air conditioning system
Figure 4-141
1. Warm water guide A. Outside air
2. A/C compressor (DENSO.2) B. Inside air
3. Refrigerant pipeline C. Warm air/cool air
4. Condenser (SG447750-A040)
5. Reservoir (DENSO.4)
6. Warm water return pipe
7. A/C unit
8. Air duct

Arrangement diagram of A/C elements
Figure 4-142
1. Sunshine sensor
2. Control Panel
3. A/C unit
4. Condenser
5. Compressor

A/C control panel
Figure 4-143
1. OFF Switch 5. Setting Switch of Automatic Mode
2. Setting Switch of Fan Speed 6. Internal/external air selector switch
3. Temperature Setting Switch 7. Liquid crystal display area
4. Air outlet mode setting switch 8. A/C Switch
Remarks:
After the automatic mode setting switch (5), inside/outside air changeover switch (6) and A/C switch (8) are
turned on, the light on upper portion of corresponding switch will come on.

Schematic diagram for circuit
Figure 4-144

Wire Wire
Wire no. diameter/wire Wire color Wire no. diameter/wire Wire color
color symbol color symbol
B Black 0.5VW Purple white stripe
Br(R) Brown 0.5YB Yellow +black stripe
0.85W White 0.5WO White +orange stripe
RL Red +blue stripe 0.5PB Pink black stripe
G Green 0.5VR Purple red
0.5BL Black blue stripe 0.5BG Black green stripe
0.5R Red +blue stripe 0.5WY White +yellow stripe
0.5Y Yellow 0.5WR White red stripe
0.5BR Black red stripe 0.5BrW Brown white stripe
0.5BrY Brown yellow stripe 0.5GO Green + orange stripe
0.5BY Black yellow stripe 0.5Sb Light blue
0.5GW Green + white stripe 0.5OW Orange white stripe
0.5LO Blue orange stripe 1.25 V Purple
0.5PG Pink green stripe 1.25RG Red green stripe
0.5RY Red yellow stripe 1.25RW Red + orange stripe
0.5BW Black + white stripe 0.85GL Green +blue stripe
Light green + red
0.5LgR
stripe
Code Name Code Name Code Name

Condenser high speed
ACM A/C amplifier FUCD Condenser fuse RLCH
relay
BAT Power supply FUM A/C main fuse RLSF Protective relay
Speed-regulating
BLC G Alternator SSD Sunshine sensor
resistor
Condenser pressure
CMB Power relay MAM A/M servo motor SPCD
switch
High/low pressure
D Diode MB Blower motor SPHL
switch
D1 Diode 1 MCD Condenser motor SW Changeover switch
Internal/external air servo External air thermal
D2 Diode 2 MRF THAM
motor resistor
Anti-frost thermal
ECC Compressor clutch MV1 Air outlet servo motor THF
resistor
Internal air thermal
FL1 Fuse MV2 Front air outlet servo motor THI
resistor
Water temperature
FL2 Fuse RCD Condenser resistance THW
thermal resistor
FUBM Blower fuse RLBM Main relay of blower
RLCC Compressor relay RLCD Condenser relay

Principle for refrigeration

Schematic diagram of refrigeration cycle
Expansion
valve
Cooling air
Low-temperature and
Evaporator low-pressure liquid
(mist)
high-pressure gas
High-temperature
low-pressure gas
Low-temperature
Cooling
Blower motor fan
Indoor air
Outdoor cooling
air
High-temperature and
high-pressure gas
Low-
pressure High-pressure
Condenser
side side Reservoir
Compressor
Hot air
Low-pressure High-pressure
portion portion
Figure 4-145
Schematic diagram of heating cycle
Water tank radiator Water valve switch
Water pump Warm air
Engine
Blower motor
Indoor air
Low-temperature water
High-temperature water
Figure 4-146

Compressor
Figure 4-147
1. Stator 9. Sliding shoe
2. Front radial bearing 10. Front cylinder body
3. Thrust bearing 11. Piston
4. Rear radial bearing 12. Front cylinder head
5. Rear cylinder head 13. Shaft seal
6. Safety valve 14. Main shaft
7. Rear cylinder body 15. Hub
8. Inclined plate 16. Rotor

Operating principle
The 10S15C compressor is adopted. This compressor has 5 plungers, each with one piston at both front
and rear end(10 pistons in total). The rotation of inclined plate will lead to the reciprocating movement of
piston, and then the low-temperature & low-pressure gaseous refrigerant sucked from evaporator will turn
into high-temperature high-pressure state.
Engineering 1 Engineering
2
High-pressure Low-pressure High-pressure Low-pressure
side pipes side pipes side pipes side pipes
Valve plate
Exhaust valve
plate
Main shaft and Air suction

swashplate valve plate
Engineering Engineering
6 3
Engineering 5 Engineering
4
Figure 4-148

Clutch
1. Clutch rotor
2. Stator coil
3. Snap ring
4. Ball bearing
5. Clutch stator
6. Central plate
● The electromagnetic clutch is used to transmit

the torque. When the engine is running, the
compressor does not necessarily work; the
electromagnetic clutch will make the
compressor work only when the air conditioner
is carrying out refrigeration. Figure 4-149
● Operating principle
When the A/C switch is connected, the clutch
coil with electromagnet will generate magnetic
field. As a result, the iron piece will be
attracted, the stator and rotor of clutch will be
engaged with each other, and the main shaft of
compressor will rotate.

Condenser
Figure 4-150
1. Condenser core Functions
2. Condenser bracket ● Through radiation, the high-temperature and
high-pressure gas refrigerant (16kgf/cm²,
3. Bolt with gasket
about 80℃) will be converted into high-
4. Refrigerant inlet temperature and high-pressure liquid
5. Refrigerant outlet refrigerant (16kgf/cm², about lower than 60℃).

Expansion valve
1. Spring
Evaporator
2. Diaphragm
3. Temperature-sensing bar
4. Needle valve
Principle
● The refrigerant coming from reservoir will be
spouted out from small hole, expand quickly,
form the low-temperature & low-pressure liquid
(mist) and enter the evaporator.
Compressor
Reservoir
Figure 4-151
Evaporator
1. Expansion valve
2. Evaporator
Principle
● The evaporator and condenser have the similar
structure, and both of them are heat exchanger.
The hot air in cab will be sent by blower motor
to evaporator, carry out heat exchange with
surface of evaporator, become cold air after the
heat is absorbed, and then be sent back to cab
via air ducts. The surface of evaporator
absorbs heat → The refrigerant in evaporator
absorbs heat →The refrigerant is evaporated.
The evaporated refrigerant (gas) will be sucked
by compressor.
Figure 4-152

Drier
1. Inlet
2. Outlet
3. Receiver/drier
4. Drying agent
Functions
● Temporarily store the refrigerant
● Eliminate the water in refrigerant
● Filtrate the dust in refrigerant
● Inspect the amount of refrigerant
Figure 4-153

Pressure switch
1. O-ring Pressure
2. Movable connection point

3. Cover
4. Electrical plug & fixed connection point
5. Spring
6. Chamber
7. Film
Function:
● The pressure switch is located between
reservoir and expansion valve (high-pressure
pipe), and is a combined switch (high/low-
pressure combined switch).
● When the pressure is too high, the compressor
will stop.
● The pressure is too low, and low-temperature Figure 4-154
environment stops.
Action features:
Features
More than
High-
0.02Mpa
pressure
action value
Low-pressure
action value
Medium-
pressure
action value

Refrigerant
1. General features of refrigerant
● It has high heat-absorbing ability and is easy to liquefy
● It is neither inflammable nor explosive
● It has stable chemical composition and will not deteriorate
● It is not toxic
● No corrosion
● It will not damage clothing
2. Circulation of refrigerant
● After the refrigerant is evaporated in evaporator, it will be converted from gaseous form to liquid
form by compressor and condenser, so as to achieve the circulation of refrigerant.
Low-pressure side (inlet) of compressor: low-
temperature \low-pressure \gas \pressure,
Compressor temperature: 2kgf/cm², about 8℃
Suck air → discharge Evaporator
air Absorb heat →emit
cool air
High-pressure side (outlet) of compressor: low-

temperature \low-pressure \gas \pressure,
temperature: 16Kgf/cm², about 80℃
Condenser (outlet): low temperature \low

pressure\mist\pressure, temperature:
2kgf/cm2, about 0-2℃left right
Condenser (outlet): low temperature \low

pressure \liquid \pressure, temperature: Expansion valve
Condenser 16kgf/cm2, about 60℃ High pressure →low pressure
Through radiation: gas High temperature →low
refrigerant →liquid temperature
Liquid →mist
refrigerant

● Circulation principle of refrigerant (pressure-enthalpy diagram)
Completion of Circulation curve of refrigerant

liquefaction
Start of
liquefaction
Throttling Condenser
point
Condensation
Liquid process
Expansion
Compressi
throttling
Expansion valve Compressor

on process
Evaporation process
Evaporator
Gas-liquid mixed state

Gasification
U-internal p - Pressure V-specific A- mechanical

energy volume equivalent of
heat
Figure 4-155

3. Filling of refrigerant
● Filling method and filling amount of
refrigerant:
(1) Refrigerant: HFC-134a;
(2) Filling amount of refrigerant: 1150±50
g (reference);
(3) Filling method for refrigerant: It is
prohibited to fill liquid refrigerant from
low-pressure side. If the operation fails
and it is necessary to carryout
operation again, please drain the
refrigerant filled, and then fill it again.
Figure 4-156
● Inspect the flowing state of refrigerant in Observation

A/C circulation system through the glass
observation glass:
(1) Appropriate filling: Almost no bubble
can be seen when the refrigerant is
flowing. When the engine is
accelerated from idle speed to Filling of appropriate
amount
1500rmp, the bubble will disappear
and the refrigerant will be transparent;
(2) Excessive filling: No bubble can be
seen when the refrigerant is flowing;
Filling of insufficient
(3) Insufficient filling: Bubble is often seen amount
when the refrigerant is flowing.
Figure 4-157

4. Vacuumization operation
● Reason for vacuumization
When installing the A/C device, the most important is to ensure that no water exists in device. The
refrigerant (r134a) used by air conditioner is easily soluble in water. If there is a little of water in device,
the small hole on expansion valve may get frozen during use, and the compressor valve may get rust.
Therefore, before filling the refrigerant, please clear away the water in refrigerating system. In order to
minimize the contents of residual water in refrigerating system, please vaporize and clear away the
water in the device by means of vacuumization, and there is no better method.
● Steps for vacuumization

(1) Connect the manifold pressure gauge; Valve Low-pressure gauge
More than
i) Close the high-pressure valve Open Open 750mmhg Close Close
(HI) and low-pressure valve (LO) Low-pressure

gauge High -pressure gauge
of manifold pressure gauge.
ii) Connect the gas-filling hose (red, Low-pressure
blue) to the auxiliary valve of valve (opened) High-pressure valve
compressor. Green (opened)
Red hose ——high-pressure side Red
(mark D)
Blue
Blue hose ——low-pressure side
(mark S) Compressor
★ The auxiliary valve for Vacuum pump

(rotating)
compressor shall be installed on
front end of gas filling hose where
there is L-shaped bend, otherwise Figure 4-158
the valve in compressor can’t be
opened. In addition, be sure not
to connect the high-pressure side
and low-pressure side incorrectly.
iii) Connect the gas-filling hose
(green) in the middle of manifold
pressure gauge to vacuum pump.
(2) Vacuumization
i) Open the high-pressure valve (HI)
and low-pressure valve (LO) of
manifold pressure gauge;
ii) Turn on the vacuum pump switch,
and carry out the vacuumization
operation (for about 15 minutes);
iii) When the indication of negative
pressure on pressure gauge
(namely vacuum degree) is
higher than 750 mmHg, turn off
the vacuum pump switch, and
close the high-pressure valve and
low-pressure valve of manifold
pressure gauge.

(3) Inspection on seal Valve

Set aside for more
Low-pressure
i) Keep the high-pressure valve and than 5 minutes
Close Close
gauge
low-pressure valve of manifold The indicating
needle will return
pressure gauge closed for more Low-pressure gauge
to zero
than 5 minutes, and confirm that
the pressure indication will not
return to zero;
ii) When the indicating needle of The indicating
needle will
pressure gauge returns to the return to zero Tightening of pipe
position near zero, it means that joint
there is leakage. Therefore,

please further correct the
connection of pipe, tighten it up, Figure 4-159
and then carry out the
vacummization operation again,
until the leakage is eliminated.
(4) Inspection on gas leakage Valve
i) Connect the gas-filling hose Close Close
(green) which is originally

connected with vacuum pump to
freon tank;
ii) Connect the gas-filling hose Gas-release
(green) with manifold pressure valve
Open the valve
Bleed the air
gauge, open the valve for freon for freon tank
pipe, press the gas-release valve
on pressure gauge (Please don’t
directly press the gas-release
valve with hand, otherwise the Blue
refrigerant may spout out and Gas-filling hose
Red (green)
cause frostbite), so as to bleed
the air from gas source under the Connect the Freon tank
pressure of refrigerant (Loosen compressor
the gas-release valve when the
sound “zi” is heard); Figure 4-160
iii) Fill the refrigerant until the Valve
Indication of low-
pressure gauge: 1kg
indication on low-pressure gauge
is 1kgf/ cm2. At that moment, the Low-pressure Close Open Close Close
high-pressure valve of manifold gauge

Indication: 1kgf/cm2
pressure gauge will be opened.
Please close the high-pressure Open the high-
Low-pressure
valve after the filling is completed; valve (closed) pressure valve
Valve for freon tank
iv) For the sake of safety, please use (opened)
the leakage tester to inspect
whether there is leakage in
refrigerating system;
Freon tank Compressor
v) If there is leakage, please carry
out correction (tightening).
Figure 4-161

5. Filling of refrigerant
● After the vacuumization operation is completed, fill the refrigerant into refrigerating system in
accordance with the following provisions:
Inspection on gas leakage
Inspection on gas leakage

Start of vacuumization
End of vacuumization
Performance testing
Filling of refrigerant
refrigerant
Inspection on seal
Filling of
More than 75cm-Hgor
More than about 15 Set aside for The pressure

minutes 5 minutes gauge is
normal
The display on pressure gauge is abnormal

Tightening of pipe mouthpiece (1) When the compressor stops, please fill the refrigerant from high-
pressure side
(2) (2) When the compressor is running, please fill the refrigerant from
Repair the leakage location low-pressure side
● Filling from high-pressure side: Valve

(1) Dismantle the gas-filling hose (green)
Close Close
of manifold pressure gauge from
(Note)
vacuum pump, and connect it to the The refrigerant will emit
freon tank; out when the sound “zi”
is heard
(2) Open the freon tank valve, press down
Gas-release
the gas-release valve on one side of valve Open the valve for freon
manifold pressure gauge, and use the tank
pressure of refrigerant to release the Screw off the
gas in gas-filling hose; flared nut
At that moment, after the refrigerant is

released, loosen the gas-release Blue
Gas-filling hose
valve. It is prohibited to directly press Red (green)
the gas-release valve with hand, so as
to prevent frostbite. Connect the Freon tank
compressor
(3) Under the circumstance that the
engine stops, open the high-pressure
Figure 4-162
valve of manifold pressure gauge and
valve for freon tank, so as to fill one Valve
and a half tanks of refrigerant (about Fill one tank
600g). Close Open
(about 600g) Close Close
(Prohibition)
At that moment, be sure not to run the ● Don’t run the compressor
● Don’t open the low-pressure
compressor; otherwise, the return of Low-pressure valve
refrigerant may lead to explosion of valve (closed) Open the high-
freon tank and hose. Valve for freon tank
pressure valve
(opened)
If the compressor runs under the state
that there is no refrigerant, the
compressor will get damaged.
Therefore, be sure not to run the
compressor.
Please don’t open the low-pressure
valve of manifold pressure gauge Figure 4-163
(otherwise the liquid will be
compressed and the compressor will
be damaged).
(4) Close the high-pressure valve of
manifold pressure gauge and the
valve for freon tank.

● Filling of oil from low-pressure side (re-

High-pressure
filling): valve (closed) ON (opened)
Manifold
(1) Firstly, confirm that the high-pressure pressure
gauge
valve of manifold pressure gauge is
closed;
(2) Start up the engine, and open all
doors; The engine is started
(Note)
(3) Turn on the A/C switch; set the If the high-pressure valve is opened, the
temperature control at the “coolest” freon tank may get cracked, and thus
major injury may occur.
position;
(4) Set the engine speed as 1300- Figure 4-164
1500rpm;
(5) When filling the refrigerant, open the
low-pressure valve of manifold
pressure gauge and the valve for
freon tank, until no bubble is observed
in reservoir;
Note: Fill the refrigerant to the
observation glass
Valve Until no bubble can be seen
Indication of manifold pressure gauge
(reference): Low-pressure Open Close Close Close
2( gauge
High-pressure pressure 13-17kgf/cm when the (1.5~2.5kgf/cm2) High -pressure gauge
(13~17kgf/cm2)
outdoor atmospheric temperature is 30℃);
2 Low-pressure
Low-pressure pressure 1.5-2kgf/cm (when the valve turn on
High-pressure valve
(closed)
outdoor atmospheric temperature is 30℃). Valve for freon (Be sure not to open it)
tank (opened)
(6) After the filling of refrigerant is completed,
close the low-pressure valve of manifold
pressure gauge and the valve for freon
tank;
Compressor
Freon tank (Don’t Operation
(7) Use the leakage detector to carefully
place it upside down)
inspect whether there is any leakage;
Be sure not to open the high-pressure Figure 4-165
valve (HI) of manifold pressure gauge;
otherwise, the high-pressure gas will low
back, the freon tank and gas-filling hose
may break, and thus danger may occur
(major injury);
Be sure not to place the freon tank upside
down. (Under the circumstance that the
filling is carried out with the engine
running). If the freon tank is placed upside
down, the liquid refrigerant will be directly
sucked into compressor, and thus the
liquid will be compressed and damage the
valve and gasket of compressor. Please
place the freon tank vertically and fill the
refrigerant in gaseous form.
(8) When the outdoor atmospheric
temperature is low
If the filling of refrigerant can’t be carried
out owing to the too low outdoor

atmospheric temperature, please heat up Valve

Fill the refrigerant
until no bubble can
the freon tank in warm water at be seen through
observation glass
temperature no higher than 40℃, so as to Open Close Close Close
increase the pressure of refrigerant in

freon tank.
(9) When the outside atmospheric Low-pressure High-pressure
temperature is high valve turn on valve (closed)
Valve for freon
When the outdoor atmospheric tank (opened)
temperature is high, if the electrical fan is
used to cool down the compressor, the
filling work will become smooth.
The
Warm water at temperature no
compressor
higher than 40℃
is running
(It is prohibited to heat up the
feron tank with hot water)
Figure 4-166
● Replace the freon tank: Hand
wheel
During the filling of refrigerant, if the
refrigerant in freon tank is used out, please
replace a new freon tank in accordance with
the following provisions. Gas filling hose
mouthpiece
(1) Close the high-pressure valve and
low-pressure valve of manifold Needle
valve
pressure gauge;
Liner
(2) Lift up the tip and round plate of valve
for freon tank, and dismantle the Round plate
empty tank;
Refrigerant
tank
(3) Mount the new freon tank above freon
tank valve;
(4) Bleed the air in gas-filling hose in Figure 4-167
accordance with the following method:
Valve
i) Firstly tighten up the valve for
freon tank, and then loosen it Slightly Close
When the sound “zi” is heard
slightly; opened
The refrigerant will be drained
Please immediately close the
ii) Slightly open the low-pressure low-pressure valve
valve of manifold pressure gauge;
iii) Press the gas-release valve so as
Slightly loosen the valve
to discharge the refrigerant, and for freon tank
then immediately close the valve Low-pressure
for freon tank and the low- valve
pressure valve of manifold
pressure gauge. Green
Blue
★ It is prohibited to directly press
Red
the gas-release valve with hand,
so as to prevent frostbite. Connect the Refrigerant
compressor tank
(5) Turn the handle of valve for freon tank
so as to open the freon tank, and
continue the fill operation. Figure 4-168

6. Use the manifold pressure gauge to carry out trouble inspection

After the engine is preheated, read the pressure indicated by manifold pressure gauge under the
following conditions.
1) The temperature at air inlet is 30-35℃.
2) The engine speed is 1,500rpm.
3) The blower speed is set as high speed.
4) The temperature control knob is at the coldest position.
5) The “repeated circulation” mode is adopted.
● The refrigerating system is in normal state
Indication of measuring gauge:
Low-pressure end: 0.15-0.25mpa (1.5-2.5kgn/cm2)
High-pressure end: 1.37-1.57mpa (14-16kgn/cm2)
Figure 4-169

● There is water in refrigerating system

Condition: Intermittent refrigeration, or no refrigeration
Figure 4-170
Symptoms of
Possible causes Diagnosis Troubleshooting method
refrigerating system
• The water in refrigerating • The drier is in over-
• Replace the
• When the system is system is frozen in saturated state.
receiver/drier.
running, there will be expansion valve, so that • The water in
• Please eliminate the
vacuum sometimes the circulation stops refrigerating system is
water in system by
and will be normal temporarily. However, frozen in expansion
continuous air bleeding.
pressure sometimes after the ice melts, the valve, which blocks the
at low-pressure end. system resumes to normal circulation in • Fill the new refrigerant of
appropriate amount.
state. refrigerating system.
● The refrigeration is insufficient

Condition: The refrigeration is insufficient
Figure 4-171
Symptoms of refrigerating
system
• Use the leakage detector to
inspect whether there is gas
• Both the pressure at
leakage. If necessary, then carry
high and low-pressure
out repair.
ends is too low • The gas leakage
• • Fill the refrigerant of appropriate
• The bubble is occurs at certain The refrigerant in
amount.
continuously seen position in system is insufficient.
The refrigerant leaks. •
When it is connected with
through observation refrigerating •
measuring gauge, if the pressure
glass system
is close to 0, please set the
• The refrigeration is
system in vacuum state after
insufficient
carrying out inspection and
repair.

● The circulation of refrigerant is poor

Condition: The refrigeration is insufficient
Figure 4-172
Symptoms of refrigerating system Possible causes Diagnosis Troubleshooting method

● Both the pressure at high and ● The dirt in
low-pressure ends is too low. reservoir blocks ● The reservoir ● Replace the
● Dew is generated on pipe from the flowing of is blocked up reservoir
component to reservoir. refrigerant
● The refrigerant does not circulate

Condition: No refrigeration is achieved (intermittent refrigeration under certain circumstances)
Figure 4-173
Symptoms of
● Inspect the expansion valve
● Vacuum occurs at and EPR.
● The water and dirt in
low-pressure end, ● Blow away the dirt in expansion
refrigerant may block
and the pressure at valve. If this method does not
the flowing of
high-pressure end ● The work, please replace the
refrigerant.
is very low. refrigerant expansion valve.
● Gas leaks from
● Frost or dew is does not ● Replace the receiver.
thermo-sensitive pipe
generated on pipes circulate. ● Bleed the air and fill the
of expansion valve,
in front and behind refrigerant of appropriate
so that the flowing of
the expansion valve amount. If gas leaks from
refrigerant is affected.
or receiver/drier. thermo-sensitive pipe, please
replace the expansion valve.

● Too much refrigerant is filled or the condenser can’t fully refrigerate

Condition: The refrigerating effect is insufficient
Figure 4-174
system
● There is too much
● There is too much ● Clean up the condenser.
● Both the pressure at refrigerant in system
refrigerant in the ● Inspect the operation of fan
high and low-pressure →Too much refrigerant
system, and the motor.
ends is too high. is filled.
refrigerating effect ● If the results of the above
● Even if the engine ● The condenser can’t
can’t be brought into two inspection items are
speed reduces, no fully refrigerate →The
full play. normal, please inspect the
bubble can be seen radiating fin of
● The refrigerator can’t amount of refrigerant.
through observation condenser is blocked up
fully carry out Please fill the refrigerant of
glass. or the fan motor is in
refrigeration. appropriate amount.
trouble.
● There is air existing in refrigerating system

Condition: The refrigerating effect is not good
If the refrigerant is filled after the refrigerating system is turned on without vacuumization, then the
following situations may occur to the indication of measuring gauge.
Figure 4-175
system
● Both the pressure at high
● Inspect whether the
and low-pressure ends is
● The air enters the compressor oil is not
too high;
● The air enters the refrigerating system; clean or is not
● The low-pressure pipe is
refrigerating system. ● The vacuumization is sufficient;
hot when being touched;
insufficient. ● Bleed the air and fill
● The bubble can be seen
the new refrigerant.
through observation glass.

● The expansion valve is installed incorrectly/The thermo-sensitive tube is defective (the opening is too
wide) Condition: The refrigeration is not full
Figure 4-176
Symptoms of
● There is too
● Both the pressure much ● Inspect the installation of
● The expansion valve
at high and low- refrigerant in thermo-sensitive pipe;
is installed
pressure ends is low-pressure ● If the result of the above
incorrectly/The
too high; pipe; inspection is normal, then
thermo-sensitive pipe
● Frost or a lot of dew ● The opening inspect the expansion
is defective (the
is generated on of expansion valve. If any defect is
opening is too wide)
low-pressure pipe. valve is too found, please replace it.
wide.
● Compression trouble symptom of compressor: No cool air
Figure 4-177
Symptoms of
● The pressure at ● There is
low-pressure end compression
is too high; ● The compressor trouble; ● Repair or replace the
● The pressure at internally leaks ● The valve leaks or is compressor
high-pressure end damaged, or any
is too low. part falls off.

Compressor oil
Attention
● The new compressor shall be filled with the oil in the amount required by circulation system. When
replacing the compressor, please drain the excessive oil in compressor.
● Filling of compressor oil at inappropriate amount: If too much compressor oil is filled into A/C system,
the refrigerating ability will reduce; if the compressor oil in system is insufficient, the compressor will
be abnormal.
● When dismantling the compressor, please keep the pipeline joint and O-ring clean.
Some oil must be filled into the A/C system so as to achieve the lubricating effect, and the compressor oil
is solved in refrigerant and circulate in the whole system. When the A/C system is turned off, the
compressor oil will stay in every component of the system. As a result, when any main component is
replaced, if no oil is added into the system, the lubrication will be insufficient.
ND8# oil (10P, 10PA or 10S compressor)

Designation of compressor oil
ND9 oil (TV compressor)

Engine control
Figure 4-178
1. Storage battery relay Overview
2 Storage battery ● The engine is only started and stopped by start
switch (3).
3. Start switch
● The controller (8) will receive the signal from
4. Fuel control knob
fuel control knob (4) and transmit the target
5. Start motor speed to ECM controller (6) via CAN bus, so as
to control the fuel injection pump (7) and control
6. ECM controller
the engine speed.
7. Fuel injection pump ● If the start switch (3) is turned to the position
8. Controller OFF, the ECM controller (6) will power off the
fuel-supply electromagnetic valve. As a result,
the injection nozzle of fuel injection pump will
stop the supply of fuel, and thus the engine will
stop.

Operation of system
Start Engine
● When the key switch is turned to the position
“START” and the pilotswitch is locked, the
(Power
start signal will be transmitted to start motor via supply)
Starting switch
start relay, and then the start motor will run so Fuel control knob Starting motor
Engine
as to start the engine. (Starting
signal)
● At that moment, the controller will inspect the

signal voltage from throttle control knob, and Leading
switch
set the engine speed as the speed set by Storage
(Power-on signal)
(Starting signal)
Start cutoff
battery relay relay
throttle control knob. As a result, the engine will Start

Relay
be successfully started. Display screen -

Flameout
delay relay
controller
(Adjusting signal)
Figure 4-179
Engine speed control
● The fuel control knob will send a signal voltage
corresponding to rotation angle to controller. (Power supply)
The controller will, on the basis of the signal Starting switch

Fuel control knob
voltage and via CAN bus, send the speed Engine
Starting motor
(Starting
signal of throttle gear to engine controller ECM, signal)
so as to control the fuel injection pump and

finally control the engine speed Pilot
Switch
Storage
(Power-on signal)
(Starting signal)
Start cutoff
battery relay
Relay
Start
Relay
Flameout
delay relay
Display screen -
(Adjusting signal) controller
Figure 4-180
Turn off Engine
● When the start switch is at the position “STOP”,
the flameout signal will be sent to the engine (Power supply)
controller ECM, so as to stop the fuel injection Starting switch
Fuel control knob Starting motor
pump. In addition, you can also stop the engine Engine (Starting
via the emergency stop switch located under signal)
seat in cab.
Pilot
Switch
Storage
(Power-on signal)
(Starting signal)
Start cutoff
battery relay
Relay
Start
Relay
Flameout
delay relay
Display screen -
controller
(Adjusting signal)
Figure 4-181

Components of system
Fuel control knob
1st gear
10th gear
position
position
Left limit Right limit

position position
Yellow
Blue
Red
Figure 4-182
1. Knob Gear
2. Disc
Voltage
3. Spring
4. Roller Gear
5. Potentiometer Voltage
6. Electrical plug

Functions
● When the throttle knob is turned, the resistance
of slide rheostat in knob will change, so that the
voltage signal acquired by controller will also
Turning angle of knob

change. The controller will carry out calculation
on the basis of the acquired value, and then
send the speed signal to engine controller
ECM, so as to control the amount of fuel
injected by fuel injection pump and thus ensure
the engine speed reaches the set speed.
● When the throttle voltage is outside the zone,
Voltage (V)
the controller will send out the warning code,
and the engine will run at low idle speed. The
right figure indicates that the slanted-line area
is abnormal inspection area. Figure 4-183
Note: The left limit position corresponds to is 0%,

and the right limit position corresponds to
100%.

Engine control unit (ECU)

Arrangement diagram and explanation for terminals of control unit
Figure 4-184
Terminal Terminal
Connected to Connected to
NO. NO.
Public terminal of fuel injection
1 OP-COM1A 25 IA-THW Water temperature sensor
valves 1,2 and 3
Public terminal of fuel injection Earth of turbocharging
2 OP-COM1B 26 SG-5VRT4
valves 1,2 and 3 pressure sensor
3 OP-COM1C 27 N.C. /
valves 1,2 and 3
Shielding layer of crankshaft
4 N.C. / 28 SG-SLD5
position sensor
5 OM-EBM3 Phase W of EGR-A motor 29 N.C. /
Power supply for turbocharging
6 SP-5V4 30 OP-PCV2 PCV2
pressure sensor
7 N.C. / 31 OS-INJ1 1 Fuel injection valve control
9 IA-THL Fuel return temperature sensor 33 OS-INJ4 4 Fuel injection valve control
Increased temperature sensor
10 IA-THBST 34 N.C. /
signal
Common rail pressure sensor
11 IA-PFUEL 35 OM-EBM1 Phase U of EGR-A motor
signal
12 IA-OILPRESS Engine oil pressure sensor signal 36 N.C. /
Turbocharging pressure sensor
13 IA-MAP 37 N.C. /
signal
14 N.C. / 38 N.C.
15 OP-PCV2 PCV2 39 N.C.
Public terminal of fuel injection Earth of engine oil pressure
16 OP-COM2A 40 SG-5VRT7
valves 4, 5 and 6 sensor
Earth of common rail pressure
17 OP-COM2B 41 SG-5VRT5 sensor/crankshaft position
valves 4, 5 and 6
sensor
18 OP-COM2C 42 SG-5VRT6 Earth of cam position sensor
valves 4, 5 and 6
Shielding layer of cam position
19 N.C. / 43 SG-SLD6
sensor
20 OM-EBM2 Phase V of EGR-A motor 44 N.C. /
Power supply for common rail
21 SP-5V5 pressure sensor/crankshaft 45 OP-PCV1 PCV1
position sensor
22 SP-5V6 Cam position sensor power supply 46 OS-INJ3 3 Fuel injection valve control
Engine oil pressure sensor power
23 SP-5V7 47 OS-INJ6 6 Fuel injection valve control
supply

Terminal Terminal
Connected to Connected to
NO. NO.
49 N.C. / 85 IA-ACCEL1 Throttle position sensor signal
50 N.C. / 86 IA-ACCEL2 Throttle position sensor signal
Atmospheric pressure sensor
51 N.C. / 87 IA-BARO
signal
CAN_L for diagnosis
Phase U of low position sensor of C C -
52 IS-EBMPOS1 88 (connected to diagnosis plug
carbon brush of EGR DC motor ISOCAN-L
of engine)
Phase V of low position sensor of
53 IS-EBMPOS2 89 PS-+B ECM power supply
carbon brush of EGR DC motor
Phase W of low position sensor of Earth of throttle position
54 IS-EBMPOS3 90 SG-5VRT1
carbon brush of EGR DC motor sensor
55 N.C. / 91 N.C. /
56 IF-CAM Cam position sensor signal 92 N.C. /
57 IF-CRANK Crankshaft position sensor signal 93 N.C. /
Shielding layer of common rail
58 SG-SLD8 94 N.C. /
pressure sensor
59 N.C. / 95 N.C. /
60 OP-PCV1 PCV1 96 N.C. /
61 PG-POWER Earth for power supply 97 PG-SIGN Signal earth
62 PG-POWER Earth for power supply 98 N.C. /
64 PG-POWER Earth for power supply 100 IS-START Starting signal
67 PS-+B ECM power supply 103 N.C. /
68 N.C. / 104 N.C. /
Power supply for atmospheric
69 SP-5V2 105 N.C. /
pressure sensor
Power supply for fuel filter
70 SP-5V3 106 N.C. /
pressure sensor
71 N.C. / 107 N.C. /
Connected to diagnosis plug of
72 CC-KW2000 108 N.C. /
engine
73 N.C. / 109 N.C. /
CAN_H for diagnosis
C C -
74 N.C. / 110 (connected to diagnosis plug
ISOCAN-H
of engine)
75 N.C. / 111 PS-+B ECM power supply
Earth of fuel filter pressure
76 N.C. / 112 SG-5VRT3
sensor
77 N.C. / 113 N.C. /
Power supply for main relay
78 N.C. / 114 OS-MAINR
coil of ECM
79 N.C. / 115 N.C. /
80 N.C. / 116 N.C. /
Signal of intake temperature
81 IA-IAT 117 N.C. /
sensor
82 N.C. / 118 N.C. /
83 IA-FIPRESS Fuel filter pressure sensor signal 119 PG-SIGN Signal earth
84 N.C. / 120 N.C. /

Terminal NO. Connected to

121 IS-ENGSTP Emergency stop of engine
122 N.C. /
123 N.C. /
124 OS-OILRL Engine oil pressure indicator
125 N.C. /
126 N.C. /
127 N.C. /
128 N.C. /
129 N.C. /
130 OS-DIAGL Trouble indicator
131 N.C. /
132 CC-CAN-L CAN_L
133 PS-+B ECM power supply
134 IS-IGKEY Power-on signal
135 SG-5VRT2 Earth of atmospheric pressure sensor
136 OS-MAINR Power supply for main relay coil of ECM
137 PG-CASE Earth of housing
138 N.C. /
139 N.C. /
140 N.C. /
Diagnosis mouthpiece (connected to diagnosis
141 IS-DIAG
plug of engine)
142 IS-MEMCL Trouble clearing
143 N.C. /
144 N.C. /
145 OS-GLOWL Heating indicator light
146 N.C. /
147 N.C. /
148 N.C. /
149 N.C. /
150 N.C. /
151 N.C. /
152 OS-STARTR Start cut off relay control (earth of coil)
153 OS-GLOWR Preheating relay control (earth of coil)
154 CC-CAN-H CAN_H

Electrical Control System

Control function
Throttle gear control
Engine control Automatic idling

control
Engine protect
control
Pump control
Pilot locking control
High/low traveling
speed control valve
Valve control Boom bucket priority

control
Electrical control
system Boom-slewing
priority control
Boom interflow cut

off control
Cooling pump control
Extinction delay
control
Auxiliary function
control
Circulation filtration
pump control
Self-diagnosis
function Warning light control
★ As for the detailed explanation on diagnosis function, please refer to “Trouble Diagnosis”.

Control system diagram of this machine
Fuse
Storage battery Storage battery relay

Fuel oil level sensor
Starting Flameout
supply
Power
switch delay relay
Boom interflow cut off
supply
Power
Power-on electromagnetic valve
signal
Starting
signal
Preheating
Pilot locking electromagnetic

signal
valve 606
Double-travelling-speed
electromagnetic valve 607
Monitor
CAN bus Right travelling signal 201
Work mode signal
Signal Travelling speed selection
Left travelling signal 200
signal
monitoring Automatic deceleration
information signal Slewing signal 208
Monitoring signal
Boom lifting signal 206
Flameout delay relay 610 Boom lowering signal 207
Bucket arm excavation

Power-on signal signal 203
Bucket arm unloading

Starting signal signal 202
Bucket excavation signal
205
Bucket unloading signal
204
Controller Throttle knob position signal 506

Fuel control knob
Fuel level signal 509
Starting relay 600
Hydraulic oil temperature signal 100
Hydraulic oil temperature
sensor
Boom-bucket priority proportional
valve 608
Boom-slewing priority proportional
valve 602
Main pressure signal 501
of pump 1
Pilot switch 105 Main pressure signal 502 of
pump 2
Starting relay
Electromagnetic proportional
valve 702 of pump 1
Electromagnetic proportional
valve 703 of pump 2
Cooling pump pressure signal
503
Intake temperature sensor 3081
Atmospheric pressure sensor
CAN bus
PPC locking
signal
Charging indicator
light 14 Engine speed sensor
Alternator Turbocharging temperature sensor
Turbocharging pressure sensor
Start cutoff relay Engine water temperature sensor Engine

Start motor Engine Engine oil pressure sensor controller ECM
Common rail pressure sensor
Preheating signal
Electrical Cam position sensor
13a
Preheating relay intake heater Crankshaft position sensor
Figure 4-185

Boom lowering pressure sensor
PPC
Bucket arm excavation pressure sensor
valve
Bucket arm unloading pressure sensor
Bucket excavation pressure sensor
Bucket unloading pressure sensor
Slewing pressure sensor
Basic pressure of
PPC
Oil supply device of

front pump
Transmission device of working
device
Boom-bucket Boom interflow Boom-slewing Dual running PPC locking
priority cut off priority speed electromagn
proportional electromagneti proportional electromagn etic valve
valve c valve valve etic valve
Action control
valve
Proportional valve of
pump 2
Main
valve
Running
Motor
Servo
Pilot pump
Running
Motor
Main
pump Cooling Slewing
pump Oil supply device of motor
front pump
Transmission device of working
device
Cooling
Servo fan
Motor
Proportional valve of
pump 1
Figure 4-186
Note: The figure above reflects the schematic diagram of electrical control. As for specific hydraulic circuit,
please refer to the contents about hydraulic knowledge.

Engine — pump combined control function

Schematic diagram of control function
Main valve
Pressure sensor
Engine
Servo
Servo
Throttle Control Electromagnetic

Knob proportional
valve
CAN bus
Control signal of
Control signal of
pump 1
pump 2
Displayer
Controller
CAN bus
Bucket unloading signal
Right travelling signal

Boom lowering signal
Bucket arm unloading
Left travelling signal

Boom lifting signal
Bucket excavation
Slewing signal
signal
signal
signal
Figure 4-187
Note: The figure above reflects the schematic diagram of electrical control. As for specific hydraulic circuit,
please refer to the contents about hydraulic knowledge.

Functions
● This function permits the operation personnel to select the power of engine and the power absorbed
by pump on the basis of the work contents of this machine.
● The pump controller will control the pump, so as to ensure that it can absorb all output torque from
engine. The torque depends on the specification of pump to absorb torque in every mode, the setting
of fuel control knob and the actual engine speed.
ESS control
Functions
● The power of pump will be controlled on the basis of the change in speed caused by change in load,
so as to better utilize the output of engine. (When this machine is working under severe conditions,
such as working on plateau, so as to prevent the stalling of engine).
Operations
The target speed of engine is controlled through throttle knob.
● The controller will receive the actual speed signal sent by ECM (engine controller), and carry out the
closed-loop control on actual speed and target speed. Thereafter, the controller will make the output of
closed-loop control participate in calculation of control signal of electromagnetic valve, and send the
finally-adjusted current signal to pump proportional electromagnetic valve.
● The electromagnetic valve will, on the basis of the received signal from controller, supply the pilot
pressure oil to pump regulator, so as to control the flowrate of pump.

Valve Control Function
Boom lifting pilot signal
Bucket excavation pilot

Pilot locking rod signal

pilot signal
signal
CAN bus
Controller Display
screen
Boom -bucket priority
Boom-slewing priority
Boom interflow cutoff
Pilot locking signal

Double-travelling-
speed signal
Standby
signal
signal
signal
Boom-slewing Boom interflow cut Standby Boom-bucket Dual running Pilot locking
priority off electromagneti priority speed electromagnetic
proportional valve electromagnetic c valve proportional valve electromagnetic valve
valve valve
Figure 4-188

Functions
● In order to improve the working efficiency of this machine and optimize the coordination of this
machine, the boom interflow cutoff control, boom-bucket priority control and boom-slewing priority
control are adopted.
Operations
● When the boom is being lifted and the bucket arm is carrying out excavation at the same time, under
particular conditions, the boom interflow cutoff electromagnetic valve will act, so as to cut off the boom
interflow.
● When the boom is being lifted, the boom-slewing priority electromagnetic valve will act, so as to
achieve the priority of boom lifting against slewing.
● When the boom is being lifted and the bucket is carrying out excavation at the same time, under
particular conditions, the boom-bucket priority electromagnetic valve will act, so as to achieve the
priority of boom lifting against bucket.
Functions
● On the basis of the safety requirements, the pilot locking function is adopted to control the action of
excavator.
Operations
● When the pilot handle is turned to the horizontal position, the pilot locking electromagnetic valve will
be opened, and the excavator will be able to act; when the pilot handle is turned to the vertical position,
the pilot locking electromagnetic valve will be closed, and the excavator will not be able to act.
Functions
● In order to ensure that the travelling performance is suitable for work site and work type, the double-
travelling-speed function is adopted to control the travelling speed.
Operations
● Through the high/low speed travelling changeover button on display screen, the double-travelling-
speed electromagnetic valve can be opened and closed, so as to change the displacement of
travelling motor and thus achieve the changeover between high and low travelling speed.
Note: As for the specific wire number, please refer to the designation of wire number on Page 4-177.

Warning and protection for too low engine oil pressure
Engine
Engine oil
pressure sensor
Engine oil
pressure signal
Throttle Control
Knob
CAN bus
CAN bus Display

Controller screen
Figure 4-189
Functions
● The controller will acquire the signal from ● While the warning is displayed, the controller
engine oil pressure sensor. Under the will lower the engine speed to idle speed, to
circumstance that the engine speed is higher protect the engine.
than 600rpm, if the engine oil pressure is too
low, then the warning information will be
generated and sent to the display screen. After
the display screen receives the warning
information, the warning indicator will come on.

Warning and protection for too high engine water temperature
Engine
Coolant temperature
sensor
Water temperature
signal
Throttle Control
Knob
CAN bus
CAN bus
Controller Display
screen
Figure 4-190
Functions
● The controller acquires the signal from water
temperature sensor. If the water temperature is
too high (higher than 105℃), the warning
information will be generated, and be sent to
the display screen. The display screen will
receive the warning information, and then the
warning indicator will come on.
● While the warning is displayed, the controller
will lower the engine speed to idle speed, so as
to protect the engine.

Control on engine preheating
Engine
Coolant temperature
sensor
Water temperature
signal
Throttle Control
Knob
CAN bus
From wire
13 of key
switch
CAN bus
Controller Display
screen
Figure 4-191
Functions
● When the engine is started, the engine control
unit (ECU) will inspect the water temperature,
so as to judge whether it is necessary to
preheat the engine.
● When the ECU judges that it is necessary to
carry out preheating, it will send out the
preheating control signal to switch on the
preheating relay, so that the engine preheating
plug will be powered on and work.

System components
Pump pressure sensor
Sumitomo connector Body O-ring Pressure joint
Connection diagram
Terminal
Name of signal
No.
Power supply
(+5V)
Earthling
Output
Direction Z
Figure 4-193
Operations
● The relationship between the pressure (P)
applied on sensor and the output voltage (E) is
as indicated in the right figure.
Output voltage (E) of
sensor
Oil pressure (P)
Figure 4-194

Leading pressure sensor

Sumitomo Pressure
connector Body O-ring joint
Connection diagram
Terminal Name of signal

No.
Power supply
(+5V)
Earthling
Output
Direction Z
Figure 4-195
Operations
● The relationship between the pressure (P)
applied on sensor and the output voltage (E) is
as indicated in the right figure.
Output voltage (E) of
sensor
Oil pressure (P)
Figure 4-196

Figure 4-197
1. Buoy 3. Casing
2. Lever 4. Plug-in elements
Specific technical parameter

Technical parameters (↑ is lifting testing, ↓ is lowering testing)
Oil level (H) Gear Corresponding resistance Total resistance value (Ω)
value (Ω)
Full
Signal Earthling
wire wire

Display system
Displayer
CAN signal
Controller
Power
supply Sensor
Storage battery
Figure 4-198
● The state of this machine will be monitored by the sensors installed on various locations on this
machine, the relevant date will be processed by the controller, and the information obtained will be
immediately displayed on panel, so as to inform the operator of conditions of this machine.
● There are also mode selection switches and function buttons on display panel, so as to operate this
machine and control the output.
● In general, the contents displayed on panel fall into the following two parts.
1. Warning information given when trouble occurs to this machine.
2. Conditions of this machine (temperature of coolant, temperature of hydraulic oil, and level of fuel).

Displayer
Figure 4-199
Overview
● The display has the function to display the monitoring information and select the work mode.
● In the display, there is a CPU (central processor) which processes, displays and send out the
information.
● The display screen is a liquid crystal display.
Input and output signal of socket
Pin no. Name of signal Input/output Pin no. Name of signal Input/output
1 CAN low Dismantlement-proof structure

29 Input
of display screen
2 CAN high
33 Earthling
3 CAM-
34 GPS power supply
7 Resetting of display screen
Power supply (12V) for video
9
camera
12 CAM+
Power supply for display
17
screen (24V)
24 Earthling
25 GPS power supply
Note:
● When there are less than 10 black spots (unlighted points) or lighted spots (always lighted points) on
the liquid crystal display panel, the display meets the technical standard.
● When the display continuously works, blue spots may appear on black background, and this is a
normal phenomenon.
● When the display is turned on, there will be stripe flashing, and this is a normal phenomenon.

Display panel
Attention
● When the alarm indicator light is lit up, it is
necessary to stop operations immediately,
inspect and repair the relevant part.
● The displayer could not display all the working
states of the excavator.
● Do not fully rely on the display of the display
screen when maintaining or inspecting the
excavator.
The display screen panel has the function to select

the monitoring data and video and turn on/off the
electrical elements
Appearance of display
This display is mainly composed of 3 parts:
A: SANY LOG display zone
B: Display zone on home page
C: Button zone
Figure 4-200
SANY LOG display zone

SANY LOG is displayed
When the start switch of the excavator is turned to
the position “ON”, the display will be powered on
and started by battery, and the system will enter the
initial page.
Figure 4-201

Display zone on home page

After the power switch is turned on, the system will
enter the LOG page, and then go to home page 3
seconds later. The display of home page is as
indicated in the figure, including:
【1】 System time
【2】 Work mode (to be divided by gear)
【3】 GPS signal
【4】 Gear (on the basis of the position of throttle
knob)
【5】 Total work time
【6】 Fuel Oil Level Meter
【7】 Locking mark (countdown reminder for
locking of machine)
【8】 Maintenance signal and maintenance time
【9】 Instant flowrate of fuel
Figure 4-202
【10】 Work time
【11】 Cooling water thermometer
【12】 As for trouble warning, display zone of
important trouble icons, specific troubles and
codes, please refer to Page 4-195: trouble
information search
【13】 Enter the “video page”
【14】 Automatic idling state
【15】 High/low travelling speed state
【16】 Enter the icon “trouble information search”
【17】 Enter the icon “Information search”

Button zone
The button zone includes 5 function buttons. Function buttons
Namely F1, F2, F3, F4 and F5 (as indicated in Figure). The role of these 5 buttons corresponds to the
function icon displayed in display zone on home page.
● When the function icon displayed is different, the role of every button may be different.
● When the corresponding function icon is not displayed in display zone on home page, the function
button will be unavailable.
The relationship between several commonly-used function icons and buttons are detailed in the table
below.
Function
Icon display Functions Display range
buttons
F1 Enter the “video page” ——
Automatic idling
F2 Idle/Non-idle
changeover/change over
High/low running speed
F3 High speed/low speed
change-over
Enter the page for selection of
F4 ——
setting item
Select the “Information
——
Search”
F5
Return to the previous page ——

Display the page operation method for every page
Home Page
The homepage means the page displayed when the excavator is working normally.
Operation Method
1. Video display
If is pressed down, the system will enter the
video display page.
Note: The video camera is an optional part. If the
video camera is not installed, no picture will be
displayed when the system enters the video display
page.
2. Automatic idling selection

Use the to deactivate and activate the
automatic idling function.
When the symbol is displayed above , if
this button is pressed down, the automatic
idling function will be deactivated; when the symbol
is displayed above this button, if this button is Figure 4-203
pressed down, the automatic idling function will be
activated.
Note: Whenever the power switch of this machine is
turned on, the automatic idling mode will be turned
on by default.
● Under the default condition, the automatic idling
switch is turned on. After all control rods have
been at neutral position for 3.5S, the engine will
enter the idling state (The controller will
automatically adjust the speed to idle speed),
so as to save the fuel and reduce the noise.
● In the idling state, if the controller detects that
there is any action or the gear is changed, then
the corresponding speed will be resumed
automatically
3. Selection of high/low travelling speed
Please use to achieve the changeover
between “high speed” travelling and “low speed”
travelling. When the symbol is displayed
above the , if this button is pressed down,
the high speed travelling will be selected; when
the symbol is displayed above the button,
if this button is pressed down, the low speed
travelling will be selected.
Note: Whenever this machine is powered on, the
travelling speed will be set as “low speed” by
default.

4. Trouble information query

When the display warning indicator comes on,
the trouble code will be displayed on bottom of
display screen. If this button is pressed down,
the system will enter the page for search of
trouble information.
When the engine becomes abnormal, please identify the trouble of engine in accordance with the following method.
Press down
F1 to select
the engine
information,
and then
press down
F3
The current engine trouble code will

appear. If several troubles appear,
every trouble will be displayed in
turn, and you can view the specific
trouble contents by pressing down
F2, view the real-time parameters of
engine by pressing down F4, and
view the historical troubles by
pressing down F3
5. Search of system information

Press down to enter the system information
search page.
Note: Before entering the system information page,
you have to type in the password. Please contact
the local dealer of Sany.
List of Information password page

On the page “List of Information”, select the
“Operation Information” and press so as to
enter the password page for list of information (The
password shall be typed in when the page is
entered for the first time after the excavator is Information List
powered on). The operation information can be Please type in the password
searched only after the password passes the for search of list of
information:
verification.
Button Operations
● Password for increase/decrease
● Select the input digit
● Confirm the password. The password is:
31868
● Enter the [Unlocking of System] page
● Return to 【Homepage】. Figure 4-204

Page “List of Information”

On the home page, press to enter the page List
of Information. On this page, you can select the
information to be searched.
Button Operations
Information List
Button Operations
● Select the function
● - Operation
information
Trouble
information
GPS monitoring
● Determine to enter
●
System System clock Save the
Enter the page [Setting of System] language information
● Return to homepage
Figure 4-205
Engine and Throttle Signals

On the page [List of Information], select the
[Operation Information] so as to enter the operation
information search page. The system will firstly
enter the page [Signal of Engine and Throttle].
Button Operations Engine and Throttle Signals
● Enter the page [Search for Input/output Fuel level %:
Engine oil pressure Kpa:

Signal]
Coolant Temperature ℃:
● Enter the page [Pilot Pressure Signal] Engine speed r/min:
Throttle gear N:
Gear position V:
Battery voltage V:
Atmospheric pressure Kpa:
Figure 4-206

Pilot pressure signal

Press the button on the page [Signal of Engine
and Throttle], or press
on the page [Signal of Main Pump and
Cooling Pump], so as to enter the page [Pilot Pilot pressure
signal
Pressure Signal].
Boom up
Boom down
Bucket rod excavation
Button Operations
Bucket rod unloading
● Enter the [Signal of Engine and Throttle] Bucket excavation
page Bucket unloading

Slewing signal
● Enter the page [Signal of Main Pump and Traveling LEFT
Cooling Pump] Traveling RIGHT
Figure 4-207
Main pump and cooling pump signal

Press on the page [Pilot pressure signal] or
press on the page [Search for Input / Output
Signal], so as to enter the page [Signal of Main
Pump and Cooling Pump].
Main pump and cooling
pump signal
Button Operations Main pressure of pump 1
● Enter the page [Pilot Pressure Signal] Main pressure of pump 2

Pressure of cooling pump
● Enter the page [Search for Input/output Pressure of large chamber of boom
Signal] Current of proportional valve 1

Current of proportional valve 2
Current of cooling proportional valve
Hydraulic oil temperature
Cumulative travelling time
Figure 4-208

Search for input/output switch signal

Press on the page [Signal of Main Pump and
Cooling Pump], or press on the page [Signal
of Engine and Throttle], so as to enter the page
[Search for Input/output Signal].
Search for input/output signal
Starting input Hydraulic pilot
Button Operations
● Enter the page [Signal of Main Pump and Starting relay Slewing priority
Cooling Pump] Preheating signal Interflow of bucket arm 2
Pilot relay Interflow of boom 2

● Enter the [Signal of Engine and Throttle]
High/low speed relay Boom priority
page
Warning light (sound) Extinction delay
Warning light (light) Fuel filtration
Figure 4-209
Trouble information
On the page [List of Information], select the [Trouble
Information] so as to search for trouble codes and
trouble information.
Button Operations Trouble code:
●
Internal trouble of controller
Return to the previous page. The internal temperature of controller is abnormal
The power supply for sensor is abnormal
● — There is error in memory (GPS locking memory)
There is error in CPU
● — Power supply voltage is too low
Power supply voltage is too high
● —
The CAN bus is abnormal
The throttle knob is abnormal
The flameout delay relay is abnormal
● Return to the page [List of Information] The start motor relay is abnormal
The warning light (light) relay is abnormal
Note: When the trouble code appears on The warning light (sound) relay is abnormal
homepage, you can enter the page “Trouble

The pressure of pump P1 is abnormal
Information” by pressing down .
Figure 4-210

GPS monitoring information

On the page [List of Information], select the [GPS
Monitoring] so as to search for GPS monitoring
information.
Button Operations GPS monitoring information
● — Longitude °:
Latitude °:
● — Altitude m:
Speed Km/h:
Quantity of satellites:
● — Communication indication:
Signal-to-noise ratio 1:
● — Signal-to-noise ratio 2:
Signal-to-noise ratio 3:
● Return to homepage Signal-to-noise ratio 4:
Figure 4-211
Selection of System Language

On the page [List of Information], select the [System
Language] so as to enter the system language
selection page. At present, the languages available
are Chinese and English.
Selection of System Language
Button Operations
● － System in Chinese
● Chinese
● English
● －
● Return to the page [List of Information]
Chine
se
Figure 4-212

Calibration of system clock

On the page [List of Information], select the [System
Clock] so as to enter the page [Calibration of
System Clock].
Button Operations
Calibration of system clock
● Increase/decrease of calibration value
Current time:
● Select the calibration position
● Confirm the calibration
Calibrated time:
● －
Figure 4-213

Maintenance Information
On the page [List of Information], select
[Maintenance Information] so as to enter the
maintenance information search page. The
maintenance information includes the maintenance Maintenance Information
items for every 50 hours, 250 hours, 500 hours, Current maintenance period:
1000 hours and 2000 hours. Note: This page can 1. Apply the grease onto slewing
be entered only when there is the maintenance mechanism bearing, and turn it while
filling the oil;
reminder. 2. Replace the engine oil and its filter
element (replacement for the first time);
Button Operations 3. Inspect the fuel filter and intake pipeline;
● － 4. Inspect the connection between air filter

and intake pipeline;
● － After the maintenance is completed, please

fully inspect the equipment.
● Please type in the maintenance password:
31868
● Pause and start of circulated display of
maintenance items
● Return to the page [List of Information] Figure 4-214
Information List
Please type in the password

for confirmation on
maintenance:
Figure 4-215

List of setting of system

On the page [List of Information], press to
enter the page [Setting of System]. When entering
the page [Setting of System], you need to type in
the password for setting of system. The method for
typing in password is as same as that for the page System Setting
[List of Information].
Button Operations
Excavator Calibration of Working
●
configuration Excavator hours
Selection item
● － Warning Brightness of Engine
contents display information
screen
● The confirmation password is: 31868
● －
Figure 4-216
Excavator configuration
The configuration information of this machine can
be viewed by selecting the [Configuration of
Machine] on the page [Setting of System].
Button Operations
● － Excavator configuration
Excavator model:
● － Excavator No.:
Engine model:
● － Model of hydraulic system:
Model of controller:
● － Edition number of software:
● Return to the page [Setting of System]
Figure 4-217

Calibration of Working Hours

The work time of this machine can be calibrated by
selecting the [Work Time] on the page [Setting of
System]. When entering the page [Calibration of
Work Time], you need to type in the password for
calibration of work time. The method for typing in Calibration of Working Hours
password is as same as that for the page [List of
Information]. Current Working Hours:
Note: The work time may be changed for up to 2

Calibrate working hours:
times. After the remaining times become zero, you
can’t enter this page for carrying out calibration.
Button Operations
● Increase/decrease of calibration value Remaining times of
calibration: 2
● Select the calibration position

● Confirmation
● －
● Return to [Setting of System] Figure 4-218
Configuration Calibration
The configuration information of this machine can
be calibrated by selecting the [Calibration of
Configuration] on the page [Setting of System].
When entering the page [Calibration of
Configuration], you need to type in the password for Configuration Calibration
calibration of configuration. The method for typing in

password is as same as that for the page [List of Engine model:
Information].
Model of hydraulic system:
Button Operations Model of controller:
● Enter the [Calibration for Code of

Machine]
Note: For carrying out code calibration for
● Engine calibration this machine, please press down F1
● Confirm the calibration and return to the Engin Hydra Contr

Model
setting page e ulic ol
● Model calibration for hydraulic system

● Model calibration for controller
Figure 4-219

Setting of warning contents

On the page [Setting of System], select the
[Contents of Warning] so as to enter the page
[Setting of Warning Contents].
Button Operations
● Selection of setting item Setting of warning contents
● － Traveling Back Upper

swing portion
● Confirmation on setting item selected Sound
● － Light
Figure 4-220
Adjustment of brightness of display screen

On the page [Setting of System], select the
[Brightness of Display Screen] so as to enter the
page [Adjustment of Brightness of Display Screen].
Button Operations
Adjustment of brightness of display
● Increase brightness screen
● Brightness reduced Brightness of display screen: 100%
● Brightness adjustment determined

● －
● Return to the [List of Information]
Figure 4-221

Setting for travelling deviation

Setting of secondary password of system.
Button Operations
● Selection of setting item
● Increase of value Correction of travelling
deviation
● Decrease of value
Adjustment of left travelling deviation:
● Confirmation
Adjustment of right travelling deviation:
Figure 4-222
Engine information
Display the historical troubles and total running time
of engine
Button Operations
● Display the historical troubles and total
Engine information
running time
● Enter the engine trouble search page Current trouble
● Confirm the transmission of request Historical Trouble
● Enter the other engine information page Total running time
● Return to the setting selection page
Figure 4-223

Engine trouble information

Display the engine trouble information.
Button Operations
● Enter the next page
● — Trouble code:
● —
● —
● Return to the engine information
Figure 4-224
Other information of engine

Display the engine-related information.
Button Operations
● Enter the basic engine information page 4
Other information of engine
● Enter the basic engine information page 2 Restriction on fuel injection amount
● — Engine torque
● — Fuel flowrate
Turbocharging pressure
● Return to the engine information Intake temperature
Increased temperature
Pressure difference of common rail
Fuel temperature
Figure 4-225

Routine maintenance information

The information will pop up automatically when the
engine is started up for the first time every day
Button Operations
● －
Routine maintenance information
1. Inspect engine oil level
● － 2. Inspect the coolant level
3. Drain the water and sediment from fuel
● — tank and oil water separator;
4. Inspect the hydraulic oil level
● — 5. Inspect whether the engine fan belt and

A/C belt are loosened or damaged
6. Fill the grease into working device;
● Return to homepage 7. Inspect the cleanliness of air filter
element;
8. Before carrying out work, please
preheat the engine and hydraulic
system.
Note: In order to confirm the
maintenance, please press down F3.
Figure 4-226
Locking Information
When the locking signal is received, the system will
enter the locking information page. The locking
signal falls into primary locking signal and
secondary locking signal.
Button Operations Locking Information
● － Excavator model: SY750H
Excavator No.: 00008
● － State of equipment: Level-I locking
Current time: 10:13:29

● —
● —
● Enter the password unlocking page Please contact the manufacturer for release the
locking state
Figure 4-227

System unlocking page

When this picture appears on display screen, it
means that the excavator enters the system
unlocking state.
Button Operations
System unlocking
● Selection of upper or lower position Please Input Unlocking Password:
● Selection of left and right position

Model:
● Password confirmation S/N:

Random code:
Unlocking state:
● — Number of locking:
Remaining Time h:
● Return to [Setting of System]
Figure 4-228

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SY750H Hydraulic Excavator Standard value of components
Standard value of components

Table of standard values for engine-related parts ....................................................................................... 5-2
Table for standard value of body-related parts ........................................................................................... 5-3

Standard value of components SY750H Hydraulic Excavator
Table of standard values for engine-related parts

Applicable models SY750H
Engine AH-6WG1X
Operating conditions for Standard values for
Items Unit Repair limit value
measurement new machine
Maximum speed under unloaded
rpm 1750±20 1750±30
condition
Engine speed Minimum speed under unloaded rpm 850±20 850±30
condition
Rated speed rpm 1800 1800
6-cylinder, 4-stroke, water-cooled, top-
Type
mounted, valve –type, with turbocharger
Total
L 15.681
displacement
Number of
cylinders – mm 4-147×154
bore × stroke
Alternator 24V/60A
Starting motor 24V/7.0kw
Total capacity
L 57
of engine oil
Valve Intake valve mm 0.4 —
clearance Exhaust valve mm 0.4 —
● Oil temperature:
Compression 40-60℃ Compression Mpa 2.84 2.26
pressure ● Engine speed pressure {kg/cm2} 30 23
200rpm
● Between fan belt pulley and AC
generator belt pulley
Tension force
● Sagging of belt when it is mm 6~8 6~8
of fan belt
pressed by finger with the force
of about 98 N {10 kg}
● Between fan belt pulley and
Tension force
compressor belt pulley
of A/C
● Sagging of belt when it is mm 5~8 5~8
compressor
pressed by finger with the force
belt
of about 58.8 N {6 kg}

Table for standard value of body-related parts

Operating conditions for Standard values for
Category Items Unit Permissible value
measurement new machine
● Engine coolant temperature:
within the operating range
● Hydraulic oil temperature: within
operating range
When the 2 pumps
● The engine is running at high idle rpm 1750±50 1,700 ～ 1,800
is overflowing
Engine speed
speed
● Heavy load operation mode (P)
● Bucket arm retraction overflow
state
● The engine is running at high idle
speed
Speed during
● The automatic idling switch is
automatic rpm 1100±20 1,080 ～ 1,120
opened
deceleration
● All control rods are at middle
position
Lifting mm 11.5 ± 0.5 11.0 ～ 12.0
Boom control valve
Lowering mm 9.5± 0.5 9.0 ～ 10.0
Bucket arm control Retraction mm 11.5 ± 0.5 11.0 ～ 12.0

●
Stroke of slide valve
valve The engine is Extension mm 9.5± 0.5 9.0 ～ 10.0

turned off
Bucket control ● As for the key Excavation,
mm 9.5± 0.5 9.0 ～ 10.0
valve points about unloading
measurement, Left
Back slewing please refer to travelling
mm 9.5± 0.5 9.0 ～ 10.0
control valve “Control Valve” on and right
Page 5-10 travelling
Forward
traveling,
Travelling control
and mm 9.5± 0.5 9.0 ～ 10.0
valve
backward
travelling
Boom control rod mm 85 ± 10 75 ～ 95
Bucket arm control ● The engine is turned off mm 85 ± 10 75 ～ 95
rod ● Center of control rod
Bucket control rod ● Obtain the maximum value at the mm 85 ± 10 75 ～ 95
end of stroke
Back slewing
Stroke of control rod
(Deducting the play of rod at middle mm 85 ± 10 75 ～ 95

control rod position)
Running Control
mm 115 ± 12 103 ～ 127
Lever
● The engine is
turned off Working
● Gently push the mm 15 maximum Maximum 20
Device
control rod with
hand, and stop
Play of control rod
when the obviously
resistance is felt
● Obtain the Traveling mm Maximum 20 Maximum 25
maximum value at
the end of stroke


Operating conditions for Standard values Permissible
Category Items Unit
measurement for new machine value
Boom Maximum 19.6 Maximum 24.5
Operating force of control rod and pedal
control rod {Maximum 2.0} {Maximum 2.5}

Bucket arm Maximum 19.6 Maximum 24.5
control rod ● Hydraulic oil temperature: {Maximum 2.0} {Maximum 2.5}
within operating range
Bucket ● The engine is running at high Maximum 15.6 Maximum 21.6
control rod idle speed {Maximum 1.6} {Maximum 2.2}
N
Back ● The control rod is at the
{kg} Maximum 15.6 Maximum 21.6
slewing middle position
{Maximum 1.6} {Maximum 2.2}
control rod ● The pedal at the top position
Running ● Maximum indication at end of
Maximum 30.4 Maximum 39.2
Control stroke
{Maximum 3.1} {Maximum 4.0}
Lever
Travelling
Maximum 93.1 Maximum 107.6
control
{Maximum 9.5} {Maximum 11}
pedal
● Hydraulic oil temperature:
● The engine is running at high
Standby idle speed 3.5 ± 1.0 2.5 ～ 4.5
pressure ● Work mode: H {36 ± 10} {26～46}
● Output pressure of hydraulic
pump when all control rods
are at middle position
Boom ● Hydraulic oil temperature: 34.3 ± 1.0 34.3～35
overflow within operating range {350 ± 10} {350 ～ 360}
● After the engine runs at high
Bucket arm idle speed, operate the 34.3 ± 1.0 34.3～35
overflow corresponding control rod {350 ± 10} {350 ～ 360}
● Work mode: H
Hydraulic pressure
Bucket ● Output pressure of hydraulic 34.3 ± 1.0 34.3～35

overflow pump when all measurement {350 ± 10} {350 ～ 360}
oil ways overflow MPa
Slewing ● Hydraulic oil temperature: {kg/cm2} 27± 1.0 27～28
overflow within operating range {275± 10} {275 ～ 285}
● After the engine runs at high
idle speed, operate the
corresponding control rod
Travelling ● Work mode: H 33.4 ± 1.0 32.4 ～ 34.4
overflow ● Output pressure of hydraulic {342 ± 10} {330 ～ 351}
pump when all measurement
oil ways overflow
● Hydraulic oil temperature:
Control the ● The engine is running at high
source idle speed 3.9 ± 0.2 3.7 ～ 4.1
pressure in ● When all control rods are in {40 ± 2} {37 ～ 41}
oil way middle position, the pressure
will be sent out from gear
pump


Standard values Permissible
Category Items Operating conditions for measurement Unit
for new machine value
● Hydraulic oil temperature: within operating
range
● The engine is running at high idle speed
● Work mode: H
Maximum
Angle of ● Misalignment angle of slewing support Degree Maximum 100
130
slewing brake after the excavator slews for one round (mm) (—)
(—)
that stops
● As for details about measurement
posture, please refer to “Slewing 1” on
Page 5-10
● Hydraulic oil temperature: within Maximum
90 ° Seconds 3.5 ± 0.3
operating range 4.0
idle speed
● Work mode: H
Start time of
● Time required for slewing by
slewing Maximum
90°or 180° from start point 180 ° Seconds 4.8 ± 0.4
5.5
● As for details about
measurement posture, please
refer to “Slewing 1” on Page 5-
10
Back swing
range
● Work mode: H
● After carrying out slewing for one round, Maximum
Slewing time Seconds 28±3
measure the time necessary for slewing 34
for 5 rounds
● As for details about measurement
posture, please refer to “Slewing 1” on
Page 5-10
range
● The engine stops
The hydraulic ● On the 15°slope, keep the upper slewing
drifting in back platform of this machine transverse.
mm 0 0
slewing Please refer to “Slewing 2” on Page 5-10
operation ● Leave the mating marks on inner and
outer races of slewing support
● Misalignment of mating mark within 5
minutes
range
Leakage of ● The engine is running at high idle speed Maximum
ml/min Maximum 5
slewing motor ● Slewing locking switch: on 10
● During the slewing overflow, measure the
amount of oil leaking within 1 minute
● Hydraulic oil temperature: within Position
operating range lo
idle speed
● Work mode: H
Traveling
Travelling
● After carrying out slewing for one 30 ± 5 25～35
speed Seconds
round, measure the time Position 48 ± 5 43～53
(Without load)
necessary for slewing for 5 hi
rounds
● As for the specific measurement
posture, please refer to
“Attachment 1” on Page 5-10


Standard values Permissibl
for new machine e value
● Hydraulic oil temperature: within operating Low
range
Travelling ● Work mode: H 24± 3.5 20~28
speed ● Maximum power gear P11 Secon
(True ● Make the excavator travel for more than High ds
operation) 10m, and measure the time spent for 16± 3.5 12~20
travelling for another 20m. As for details
about measurement posture, please refer
to “Travelling 2” on Page 5-10
● Hydraulic oil temperature: within operating range
● Work mode: H
● Travelling speed: low
Travelling ● Firm and flat ground Maximum
mm Maximum 600
deviation ● Deviation (χ) when the excavator travels for 800
Traveling
another 20m after this machine travels for first

10m
● As for detailed measurement posture, please refer
to “Travelling 2” and “Travelling 3” on Page 5-10
● The engine stops
● Park this machine on 12°slope, and ensure the
Hydraulic
driving wheel is located below
drifting of mm 0 0
● Measure the sliding distance of this machine 5
travelling
minutes later
● As for the specific measurement posture, please
refer to “Traveling 4” on Page 5-11
Leakage of
● Travelling when the sprocket is locked
travelling mm 13.6 27.2
● When the excavator is travelling under overflow
motor
conditions, measure the amount of oil leaking
within 1 minute
Bucket ● Hydraulic oil temperature: within operating range
Maximum
tooth ● Flat and firm ground mm Maximum 600
900
tip ● The bucket is filled with soil or is applied with rated
Boom load Maximum
mm Maximum 20
cylinder ●
Hydraulic drifting of working device
The boom is placed horizontally, the bucket arm is 27

fully retracted, and the bucket cylinder is fully
Bucket extended Maximum
rod ● The engine stops mm Maximum 160
200
Working Device
cylinder ● The working device control rod is at middle

position
● After the initial setting, please measure the
amount reduced every five minutes, and measure
the total amount reduced within 15 minutes
★ Lowering distance of bucket tooth tip
Bucket ★ Boom cylinder: retraction distance of cylinder Maximum
mm Maximum 35
cylinder ★ Bucket arm cylinder: extension distance of 40
cylinder
★ Bucket cylinder: retraction distance of
cylinder
● As for the specific measurement posture, please
refer to “Working device 1” on Page 5-11

Standard values for Permissible

new machine value
operating range
● The engine is running at high Lifting Seconds 4.8± 0.4 5.2
Boom
idle speed
● Work mode: H
● Time required for operation from
the moment when the bucket
contacts with ground to the
moment when it reaches the end
of lifting stroke Lowering Seconds 3.2± 0.4 3.6
● As for details about
refer to “Working device 2” on
Page 5-11
Working device speed
operating range
Working Device
● The engine is running at high Retraction Seconds 3.5± 0.4 3.9

idle speed
● Work mode: H
Bucket ● Time required for operation from
rod end of unloading stroke to end of
excavation
● As for details about Extension Seconds 3.5± 0.4 3.9
Page 5-11
operating range
● The engine is running at high Excavating Seconds 3.7± 0.4 4.1
idle speed
● Work mode: H
● Time required for operation from
Bucket
end of unloading stroke to end of
excavation
● As for details about Unloading Seconds 2.8± 0.4 3.2
Page 5-11


Standard values
Category Items Operating conditions for measurement Unit Criteria
for new machine
range
● The engine is running at low idle speed
● Work mode: H
● Time spent from the moment when the
handle is operated to the moment when the Maximum
Boom Seconds Maximum 1.0
bucket contacts the ground and push up 1.2
this machine under the condition that the
ground clearance is less than 50mm
● As for the specific measurement posture,
please refer to “Working device 1” on Page
5-11
range
● Work mode: H
Delay
● Tilt the control rod forwards and backwards

Bucket Maximum
Working Device
and change the direction when the bucket Seconds Maximum 2.0
rod 2.8
arm acts slightly, and measure the average
operating time
● As for details about measurement posture,
5-12
range
● Work mode: H
● Tilt the control rod forwards and backwards
Maximum
Bucket and change the direction when the bucket Seconds Maximum 1.0
3.6
acts slightly, and measure the average
operation time
● As for details about measurement posture,
5-12
Cylinder ● Hydraulic oil temperature: within operating 10 0
leakage
Internal
Central range
back ● The engine is running at high idle speed ml/min
● During overflow, measure the oil leaking 20 50
slewing
joint from cylinder within one minute cylinder

Performance when combined
range
operation is carried out

Deviation when ● Work mode: H
the operation of ● Travelling speed: low
working device ● On the hard and flat ground, after the Maximum
mm Maximum 200
and travelling excavator travels for about 10m, measure 220
are carried out the deviation when the excavator travels for
at the same time another 20m
● As for the specific measurement posture,
please refer to “Traveling 2” and “Traveling
3” on Page 5-10


Cat Standard
Operating conditions for
ego Items Unit values for new Permissible value
measurement
ry machine
Flowrate L/min
Performance of hydraulic pump
Pressure MPa
● When the pump speed is 2,000 rpm, the current value of pump electromagnetic valve is 650ma
Test the output Test the output Lower limit Q

Average Standard value
Inspectio pressure of pressure of other of judgment
pressure Q of flowrate
n Item pump pump standard
(MPa {kg/cm2}) (l/min)
(MPa {kg/cm2}) (MPa {kg/cm2}) (l/min)
Any Please refer to Please refer to
P1 P2 (P1＋P2)/ 2
point the curve the curve
★ During the measurement, make effort to ensure that the output pressure P1 and P2 of pump are
close to the average pressure.
★ When using the pump installed on this machine to carry out measurement, if the engine speed
can’t be set as the specified value via fuel control knob, please measure the output of pump and
speed of engine on measuring point, and then calculate the output of pump at specified speed
on the basis of such values.

Applicable to all excavator models (posture of this machine for measurement of performance)
Control valve: Stroke of slide valve Travelling 1: Travelling speed (without load)
Figure 5-1 Figure 5-2

Slewing 1: Slewing brake angle, start time of Travelling 2: Travelling speed (true operation),
slewing, slewing time travelling deviation

Slewing 2: The hydraulic drifting in back slewing Travelling 3: Travelling deviation
operation
Driving wheel

Travelling 4: Hydraulic drifting of travelling Working device 3: Bucket arm speed

Working device 1: Hydraulic drifting of working Working device 4: Bucket speed
device

Working device 2: Boom speed Working device 5: Boom delay

Working device 6: Bucket arm delay
Figure 5-13
Working device 7: Bucket delay
Figure 5-14

SY750H Hydraulic Excavator Testing and Adjustment
Testing and Adjustment

Measurement of Color of Exhaust Gas ....................................................................................................... 6-2
Adjust the valve clearance........................................................................................................................... 6-4
Measurement of compression pressure ...................................................................................................... 6-7
Inspection and adjustment of injection timing.............................................................................................. 6-8
Measurement of engine oil pressure ........................................................................................................... 6-9
Adjustment of engine speed sensor .......................................................................................................... 6-10
Inspection and adjustment of A/C compressor belt tensioning device ...................................................... 6-11
Measurement of clearance of slewing support bearing ............................................................................. 6-12
Inspection and adjustment of crawler plate tensioning device .................................................................. 6-14
Inspection and adjustment of hydraulic pressure in hydraulic oil ways for working device, slewing and
travelling .................................................................................................................................................... 6-15
Inspection and adjustment of control oil way pressure ............................................................................. 6-18
Measurement of output pressure of electromagnetic valve ...................................................................... 6-19
Measurement of output pressure of pilot valve ......................................................................................... 6-21
Adjustment of working device and slewing PPC valve .............................................................................. 6-22
Inspection of hydraulic settlement of working device ................................................................................ 6-23
Release of residual pressure in hydraulic oil way ..................................................................................... 6-25
Measurement of oil leakage ...................................................................................................................... 6-26
Air Bleeding for Every Device .................................................................................................................... 6-29
Inspection on sensor ................................................................................................................................. 6-31

Testing and Adjustment SY750H Hydraulic Excavator
Measurement of Color of Exhaust Gas

Measuring tool
Mark Model Part name

Filter-paper type
1 YDJ-2006
smoke scope
Light-proof smoke
2 SV-2TY
scope
When installing or dismantling the

measurement tool, don’t contact high-
temperature part.
1. Measurement with filter-paper type smoke

scope
1) Mount the filter paper into smoke scope.
2) Insert the exhaust gas intake pipe into
exhaust pipe.
3) Start up the engine and make it run until
the engine coolant temperature is within
the operating range.
4) When the engine accelerates suddenly or
runs at high idle speed, lead the exhaust
gas into filter paper on smoke scope by
operating the filter-paper type smoke
scope.
5) Remove the filter paper on filter-paper type Figure 6-1
smoke scope, and use the accompanied
instrument to read the smoke value.
6) After the measurement, dismantle the
measuring tool, and ensure that this
machine returns to normal state.

2. Measurement with light-proof smoke scope

1) Mount the light-proof smoke scope on
exhaust pipe, and use the clamp to fix it at
outlet.
Figure 6-2
2) Turn on the light-proof smoke scope to
carry out preheating (about 15 minutes).
the engine water temperature increases to
the level within operating range.
4) When the engine accelerates suddenly or
runs at high idle speed, use the light-proof
smoke scope to read the smoke value of
exhaust gas.
5) After the measurement, dismantle the
measuring tool, and ensure that this
Figure 6-3

Adjust the valve clearance

Inspection/repair standard (Unit: mm)
Standard Correction
Location Repair item Limit value
value method
Air intake 0.4 — Adjustment
Valve clearance (when the
— Bleed off
engine is in cold state) 0.4 — Adjustment
the air
Special tools
Location Name and shape of tool Part no. Usage
Feeler gauge
Adjust the valve

— MH061359
clearance
The valve clearance shall be inspected and

adjusted I cold state in accordance with the
following method:
Inspection
1. Remove the rocker arm cover.
2. In accordance with the following method, turn
the cylinder 1 or the cylinder 6 to the TDC of
compression stroke.
● Turn the crankshaft forwards, and arrange
the flywheel T/C line and indicating needle
in a straight line. At that moment, inspect
that there is clearance between rocker arm
and cam of cylinder 1 or cylinder 6
(compression TDC).
Note:
If the rocker arms on intake and exhaust sides can’t
be turned by hand, it can be judged that the piston
has been turned to the TDC of compression stroke.
On this basis, if the engine is further turned for one Figure 6-4
round, then the compression TDC position of
cylinder 1 or cylinder 6 will be interchanged.
When the cylinder head cover is dismantled, some
oil may flow out. Therefore, please prepare the
wiping cloth, so as to wipe away the oil.

3. Align the cylinder 1 with the compression TDC,

or align the cylinder 6 with the compression
TDC.
Table of adjustment
Cylinder number 1 2 3 4 5 6
Valve IN EX IN EX IN EX IN EX IN EX IN EX
Compression TDC of cylinder
1
○ ○ ○ ○ ○ ○
(The mark 0 indicates that the
component is adjustable)
Compression TDC of cylinder
6
○ ○ ○ ○ ○ ○
(The mark 0 indicates that the
component is adjustable)
1) When the measurement is carried out with

a thickness gauge, some resistance shall Rocker arm
be felt when the thickness gauge is moved
in the clearance.
2) If the thickness gauge can move freely in
the clearance, then the accurate measured
value can’t be obtained.
4. If the measured value exceeds the specified
value, please carry out adjustment in
accordance with the following method.
Figure 6-5

Adjustment Adjusting screw

1. When adjusting the valve clearance, firstly
loosen the locking nut, and then turn the
adjusting screw, until the slight resistance is felt Locking
when the thickness gauge is pulled out from nut
standard clearance.
Valve clearance
Figure 6-6
2. After the adjustment, use the screwdriver to
stop the adjusting screw, and fix it by tightening Adjusting
up the locking nut. screw
Locking nut: 78Nm {8.0 kgfm}

Carry out the next stop, until all valve
clearances have been adjusted.
3. Inspect the valve clearance with thickness
gauge again. If the clearance deviates from
standard value, please carry out adjustment
again.
Transverse arm
Figure 6-7

Measurement of compression pressure

Inspection standard
Correction
Location Repair item Standard value Limit value
method
Every cylinder (at
2940 kPa {30kgf/cm2} 2260 kPa {23kgf/cm2} Inspection
Compression 200rpm)
—
pressure Pressure difference Less than 196 kPa
— Inspection
between cylinders {2kgf/cm2 }
Special tools
Symbols Name and shape of tool Part no. Usage
Compression pressure gauge joint

A Measurement of
1-8531-7019-0
Compression Pressure
M14×1.5
Note: Confirm that the battery and starter are not

abnormal.
1. Disconnect the earthling cable of battery
Carefully: After turning the ignition switch to the
position OFF, please don’t get the battery cable
disconnected for more than 1 minute
2. Dismantle the intake pipeline
3. Dismantle the EGR cooler
4. Dismantle the preheating plug from cylinder
head. Note: Please dismantle preheating plugs
of every cylinder.
5. Remove the fuel injector harness joint from
lower end cover
Figure 6-8
6. Install the special tool onto cylinder head
assembly
Attention
Note: Insert the compression pressure gauge joint
into the installation hole for preheating plug, and During the operation, air may emit from preheating
then install the pressure gauge. plug hole, which is very dangerous. When the
7. Measurement of Compression Pressure engine is running, be sure not to touch or watch
the preheating plug hole.
Note: Make the engine rung, and read the stable
compression pressure indicated by the indicating If the ignition switch is turned to the position ON
needle of pressure gauge when the engine speed is under the circumstance that the fuel injector
about 200r/min. harness joint has been removed, the engine
control module will deem this as a trouble and
8. Measure the compression pressure of every
record the trouble diagnosis code. Therefore, be
cylinder
sure to clear away the trouble diagnosis code after
Note: Please measure the compression pressure the inspection is completed.
after the engine cools down.

Inspection and adjustment of injection timing

Inspection standard
Component to be
Location Standard value Limit value Correction method
tightened up
Injection timing
— 0° — Adjustment
(BTCD)
Tightening Torque Unit: kef｝

Location Component to be tightened up Tightening Torque Remarks
7 Timing adjusting bolt 31｛3.2｝ —
Inspection
1. Reversely turn the crankshaft to the position
before TDC 90°, and then turn the crank shaft
forwards, and align the P-P mark on flywheel
with timing indicating needle. At that moment,
inspect whether the cylinder q is located near
the compression TDC.
Figure 6-9
2. If the mark is not aligned, please loosen the two

long-hole coupling bolts. Turn the coupling and
align the mark on fuel feed pump and the mark
on coupling side, and then fix the coupling.
1. Coupling bolt
2. Mark on coupling side
3. Mark on pump side
4. With pin bolt
Tightening Torque:
Joint oil groove side: 54 N·m {5.5 kgf·m}
Fuel feed pump side: 44 N·m {4.5 kgf·m} Figure 6-10

Measurement of engine oil pressure

Inspection standard
Correction
Location Repair item Standard value
method
At maximum
Engine oil pressure (when
speed under
— the engine oil temperature is 540kPa｛6kgf/cm2｝ Adjustment
unloaded
70-90°)
condition
Tightening torque Unit: kef｝
Location Parts tightened Tightening Torque Remarks

Carry out inspection when
1 Engine oil pressure sensor 18{1.8}
the engine is in cold state
2 Switchover joint 59{6}
1. Dismantle the engine oil pressure sensor (1).
Attention
The engine oil pressure switch shall be installed
when the engine is in cold state.
Figure 6-11
2. Connect the engine oil pressure gauge to
transition joint (2) or switchover joint.
3. Preheat the engine until the engine oil
temperature reaches 70-90°.
4. Measure the engine oil pressure at minimum
speed under unloaded condition and maximum
speed under unloaded condition. If the
measured value is lower than the specified
standard value, please thoroughly inspect the
lubricating system.
5. After carrying out the measurement, mount the
engine oil pressure switch (1) and tighten it up
to the specified torque.
Figure 6-12

Adjustment of engine speed sensor

★ Disconnect the earthling wire of battery,
disconnect the harness joint of crankshaft
position sensor, and dismantle the crankshaft
position sensor from flywheel housing.
Note: Inspect whether the sensor is damaged, and
inspect whether the terminal drops off and is bent.
1. Insert the sensor (1), and confirm that the
sensor contacts with flywheel housing.
2. Tighten up the fixing bolt.
★ Tightening torque: 10Nm {1.0kgfm}
3. Connect the harness joint to crankshaft position
sensor, and connect the earthling cable of
battery to battery.
4. After the adjustment, confirm that the correct
engine speed is displayed in monitor panel.
Figure 6-13

Inspection and adjustment of A/C compressor belt tensioning device

Inspection
Use a finger to press down the belt at middle
position between driving belt pulley and compressor Compressor
belt pulley with the force of about 58.8 N (6kgf), and belt pulley
inspect the sagging (A). Its value shall be 5~8 mm
(0.20 in~0.31in).
Adjustment
★ If the sagging of belt is abnormal, please carry Driving belt
out adjustment in accordance with the following pulley
steps.
1. Screw off the bolts (1) and (2). Figure 6-14
2. Move the compressor (3) and bracket (4)
together, so as to adjust the belt tension force.
3. After locating the compressor (3), tighten up the
bolts (1) and (2).
4. After the adjustment, inspect the belt tensioning
device again.
Reference
Use the tension meter to inspect the tension force of
compressor belt
New belt Used belt

637±108 N 441±88.2 N
{65±11 kgf} {45±9 kgf}
Figure 6-15
Note:
● Inspect whether any belt pulley is damaged,
whether the V-shaped groove is worn and
whether the V-shaped belt is worn. In addition,
especially ensure that the V-shaped belt does
not contact the bottom of V-shaped groove.
● In case any of the following situations occurs,
please contact the authorized dealer of Sany
Heavy Machinery in your area, and get the belt
replaced with a new one in time.
● The fan belt has been stretched, and there
is no room for adjustment.
● Cut or crack is found on belt.
● There is abnormal sliding or abnormal
noise.
● After installing the new V-belt, please carry out
adjustment again after it has been put into
operation for one hour.

Measurement of clearance of slewing support bearing

Measuring tool
Symbols Component no. Name of component

H 60033930 Dial indicator
★ When measuring the clearance of slewing

support bearing installed on this machine,
please use the following method.
Park the excavator on the level ground, and
lower then working device to the ground.
During the measurement, don’t put your hand
or foot under the lower travelling body.
1. Fix the dial gauge H on crawler carrier, and
make the measuring needle point at the lower
end face of outer race.
Figure 6-16
2. Set the working device at the maximum work
distance, and make the end of bucket is as high
as the lower side of slewing table.
★ At that moment, the front end of upper slewing
platform will lower and the rear end will rise.
Figure 6-17

3. Return the indication of dial gauge H to zero.

4. Make the bucket arm vertical to ground, and
lower the boom until the front crawler plate
rises.
★ At that moment, the front end of upper slewing
platform will rise and the rear end will lower.
5. At that moment, read the value indicated by dial
gauge H.
★ The value of dial gauge H indicates the
clearance of bearing.
★ As for details about standard value, please
refer to structure, function and maintenance
standard for “slewing support ”. Figure 6-18
6. Return this machine to the state specified in
Step 2, and inspect whether the indication of
dial gauge H returns to zero.
★ If the dial gauge is not returned to zero, please
repeat the steps 3 through 5.

Inspection and adjustment of crawler plate tensioning device

Inspection
1. Make this machine travel forwards for a
distance which is equivalent to the length of
crawler on ground, maintain the engine speed
at low idle speed, and slowly stop this machine.
2. Place a straight bar on the crawler plate above
guiding wheel (1) and first sprocket (2).
★ It is advised to use angle-steel straight bar,
because its bend is relatively small. In
addition, L-shaped beam structure also
has the good bending property.
3. Measure the maximum clearance a between
upper surface of crawler and bottom face of
straight bar.
● Maximum standard clearance a: 10~30 Figure 6-19
mm(0.4~1.2 in)
Adjustment
★ If the tension force of crawler is incorrect,
please carry out adjustment in accordance with
the following method.
1. Reduce the tension force
1) Loosen the valve (1), drain the lubricating
grease, and then tighten up the valve.
Don’t screw off the valve for more than one
round. If the valve is excessively loosened,
the high-pressure grease in valve may
eject the valve out.
2) After the adjustment, re-inspect the tension
force of crawler plate in accordance with
the above-mentioned inspection method.
2. Increase the tension force Figure 6-20
1) Use the lubricating grease gun to fill the
lubricating grease via lubricating grease
nozzle (2).
2) After the adjustment, re-inspect the tension
force of crawler plate in accordance with
the above-mentioned inspection method.
★ Fill the lubricating grease, until the size
between guiding plate of guiding wheel and
end of crawler carrier becomes 0mm. If the
tension force is still very low, it means that the
axis pin and bushing are seriously worn, and
the axis pin and bushing must be replaced or a
link of crawler must be cancelled.
Figure 6-21

Inspection and adjustment of hydraulic pressure in hydraulic oil ways

for working device, slewing and travelling
★ Inspection and adjustment of hydraulic pressure in hydraulic oil ways for working device, slewing and
travelling
Mark Part no. Part name
60038932 Hydraulic tester
—
B210770000084 Pressure-measuring joint
★ The hydraulic oil pressure in hydraulic oil way for working device, slewing and travelling (output
pressure of hydraulic pump) can also be monitored through display screen.
Measurement
1. Preparatory work for measurement
Lower down the working device onto the
ground and turn off the engine. After the engine
stops, operate the control rod for several times
so as to release the residual pressure in
pipeline, and then screw off the disc-shaped
nut on breather valve, and press down the
release button, so as to release the pressure in
hydraulic oil tank.
1) Dismantle the hydraulic oil pressure
measuring plugs (1) and (2).
● Plug (1): Used for oil way of rear hydraulic
pump.
● Plug (2): Used for oil way of front hydraulic
pump.
2) Install the oil way pressure-measuring joint
and connect it to the hydraulic tester.
★ Please use the oil pressure gauge of
which the capacity is 40 MPa {408
kgf/cm2}.
3) Start up the engine and make it run until Figure 6-22
the hydraulic oil pressure increases to the
level within operating range.
2. Measurement of Unloading Pressure
1) Start Engine。
2) When the engine is running at high idle
speed and all control rods are moved to
middle position, measure the hydraulic oil
pressure.
★ Display the hydraulic oil pressure when the
unloading valve is carrying out unloading.
3. Measurement of overflow pressure of
working device
1) Start up the engine and move the cylinder
measured to the end of stroke.
speed and the cylinder is in overflow state,
measure the hydraulic oil pressure. Figure 6-23
★ Display the hydraulic oil pressure when the
main overflow valve is in overflow state.

4. Measurement of slewing overflow pressure

1) Start up the engine, extend the working
device forwards as much as possible, and
place the bucket on ground, so as to limit
the slewing.
speed and the slewing oil way is
overflowing, measure the hydraulic oil
pressure.
★ When the slewing motor safety valve is
overflowing, the hydraulic oil pressure will
be displayed.
★ The overflow pressure of slewing motor is
lower than main overflow pressure.
5. Measurement of travelling oil way overflow

pressure
1) Start up the engine and lock the travelling.
Place the pin ① between sprocket and
crawler bracket, so as to ensure that the
travelling is locked.
2) When the engine is running at high idle Figure 6-28
speed and the travelling oil way overflows,
measure the hydraulic oil pressure.
★ When the main overflow valve is in the
overflow state, the hydraulic oil pressure
will be displayed; when the travelling oil
way overflows, the pressure will always
lead to high-pressure overflow.
Adjustment
★ The unloading and safety valves used for boom
can’t be adjusted.
1. Adjustment of main overflow pressure (high-
pressure setting side)
★ If the high-pressure overflow pressure in oil
Figure 6-29
way for working device and travelling is not
normal, please adjust the high-pressure
setting side of main overflow valve (3) in
accordance with the following sequence.

1) Disconnect the pilot hose.

2) Screw off the locking nut (4), and adjust
the pressure by turning the adjusting screw
(5).
★ If the retainer turns to right side, the
pressure will increase. If the retainer
turns to left side, the pressure will
reduce.
★ Adjustment amount of every round of
retainer:
About 12.5 MPa {About 128 kg/cm2}
Locking nut:
49±6 Nm Figure 6-25
3) After the adjustment, inspect the pressure
again, and carry out measurement in
accordance with the above-mentioned
steps.
★ When measuring the pressure,
connect the pilot hose.
★ If the high-pressure side is adjusted,
the low-pressure side will also be
affected. Therefore, the low-pressure
side shall also be adjusted.
2. Adjustment of slewing overflow pressure

★ If the slewing overflow pressure is not
normal, adjust the slewing motor safety
valve (6) in accordance with the following Figure 6-26
sequence.
1) Screw off the locking nut (7) and adjust the
pressure by turning the adjusting screw
(8).
★ If the retainer turns to right side, the
pressure will increase. If the retainer
turns to left side, the pressure will
reduce.
★ Adjustment amount by every round of
adjusting screw:
About 6.71 MPa {About 68.4 kg/cm2}
Locking nut:
78-103 Nm{8.0-10.5 kgm}
2) After the adjustment, inspect the pressure Figure 6-27
again, and carry out measurement in
accordance with the above-mentioned
steps.

Inspection and adjustment of control oil way pressure

★ Tools for inspection and adjustment of pressure
in control oil way

— Pressure-measuring
B210770000084
joint
Measurement
hydraulic oil tank.
1. Dismantle the oil pressure measuring plug (1).

2. Install the pressure-measuring joint and
Oil outlet
connect it to the hydraulic tester.
port
★ Use the oil pressure gauge of which the
capacity is 6 MPa{61 kgf/cm2}.
3. Start up the engine and make it run until the
hydraulic oil temperature increases to the level Oil suction port
within operating range.
4. When the engine is running at high idle speed Figure 6-33
and all control rods are at middle position,
measure the oil pressure.
5. After the measurement, dismantle all
measurement tools, and ensure that this
★ It is prohibited to adjust the oil pressure
overflow valve of control oil way.

Measurement of output pressure of electromagnetic valve

Measuring tool

B210770000084
joint
★ After confirming that the initial pressure of
control oil way is normal, measure the output
pressure of electromagnetic valve.
hydraulic oil tank.
1. Disconnect the hose of electromagnetic valve,

so as to carry out measurement on outlet side.
No. Electromagnetic valve measured

A1 Pilot locking electromagnetic valve
High/low travelling speed changeover
A2
electromagnetic valve
Boom-slewing priority electromagnetic
A3
valve Figure 6-29
A4 Standby electromagnetic valve
Boom interflow control electromagnetic
A5
valve
A6 Boom-bucket priority electromagnetic valve
2. Respectively install three-way joints on

positions A1-A6 on electromagnetic valve, and
connect the hoses.
3. Install the pressure-measuring joint onto three-
way joint, and connect it to hydraulic tester.
★ Please use the hydraulic tester of which
2
the capacity is 6 MPa{61 kg/cm }.
hydraulic oil temperature increases to the level

5. Make the engine run with the throttle fully

opened, open or close every electromagnetic
valve by operating the control rod, and
measure the pressure.
★ The function of every electromagnetic
valve can be confirmed by the monitoring
function in monitor panel. (special function
of monitor on this machine).
★ When every output pressure is displayed
as the following value, it will be judged as
normal.
Table 1: boom-slewing priority, and high/low

travelling speed
Electromagnetic
Output pressure
valve
OFF
0{0}
(demagnetization)
ON
3.9~4.1MPa{39~41kgf/cm2}
(magnetization)
Table 2: boom 2 interflow and boom-bucket priority
Electromagnetic
Output pressure
valve
OFF
0{0}
(demagnetization)
ON
3.0~3.9MPa{30~39kgf/cm2}
(magnetization)
Table of state and function –PPC locking

Functions and states Functions
Safety Locking Locking OFF

Lever Unlocking ON
6. After the measurement, dismantle all

measurement tools, and ensure that this

Measurement of output pressure of pilot valve

Measuring tool
B210770000084
joint
★ After confirm that the initial pressure of control

oil way is normal, measure the output pressure
of PPC valve.
1. Dismantle the pilot oil pressure switch.

Oil way Oil way
No. No.
measured measured
1 Boom up 7 Slewing LEFT
2 Boom down 8 Slewing RIGHT
Bucket
3 9 Traveling LEFT
excavation
Bucket Traveling
4 10
unloading RIGHT
Bucket rod
5
unloading
Bucket rod
6
excavation
2. Install the pressure-measuring joint and

connect the hydraulic tester. Figure 6-30
★ Use the oil pressure gauge of which the
capacity is 6 MPa{61 kg/cm2}.
hydraulic oil temperature increases to the level
4. When the engine is running at high idle speed,
carry out measurement, and maintain the
control rod of oil way measured at the middle
position or full-stroke position.
★ If the measured output pressure of PPC
valve is as indicated in the table below,
then it will be judged as normal.
Control rod Hydraulic pressure
At middle position 0{0}
Close to average start
pressure for control
At full stroke
(Please refer to the table of
standard value)
5. Dismantle all measurement tools, and ensure

that this machine returns to normal state.

Adjustment of working device and slewing PPC valve

★ If the play of working device or slewing control
rod is too large, please carry out adjustment in
1. Dismantle the working device and slewing PPC
valve assembly.
2. Dismantle the rubber sleeve (1).
3. Screw off the locking nut (2), and then screw in
the disc (3) until it contacts the 4 heads of
plunger (4).
★ At that moment, don’t move the plunger.
4. Fix the disc (3), and then tighten up the locking
nut (2) to the specified torque.
Locking nut:98~127 Nm {10~13 kgm}
5. Install the rubber sleeve (1).
6. Install the working device and slewing PPC
valve assembly.
Figure 6-31

Inspection of hydraulic settlement of working device

★ If the working device (cylinder) has any
hydraulic settlement, please carry out
inspection in accordance with the following
procedure, and confirm whether the trouble
occurs in cylinder seal or control valve.
1. Inspection of boom and bucket cylinder
1) When carrying out the measurement,
maintain this machine in the posture as
indicated in right figure, and stop the
engine.
★ Fill the bucket with soil or apply the
rated load onto bucket.
2) Operate the control rod, so as to set the
boom at lifted position and the bucket at Figure 6-32
excavation position.
● If the lowering speed increase, the
cylinder seal is in trouble.
● If there is no change, the control valve
is in trouble.
★ When the engine start switch is at the
position ON, operate the control rod.
★ If the pressure in accumulator
reduces, make the engine run for
about 10s, so as to pressurize the
accumulator again.
2. Inspection of bucket arm cylinder

1) Set the machine in the posture as
indicated in right figure, set the bucket arm
cylinder at the position 100m away from
end of excavation stroke, and stop the
engine.
2) Operate the control rod, so as to set the
bucket arm at excavation position.
● If the lowering speed increase, the
cylinder seal is in trouble.
● If there is no change, the control valve
is in trouble.
position ON, operate the control rod. Figure 6-33
★ If the pressure in accumulator

reduces, make the engine run for
about 10s, so as to pressurize the
accumulator again.

[Reference] If the hydraulic settlement is caused by

trouble in seal of cylinder, then when
carrying out the above-mentioned
operation, the mechanism for reducing
acceleration is as follows:
1) If the working device displaced at the above-
mentioned position (the pressure is applied on
large chamber), the oil pressure of large
chamber will leak into small chamber, and thus
the pressure in small chamber will also
increase.
2) When the pressure in small chamber increases,
the pressure in large chamber will have to
increase so as to get balanced with it.
Repeatedly, the balance with be reached under
a certain pressure (on the basis of the
difference in leakage).
3) When the pressure is balanced, the downward
movement will slow down. If the control rod is
operated in accordance with the above-
mentioned procedure, the oil way of small
chamber will be opened to the oil discharge
way (the large chamber will be closed via the
one-way valve), the oil in small chamber will
flow into oil discharge way, and the downward
movement will speed up.
3. Inspection of PPC valve

When the accumulator is pressurized and the
safety locking rod is at the “locking” and
“unlocking” position, respectively measure the
hydraulic settlement of working device.
position “ON”, operate the control rod.
★ If the pressure in accumulator reduces,
please make the engine run for about 10
seconds, and then pressurize the
accumulator again.
★ If the hydraulic settlement of working
device is different when the safety locking
rod is at “locking” and “unlocking” position,
it means that the pilot valve is in trouble
(internal trouble).

Release of residual pressure in hydraulic oil way

Before disconnecting the pipeline between
hydraulic cylinders or between hydraulic motor
and control valve, please release the residual
pressure in accordance with the following
method.
★ Even if there is no residual pressure in slewing
motor oil way and travelling motor oil way, they
will also be affected by the internal pressure of
hydraulic oil tank. Therefore, please open the
breather valve to release the pressure before
the operation.
1. Stop the engine, screw off the disc-shaped nut

of breather valve, and press down the air
release button so as to release the pressure in
oil tank.
2. Turn the engine start switch to the position
“ON” and operate the control rod for several
times.
★ Please power on the PPC locking valve,
and operate the control rod when the
engine start switch is at the position ON.
★ After the control rod is operated for 2-3
times, the pressure in accumulator will be
released.
3. Start up the engine, make it run at low idle
speed for about 10 seconds so as to pressurize
the accumulator, and then stop the engine.
4. Repeat the above-mentioned steps 2 and 3 for
several times.

Measurement of oil leakage

1. Measurement of boom cylinder oil leakage
the hydraulic oil temperature increases to
the level within operating range, and then
extend the boom cylinder to the end of
stroke.
Release the residual pressure in pipeline.
Please refer to “Release of Residual
Pressure in Hydraulic Oil Way” in previous
section
2) Disconnect the hose (1) of small chamber
of cylinder and install the blind plug on end
of hose.
Be careful not to disconnect the hose of
Figure 6-39
large chamber of cylinder.
3) Start up the engine, make it run at high idle
speed, and apply the overflow pressure
onto large chamber of cylinder.
4) Maintain this state for 30 seconds, and
then measure the amount of oil leaking
within one minute.
5) After carrying out the measurement, make
sure that this machine returns to normal
state.
2. Measurement of oil leakage in bucket arm
cylinder
the level within operating range, and then
extend the bucket arm cylinder to the end
of its stroke.
section
2) Disconnect the hose (2) on small chamber
of hose.
Be careful not to disconnect the hose of Figure 6-40
within one minute.
state.

3. Measurement of oil leakage in bucket cylinder

the level within operating range. And then
extend the bucket cylinder to end of
excavation stroke.
section
2) Disconnect the hose (3) on small chamber
of hose.
Be careful not to disconnect the hose of Figure 6-41
within one minute.
state.
4. Measurement of oil leakage in slewing motor

1) Fully extend the working device, place the
bucket on ground so as to slightly lift up
the excavator, and stop the engine.
2) Disconnect the drain hose (4) and (5) and
install a blind plug into the hose.
3) Start up the engine. When the engine is
running at high idle speed, apply the
slewing overflow pressure, and measure
the oil leakage.
★ After the state specified in Step 3) is
maintained for 30 seconds, measure the
amount of oil leaking within one minute.
★ After the measurement is carried out for Figure 6-42
the first time, turn the upper slewing
platform for 180° and carry out
measurement again in accordance with the
same method.
state.

5. Measurement of oil leakage in travelling motor

1) Dismantle the travelling motor cover.
2) Start up the engine and lock the travelling.
Place the pin ① between sprocket and
crawler carrier, so as to prevent travelling.
3) Disconnect the drain hose (6) of travelling
motor and install a blind plug on hose end.
4) Start up the engine. When the engine is
running at high idle speed, apply the
travelling overflow pressure, and then
measure oil leakage.
During the measurement, the
Figure 6-38
misoperation of control rod may cause
serious accident. Therefore, please
ensure that all signals are correct.
★ After the state specified in Step 4) is
maintained for 30 seconds, measure
the amount of oil leaking within one
minute.
★ Repeat the measurement for several
times, gently rotate the motor, change
the position of oil distribution disc
between cylinder and the position
between cylinder and piston, and
repeat the measurement for several
times .
5) After carrying out the measurement,
please ensure that this machine returns to
normal state. Figure 6-39

Air Bleeding for Every Device

Air Bleeding Steps
Air Bleeding Item
Bleed the air Start the Bleed the air Bleed the air Bleed the air Start of
Work Contents from hydraulic engine from cylinder from back from travelling operation
pump slewing motor motor
Replace the hydraulic oil
Cleaning of filter element (Note) (Note)

Replacement of return filter element
Repair or replacement of hydraulic pump

Dismantlement of oil suction pipe
Repair or replacement of control valve
Replacement of cylinder
Dismantlement of cylinder pipeline
Replacement of back slewing motor
Dismantlement of pipeline of back slewing motor
Replacement of travelling motor
Dismantlement of pipeline of travelling motor
Note: When the oil in casing is drained, please bleed the air only from back slewing motor and travelling
motor.
1. Bleed the air from hydraulic pump.
1) Screw off the bleeding plug (1) and confirm
that the oil leaks from bleeding plug.
2) If oil leakage is confirmed, please tighten
up the bleeding plug (1).
Air bleeding plug: 7.8~9.8 N·m{0.8~1.0
kgf·m}
★ Notices for Starting of Engine
When starting up the engine after carrying
out air bleeding work as mentioned above,
make the engine run at low idle speed for
10 minutes.
Figure 6-45

2. Bleed air from hydraulic cylinder

1) Start up the engine and make it run at low
idle speed for 5min.
2) When the engine is running at low idle
speed, lift up and lower down the boom for
4-5 times.
★ Don’t apply the overflow pressure, and
stop the piston rod at about 100mm before
end of stroke.
3) Repeat the above Step (2). At that time,
the engine is running at high idle speed.
4) Please apply the overflow pressure by
extending the piston rod to end of stroke
when the engine is running at low idle
speed.
5) Bleed air from bucket arm cylinder and
bucket cylinder in accordance with the
steps stated in 2) through 4) above.
★ When replacing a new cylinder, please
carry out air bleeding for it before it is
mounted onto working device. As for boom
cylinder, after it is installed onto working
device, its piston rod can’t be extended to
the end of stroke at lowering side.
Therefore, be sure to bleed the air before it
is installed onto working device.
3. Bleed the air from back slewing motor

idle speed.
2) Bleed the air from motor by slowing turning
the upper back slewing platform.
4. Bleed the air from travelling motor

idle speed.
2) Screw off the oil discharge pipe (2) and
confirm that oil leaks out from bleeding
plug. Figure 6-41
3) If the oil leakage is confirmed, please
tighten up the oil discharge pipe (2).
:27.5~35.3 Nm{2.8~3.6 kgm}

Inspection on sensor
1. Inspection on water temperature sensor
● Place the sensor into a container which
contains engine oil.
● Increase the oil temperature to the specified
value, and at the same time agitate the engine Body
oil.
● Respectively measure the resistance between
terminal (1) and body.
50℃ 867.2 Ω
60℃ 586.5 Ω
Standard 80℃ 322.2 Ω
value 100℃ 188.4 Ω
Figure 6-42
106℃ 168.4 Ω
120℃ 116.3 Ω
● If the measured value exceeds the standard
value, please replace the sensor.
2. Inspection of engine speed sensor
● Measure the resistance between terminals 1
and 2.
Standard value (at 25
2.3±0.2 kΩ
degrees)
● If the measured value exceeds the standard
value, please replace the sensor.
Attention
● If the tightening torque of engine speed
sensor is insufficient, there may be no output
signal from sensor. Please tighten up the
engine speed sensor to the specified torque.
Figure 6-43
3. Inspection of pressure sensor
Connec Body Pressure
● Input voltage: 4.75~5.25VDC tor joint
● Output voltage: 0.5~4.5V
● Inspect the pressure range: 0-50BAR
Terminal B
Terminal Terminal C
A
Figure 6-44

4. Inspection on fuel level sensor

● Swing the buoy upwards and downwards, and Buoy
measure the effective radius and rotation angle
of lever. The rotation angle of connection line
bwteen buoy and rotation point shall be 105°.
● Swing the buoy upwards and downwards. The Lever
vertical distance between upper position and
lower position of buoy shall be 500mm.
● Move the buoy to upper end, and use the Terminal
multimeter to measure the resistance between R
Casing
terminal R of sensor and earth. The resistance
Ru shall be≦9.6Ω.
Plug-in
● Move the buoy to lower end, and use the elements
multimeter to measure the resistance between
terminal R of sensor and earth. The resistance
Rd shall be ≧86Ω.
Figure 6-45

SY750H Hydraulic Excavator Trouble diagnosis and troubleshooting
Trouble diagnosis and

troubleshooting
Work Procedure for Trouble Diagnosis ....................................................................................................... 7-4
Inspection before Trouble Diagnosis ........................................................................................................... 7-5
Category and steps of trouble diagnosis ..................................................................................................... 7-6
Category of trouble diagnosis .............................................................................................................. 7-6
Steps for trouble diagnosis ................................................................................................................... 7-6
Connector .................................................................................................................................................... 7-7
List of connectors ................................................................................................................................. 7-7
Position diagram of connector ............................................................................................................ 7-11
SWP connector .................................................................................................................................. 7-13
A/AMP connector ............................................................................................................................... 7-14
DT connector ...................................................................................................................................... 7-15
Trouble diagnosis when current trouble code is displayed ....................................................................... 7-16
Information contained in table of trouble diagnosis ............................................................................ 7-16
Trouble code E101 Internal trouble of controller ............................................................................. 7-17
Trouble code E102 The internal temperature of controller is abnormal ......................................... 7-18
Trouble code E103 The power supply for sensor is abnormal ....................................................... 7-19
Trouble code E104 There is error in memory ................................................................................. 7-20
Trouble code E105 There is error in CPU....................................................................................... 7-21
Trouble code E201 Power supply voltage is too low ...................................................................... 7-22
Trouble code E202 The voltage is too high .................................................................................... 7-23
Trouble code H402 The hydraulic oil temperature is too high ........................................................ 7-24
Trouble code P101 Engine oil pressure is too low .......................................................................... 7-25
Trouble code P301 The coolant temperature is too high ................................................................ 7-26
Trouble code P401 Fuel oil level is too low..................................................................................... 7-27
Trouble code P501 Air filter blocking .............................................................................................. 7-28
Trouble code P601 The water level in oil water separator is too high ............................................ 7-29
Trouble Diagnosis for Electrical System (Mode E) .................................................................................... 7-30
Table for connection of fuse box ........................................................................................................ 7-30
Information contained in table of trouble diagnosis ............................................................................ 7-31

Trouble diagnosis and troubleshooting SY750H Hydraulic Excavator
E-1 The engine could not be started .................................................................................................. 7-32

E-3: The engine can’t stop ................................................................................................................. 7-33
E-4 The automatic idling does not work ............................................................................................. 7-34
E-5 The preheating function does not work ....................................................................................... 7-35
E-6 All devices could not work ........................................................................................................... 7-36
E-7: The boom lifting acts slowly and powerlessly ............................................................................. 7-37
E-8: The bucket arm acts slowly and powerlessly ............................................................................. 7-38
E-9: The bucket acts slowly and powerlessly ..................................................................................... 7-39
E-10: The travelling is slow and powerless ........................................................................................ 7-40
E-11 The display screen goes black .................................................................................................. 7-41
E-12 The display screen could not display ......................................................................................... 7-42
E-13 The dual running speed function does not work ........................................................................ 7-43
E-15 The indication of fuel oil level is inaccurate ............................................................................... 7-44
E-16 The wiper does not work ............................................................................................................ 7-45
Trouble diagnosis for hydraulic and mechanical systems (mode H) ......................................................... 7-46
System diagram for hydraulic system and mechanical system ......................................................... 7-46
Information contained in table for trouble diagnosis ........................................................................... 7-47
H-1 The working device acts slowly, or the running and slewing speed is low. ................................. 7-48
H-2: The engine speed obviously reduces or the engine stalls ......................................................... 7-49
H-3: The working device, travelling or slewing functions can’t be activated ...................................... 7-49
H-4 The hydraulic pump has abnormal noise .................................................................................... 7-50
H-5 The automatic idling could not work. ........................................................................................... 7-51
H-6: The boom moves slowly ............................................................................................................. 7-52
H-7: The bucket arm moves slowly .................................................................................................... 7-53
H-8: The bucket moves slowly ........................................................................................................... 7-54
H-9 Single cylinder of working device could not act ........................................................................... 7-55
H-10 The settling volume of working device cylinder is too big ......................................................... 7-56
H-11 The action of working device is lagged...................................................................................... 7-58
H-12 Other working devices move when single oil way is overflowing .............................................. 7-58
H-13: During the slewing +travelling operation, the travelling speed obviously reduces ................... 7-59
H-14 The excavator deviates when running ....................................................................................... 7-60
H-15 The excavator runs slowly ......................................................................................................... 7-61
H- 16 It is not easy for the excavator to make a turn or the power is insufficient............................... 7-62
H-17 The running speed could not be changed ................................................................................. 7-63
H-18 The excavator could not run (only on one side) ........................................................................ 7-64
H-19 The excavator could not slew .................................................................................................... 7-65
H-20: The slewing acceleration performance is poor, or the slewing speed slow ............................. 7-66
H-21 The overrunning is too big when the slewing stops................................................................... 7-67
H-22 The impact is too big when the slewing stops ........................................................................... 7-68
H-23 The abnormal noise is too high when the slewing stops ........................................................... 7-68
H-24: The natural drifting during slewing is too large ......................................................................... 7-69

Precautions during Trouble Diagnosis

Park the excavator on the level ground and confirm the functions of safety pins, cushion blocks and
parking brake.
When operating collaboratively, it is necessary to use uniform signals and keep any irrelevant
personnel away.
The hot water would be sprayed and cause scald if the radiator cover was removed when the engine
is still hot. Thus, it is necessary to start the overhaul after the engine cools down.
Please be extremely careful, and don’t touch any hot part, or hold any rotating part.
Be sure to remove the negative (-) terminal of storage battery when removing the electric wires.
It is necessary to release the internal pressure when removing the plug or cap of the compartments
containing oil pressure, water pressure or air pressure etc.; it is necessary to connect properly when
installing the measuring equipment.
The purpose of trouble diagnosis is to accurately determine the root cause of trouble, quickly eliminate the
trouble, and prevent the recurrence of such trouble. For the purpose of carrying out trouble diagnosis, it is
important to understand the structure and function.
However, it would be a shortcut if learning about the possible causes for the trouble preliminarily from the
operating personnel for effective trouble diagnosis.
1. Do not rush to disassemble the parts when 5) Other daily maintenance items may be
performing trouble diagnosis. If the part was inspected from the appearance so that it
disassembled, the consequent might be: is only allowed to inspect the items
● The disassembled part is irrelevant to the deemed necessary.
trouble, or unnecessary part is 4. Confirm the trouble
disassembled. ● Confirm the trouble by yourself, and judge
● The trouble cause could not be found. whether it is a real trouble or a problem on
The trouble causes could not be found. This use or operation.
would waste labor, part, oil or grease, and ★ Do not perform any inspection or
meanwhile make the user or operating measurement which makes the
personnel lose confidence to the product. problem worse when operating the
Therefore, it is necessary to inspect first when excavator or the trouble phenomenon
performing trouble diagnosis, and carry out re-occurs.
according to the specified procedures. 5. Trouble Diagnosis
2. Questions for the user or operating personnel: ● Reduce the scope of trouble causes on
1) Were there any problems that had not the basis of the results of
been reported? inspection/testing items 2-4, and then
2) Was there any abnormal phenomenon on determine the trouble position on the
the excavator before the trouble occurs? basis of the flowchart for trouble
diagnosis.
3) Did the trouble occur suddenly or was
there any problem on the excavator ★ Basic procedures for trouble
before? diagnosis are as follows:
4) Under what conditions the trouble 1) Start from the simple items
occurred? 2) Start from the places with high
5) Was any repair carried out before the potential
occurrence of trouble? When was the 3) Inspect other relevant contents.
repair carried out? 6. Method for solving the primary trouble causes.
6) Did the same trouble occur before? ● If the root cause has not been removed,
3. Inspect other inspection items. the same trouble still will happen again
1) Inspect engine oil level. even though the trouble was solved.
2) Inspect whether the oil leaks from the Therefore, it is necessary to ascertain the
pipeline or hydraulic equipment. trouble causes and solve the root cause of
3) Inspect the stroke of control lever. troubles.
4) Inspect the stroke of control valve core.

Work Procedure for Trouble Diagnosis

Office Work Place
Step 1
Inspection and Determination of Symptom
When receiving the request for maintenance/repair from

customer, please firstly make sure the following matters:
Name of Customer
Model No. and Serial No. of Machine
Details of construction site, and etc.
Master the details of problem through inquiry
Trouble conditions Step 8

Work situation when trouble occurs
Carry out repair on site The trouble
work environment occurs!
Maintenance/repair history and etc.
Step 2
Determine the possible position where the cause
of trouble is located
Refer to the contents about trouble
diagnosis in Service Manual, so as to
identify the possible position where the Step 7
cause of trouble is located.
Determine the position of trouble (carry out
trouble diagnosis)
Decide the repair program
Step 8
Before carrying out the trouble diagnosis,
Carry out repair in please determine the simple trouble position
workshop
and repair.
Inspection items before start
Other inspection items

Mechanical
Manual Select the trouble diagnosis process on the basis of symptoms of
this machine by reference to contents about trouble diagnosis in
Service Manual, and then carry out inspection and repair.
Service
Manual
Step 3
Step 6
Prepare the trouble diagnosis tool
Reproduction of trouble
Refer to the table of trouble diagnosis
tools in Service Manual and prepare the Start and operate this machine, confirm the symptom of this
necessary tools. machine and judge whether there is a trouble.
T-shaped Joint
Hydraulic instrument and etc.
Refer to the catalogue of parts and prepare the

necessary replacement parts. Step 5
Inquire the operation personnel about detailed
Step 4 trouble situation
Was there any abnormal phenomenon before
Go to the site the trouble occurs?
Did the trouble occur suddenly?
Was any repair carried out when the trouble
occurred?

Inspection before Trouble Diagnosis

Items Criteria Measures
1. Confirm the level and variety of fuel oil — Fill in oil
2. Inspect whether there are foreign matters in the fuel oil — Clean and drain
Lubricating Oil, Coolant
3. Inspect the hydraulic oil level — Fill in oil

4. Inspect the filter screen of hydraulic oil — Clean and drain
5. Inspect the oil level of slewing mechanism — Fill in oil
6. Inspect the engine oil level (oil level of oil pan) — Fill in oil
7. Inspect the coolant level — Fill in water
8. Inspect the blocking situation of dust indicator — Sweep or replace
9. Inspect the hydraulic oil filter core — Replacement
10. Inspect the level of transmission oil — Fill in oil
1. Inspect whether the terminals and wires of storage
— Tighten or replace
battery are loose or corroded
equipment
Electrical
2. Inspect whether the terminals and wires of alternator

are loose or corroded
3. Inspect whether the terminals and wires starting motor
are loose or corroded
—
Hydraulic-
mechanic
1. Inspect the abnormal noise and odor Repair

al device
2. Inspect oil leakage — Repair

3. Bleed off the air — Bleed off the air
1. Inspect the storage battery voltage (engine extinction) 20-30V Replacement
2. Inspect the level of battery electrolyte — Add or replace
3. Inspect whether the electric wires are discolored,
Electrics and electrical equipment
— Replacement
scorched or peeled off
4. Inspect whether the wire clips drop or whether the
— Repair
electric wires are suspended
Remove the
5. Inspect whether the electric wires get wet (inspect
— connector and dry
carefully the connectors or terminals)
it
6. Inspect whether the fuses are blown or rusted — Replacement
After the engine
7. Inspect the alternator voltage (the engine is running at has run for
Replacement
semi-throttle opening) several
minutes:
27.5~ 29.5 V
8. Inspect the noise when the battery relay works (the
— Replacement
switch is turned ON/OFF)

Category and steps of trouble diagnosis

Category of trouble diagnosis
Mode Contents
When the service code (electrical system) and trouble code (mechanical system)
Code display
are displayed, please carry out trouble diagnosis.
Mode E Trouble Diagnosis for Electrical System
H mode Trouble Diagnosis for Hydraulic and Mechanical Systems
Steps for trouble diagnosis

When any trouble occurs to this machine, please determine the relevant trouble diagnosis code, and
explain the diagnosis.
You may diagnose and analyze the trouble in accordance with the following 6 basic steps, so as to identify
the cause of trouble and formulate the corresponding handling method:
1. Please carefully refer to the relevant Before carrying out trouble diagnosis, please
technical manual, and understand the inspect the records about operation and
relevant systems and their operating maintenance in driver manual, inquire about
principles as well as the structure, function whether the relevant personnel have ever
and technical specification of every carried out operation or maintenance in
component thereof. violation of rules, and inspect whether there is
any wrong operation or maintenance.
2. Inquire the driver
Inspect whether any part of mechanical
Before carrying out inspection, please inquire
equipment is abnormal; such as leakage or
the driver about all details of trouble.
leakage of oil or water, loosening of pipeline, or
Before carrying out inspection, please inquire abnormal cracking. In addition, inspect the
the driver about all details of trouble. electrical system; for example, whether the
battery voltage is normal, whether the
a) Current use condition of this machine: connector of power line falls off or is burnt out,
Does this machine operate correctly?
and whether the fuse has blown (with
b) Time when the trouble was found: Which multimeter).
operation was this machine carrying out at
4. Operate this machine (trial operation)
that time?
When it is confirm that no third item is
c) Development of trouble: Is the trouble abnormal, please carry out the start inspection
becoming more and more serious or does for equipment in accordance with the normal
it occur suddenly for the first time?
operation method, and confirm the cause of
d) Which other troubles have ever occurred trouble. If the trouble can’t be confirmed,
to this machine? For example: which please stop the engine, and further obtain the
components have been repaired or details of trouble from driver.
replaced?
5. Carry out the trouble diagnosis
e) Has any handling been carried out after Please carry out detailed analysis and
this trouble occurred?
confirmation on the basis of the phenomena of
f) Is the trouble reproducible? Is there any mechanical equipment and the information
law? displayed.
3. Inspection before trouble diagnosis 6. Identify the possible causes
Before making the conclusion, inspect the
most possible causes again, and make efforts
to determine the true cause of trouble. On the
basis of your conclusion, formulate the
appropriate repair program.

Connector
List of connectors
Number of
Type Number of Pins Name of device
Connector
CN-109M Plug-in elements 2 To horn button
CN-112M Plug-in elements 7 To radio
CN-113F Plug-in elements 2 To pilot locking rod
CN-116F Plug-in elements 12 To A/C
CN-118M Plug-in elements 2 To emergency stop switch
CN-119M Plug-in elements 3 Middle connector
CN-110F Plug-in elements 12 Middle connector
CN-117M Plug-in elements 6 To wiper controller
CN-161M Plug-in elements 8 To dome light switch
CN-162M Plug-in elements 8 To washer switch
CN-163M Plug-in elements 8 To wiper switch
CN-164M Plug-in elements 8 To working light switch
CN-165M Plug-in elements 3 To throttle knob
CN-166M Plug-in elements 6 To key switch
CN-210F Plug-in elements 3 To fuel filtration pump
CN-211F Plug-in elements 2 To oil filling pump
CN-212F Plug-in elements 2 Diode
T-214 Terminal 1 To earth of fuel level sensor
CN-213M Plug-in elements 1 To fuel oil level sensor
T-228 Terminal 1 To battery relay contact input
T-229 Terminal 1 To battery relay contact output

Number of
Connector
T-208 Terminal 1 To battery relay coil+
T-209 Terminal 1 To battery relay coil+
CN-207M Plug-in elements 2 To start relay coil
CN-472M Plug-in elements 2 To start relay contact
CN-206M Plug-in elements 2 To preheating relay coil
CN-223M Plug-in elements 1 To preheating relay contact input
CN-224M Plug-in elements 1 To preheating relay contact output
T-201 Terminal 1 To always-on fuse input
T-202 Terminal 1 To always-on fuse output
T-225 Terminal 1 To preheating fuse output
T-226 Terminal 1 To main circuit fuse input
T-227 Terminal 1 To main circuit fuse output
T-230 Terminal 1 To start relay fuse output
CN-205F Plug-in elements 2 To oil filling pump switch
T-216 Terminal 1 To earthling point of electrical equipment
T-217 Terminal 1 To earthling wire of controller
CN-219F Plug-in elements 2 To platform working light
CN-305M Plug-in elements 3 To pressure sensor of pump 1
CN-306M Plug-in elements 3 To pressure sensor of pump 2
CN-307M Plug-in elements 2 To cooling pump proportional valve
CN-308M Plug-in elements 2 To proportional valve of pump 1
CN-309M Plug-in elements 2 To proportional valve of pump 2
CN-310M Plug-in elements 2 To hydraulic oil temperature sensor
CN-311F Plug-in elements 3 To oil water separator water level sensor
CN-439M Plug-in elements 94 To electrical socket for pin 94 of ECM
CN-438M Plug-in elements 60 To electrical socket for pin 60 of ECM
CN-436M Plug-in elements 40 To main controller 40pin socket
To electrical socket for pin 81 of main
CN-437M Plug-in elements 81
controller
CN-435M Plug-in elements 14 External communication mouthpiece

Number of
Connector
CN-433M Plug-in elements 16 Engine diagnosis mouthpiece
CN-100M Plug-in elements 2 Engine trouble clearing mouthpiece
CN-408M Plug-in elements 3 To atmospheric pressure sensor
CN-409M Plug-in elements 2 To intake temperature sensor
CN-410M Plug-in elements 2 To air filter blockage switch
To bucket arm excavation pilot pressure
CN-411F Plug-in elements 3
sensor
To bucket arm unloading pilot pressure
sensor
CN-413F Plug-in elements 2 To pilot locking electromagnetic valve
To double-travelling-speed electromagnetic
valve
CN-415F Plug-in elements 2 To boom priority 1proportional valve
CN-416F Plug-in elements 2 To standby electromagnetic valve
To boom interflow cut off electromagnetic
valve
CN-418F Plug-in elements 2 To boom priority 2 proportional valve
CN-419F Plug-in elements 3 To cooling pump pressure sensor
CN-420F Plug-in elements 3 To boom lifting pilot pressure sensor
CN-421F Plug-in elements 3 To boom lowering pilot pressure sensor
CN-422F Plug-in elements 3 To bucket excavation pilot pressure sensor
CN-423F Plug-in elements 3 To bucket unloading pilot pressure sensor
CN-424F Plug-in elements 3 To slewing pilot pressure sensor
CN-425F Plug-in elements 3 To left travelling pilot pressure sensor
CN-426F Plug-in elements 3 To right travelling pilot pressure sensor
T-480 Terminal 1 To generator terminal E
T-479 Terminal 1 To generator terminal B
T-481 Terminal 1 To earthling point of engine supporting leg
CN-407M Plug-in elements 2 To generator
CN-406M Plug-in elements 1 To A/C compressor
CN-301F Plug-in elements 5 To video camera
CN-427F Plug-in elements 2 To electromagnetic pump
CN-303F Plug-in elements 2 To electromagnetic pump switch
CN-482F Plug-in elements 1 To plug-in part H of engine
CN-405F Plug-in elements 16 To plug-in part B of engine
CN-404F Plug-in elements 20 To plug-in part D of engine
CN-403F Plug-in elements 32 To plug-in part A of engine
T-486 Terminal 1 To terminal S of start motor
T-485 Terminal 1 To start motor terminal B

Number of
Connector
CN-456F Plug-in elements 3 To boom large chamber pressure sensor
CN-454F Plug-in elements 2 To high-pitch horn
CN-455F Plug-in elements 2 To low-pitch horn
CN-119M Plug-in elements 2 To washer
T-125 Terminal 1 To terminal 5S of fuse box
T-134 Terminal 1 To socket of inspection light -
T-135 Terminal 1 To socket of inspection light +
CN-450F Plug-in elements 5 To KC main relay
CN-451F Plug-in elements 5 To start cutoff relay
CN-121M Plug-in elements 8 Grey electrical plug of fuse box
CN-122M Plug-in elements 8 Red electrical plug of fuse box
CN-123M Plug-in elements 8 Black electrical plug of fuse box
CN-124M Plug-in elements 8 Orange electrical plug of fuse box
CN-129M Plug-in elements 8 Blue electrical plug of fuse box
CN-130M Plug-in elements 8 Yellow electrical plug of fuse box
CN-131M Plug-in elements 8 Green electrical plug of fuse box
CN-132M Plug-in elements 8 Brown electrical plug of fuse box
CN-501F Plug-in elements 2 To left working light on boom
CN-502F Plug-in elements 2 To right working light on boom
CN-101M Plug-in elements 34 To display screen
CN-107M Plug-in elements 2 Display screen resetting mouthpiece
CN-103M Plug-in elements 2 To sunshine sensor
CN-104M Plug-in elements 2 To cigarette lighter socket

Position diagram of connector
Figure 7-1

Figure 7-2

SWP connector
Convex Concave
(electrical plug) (electrical socket)
(The number
of pins is 1)
(The number
of pins is 2)
(The number
of pins is 6)
(The number
of pins is 8)
(The number
of pins is 16)
Figure 7-3

A/AMP connector
Convex Concave
(The number of
pins is 2)
(The number of
pins is 2)
(The number of
pins is 3)
Figure 7-4

DT connector
Housing Housing
(The number
of pins is 3)
(The number of
pins is 6)
(The number of
pins is 8)
(The number of
pins is 12)
Figure 7-5

Trouble diagnosis when current trouble code is displayed

Information contained in table of trouble diagnosis
Trouble code Code The trouble code the corresponding trouble
Trouble
Displayed on display information will be displayed on display
—— Phenomenon
screen screen
Trouble warning
Trouble symptoms listed in historical trouble record
conditions
Measures taken by the controller when any trouble is detected, so as to protect
Reaction of controller
the affected system or equipment
Phenomena occurring to Phenomenon of this machine caused by the protective measures taken by
this machine controller
Standard value in normal state and reference value for

Causes
trouble diagnosis
1 <Contents contained>
2 ● Standard value of normal state, which can be used
to judge that the assumption is justified.
3
● Reference value, which can be used to carry out
4 the above-mentioned judgment.
Estimated
causes <Symptoms of trouble of wire harness >
Assumed cause of trouble to be
and
standard
discussed ● Broken circuit
(The numbering is for the
value in Same as poor contact in connector or broken wire
purpose of facilitating the
normal harness.
writing, and does not represent
state
any priority order.) ● Troubles of earthling wire
5 The wire which may not contact with earthling wire
actually contacts with earthling wire.
● Short circuit
The wire which may not be connected with 24V circuit
actually contacts with such circuit.
Relevant Wiring Diagrams
This is a part of the wiring diagram, and mainly displays the part in trouble

Trouble code E101 Internal trouble of controller

Trouble code Code
Trouble
Displayed on display Internal trouble of controller
E101/ Phenomenon
screen
Trouble warning conditions There is error in RAM/EEPROM; the stop of task is detected
Reaction of controller Warning output
Phenomena occurring to
——
this machine

Causes
trouble diagnosis
Stop the motor, make the coil in proportional
electromagnetic valve coil rotate, and make the engine
1 There is error in RAM/EEPROM speed return to the automatic idling speed. In the
normal state, the machine will resume after being
Estimated powered on again.
causes The operation will continue, and only the abnormal code
and 2 The stop of task is detected
will be sent
standard
value in
3
normal
state

Trouble code E102 The internal temperature of controller is abnormal

Trouble code Code
Trouble The internal temperature of controller is
Displayed on display Phenomenon abnormal
E102/
screen
Trouble warning The internal temperature of controller has been higher than 110℃ or lower than
conditions -40℃ for 10Sec
The operation will continue
this machine

Causes
trouble diagnosis
The internal temperature of The internal temperature of controller has been higher
1
controller is abnormally high than 110℃ for 10Ses
Estimated The internal temperature of The internal temperature of controller has been lower
2
causes controller is abnormally low than -40℃ for 10Ses
and
standard
value in 3
normal
state
4

Trouble code E103 The power supply for sensor is abnormal

Trouble code Code
Trouble
Displayed on display The power supply for sensor is abnormal
E103/ Phenomenon
screen
Trouble warning The output of power supply to sensor is detected as abnormal and this state has
conditions lasted for 1Ses
this machine

Causes
trouble diagnosis
The supply voltage has been abnormal for more than
1 The supply voltage is abnormal
1S
Estimated The power supply for sensor is The supply voltage for sensor has been abnormal for
2
causes abnormal more than 1S
and
standard
value in 3
normal
state
4

Trouble code E104 There is error in memory

Trouble code Code
Trouble
Displayed on display There is error in memory
E104/ Phenomenon
screen
Trouble warning
There is error in memory for GPS locking
conditions
this machine

Causes
trouble diagnosis
1 There is error in memory There is error in memory for GPS locking

Estimated
causes
and 2
standard
value in
normal
state 3

Trouble code E105 There is error in CPU

Trouble code Code
Trouble
Displayed on display There is error in CPU
E105/ Phenomenon
screen
The abnormal situation is detected by CPU; the error in memory which can’t be
Trouble warning
repaired is detected; the pause of I2C communication is detected; the writing of
conditions
program is abnormal; the writing of parameter is abnormal
Warning output
Stop motor, proportional electromagnetic valve coil drive/driving
Reaction of controller
The engine speed will return to the automatic idling level
In the normal state, it will resume by connecting the power supply
The normal action is slow, and the speed is automatic idling speed
this machine

Causes
trouble diagnosis
1 There is error in CPU The abnormal situation is detected by CPU

Estimated
causes 2 There is error in memory The error in memory which can’t be repaired is detected
and
standard The I2C communication is
value in 3 The pause of I2C communication is detected
abnormal
normal
state The writing of
4 The writing of program/parameter is abnormal
program/parameter is abnormal
This is an internal trouble. If the trouble can’t be
5 Internal trouble of controller eliminated by turning on the power switch again, please
replace the controller

Trouble code E201 Power supply voltage is too low

Trouble code Code
Trouble
Displayed on display Power supply voltage is too low
E201/ Phenomenon
screen
Trouble warning
Voltage <18V and lasted for 10Sec
conditions
The action of whole machine becomes slow
this machine

Causes
trouble diagnosis
Turn the engine start switch to the position OFF for
making preparation, and remain the switch at the
1 The power supply is in trouble
position OFF for carrying out trouble diagnosis.
Estimated
Measured voltage of battery: Less than 25V
causes
and Start up the engine, and measure the voltage between
2 The generator is abnormal
standard terminal B of generator and earth: about 28V
value in
normal 3
state
4

Trouble code E202 The voltage is too high

Trouble code Code
Trouble
Displayed on display The voltage is too high
E202/ Phenomenon
screen
Trouble warning
Voltage >32V and lasted for 10Sec
conditions
——
this machine

Causes
trouble diagnosis
Start up the engine, and measure the voltage between
1 The generator is abnormal
terminal B of generator and earth: about 28V
Estimated
causes
2
and
standard
value in 3
normal
state
4

Trouble code H402 The hydraulic oil temperature is too high

Trouble code Code
Trouble
Displayed on display The hydraulic oil temperature is too high
H402/ Phenomenon
screen
Trouble warning
The hydraulic oil temperature is higher than 90℃
conditions
The normal action becomes slow
this machine

Causes
trouble diagnosis
The output of cooling pump is Inspect the output pressure of cooling pump: More than
1
abnormal 13mpa
Estimated
causes The speed of cooling fan is
2 Inspect the speed of cooling fan: More than 1920rpm
and abnormal
standard
value in 3
normal
state
4

Trouble code P101 Engine oil pressure is too low

Trouble code Code
Trouble
Displayed on display Engine oil pressure is too low
P101/ Phenomenon
screen
Trouble warning
The ECM sends the warning signal for too low engine oil pressure
conditions
Reaction of controller The warning is sent out, and the engine speed is reduced to idle speed
The engine speed is reduced to low idle speed
this machine

Causes
trouble diagnosis
Immediately stop the engine, and inspect the level of
1 The engine oil is insufficient
engine oil
Estimated
causes
2
and
standard
value in 3
normal
state
4

Trouble code P301 The coolant temperature is too high

Trouble code Code
Trouble
Displayed on display The coolant temperature is too high
P301 Phenomenon
screen
Trouble warning
The coolant temperature is higher than 105℃
conditions
Reaction of controller The warning is sent out, and the engine speed is reduced to idle speed
The engine speed is reduced to idle speed
this machine

Causes
trouble diagnosis
1 The thermostat is not turned on Inspect whether the thermostat is turned on

Estimated
causes
2 Fan belt is loose Inspect whether the fan belt is tensed
and
standard
value in 3 The fan is damaged Inspect whether the cooling fan is damaged
normal
state
4 The coolant is insufficient Inspect whether the coolant is insufficient

Trouble code P401 Fuel oil level is too low

Trouble code Code
Trouble
Displayed on display Fuel oil level is too low
P401/ Phenomenon
screen
Trouble warning
Fuel level <10% and delay for 10Sec
conditions
——
this machine

Causes
trouble diagnosis
1 The fuel level is lower than 10% Please add the fuel
Estimated
causes
2
and
standard
value in 3
normal
state
4

Trouble code P501 Air filter blocking

Trouble code Code
Trouble
Displayed on display Air filter blocking
P501/ Phenomenon
screen
Trouble warning
The air filter blockage pressure switch is closed, and the warning is generated
conditions
——
this machine

Causes
trouble diagnosis
Inspect the air filter, clear away the dust, and clean up
1 Air filter blocking
the strainer
Estimated
causes
2
and
standard
value in 3
normal
state
4

Trouble code P601 The water level in oil water separator is too high
Trouble code Code
Trouble The water level in oil water separator is too
Displayed on display Phenomenon high
P601/
screen
Trouble warning The water level sensor of oil water separator detects that the water level is too
conditions high
The water level in oil water separator exceeds the warning level
this machine

Causes
trouble diagnosis
The water level in oil water Turn on the oil water separator water level switch, and
1
separator is too high drain the water accumulated
Estimated
causes
2
and
standard
value in 3
normal
state
4

Trouble Diagnosis for Electrical System (Mode E)

Table for connection of fuse box
★ This table of connection gives the devices
which obtain power supply from fuse box and
the rated current.
★ If the power supply is normal, when carrying
out the trouble diagnosis for electrical system,
please inspect the fuse box and fuse, so as to
understand the situations.
Integrated fuse box
Fuse No./relay No. Rated value System
F1 20A Starting loop
F2 15A Power-on signal
F3 10A Starting signal
F4 5A Extinction delay
F5 10A Charging indicator
F6 20A Main controller power supply
F7 10A Power supply for display screen
F8 15A Manual/automatic
F9 10A Radio
F10 5A Warning light (light)
F11 10A Fuel filtration pump
F12 10A Cigar lighter
F13 10A +24V power supply
F14 20A Working light
F15 20A Dome light in cab
F16 5A Warning light (sound)
F17 5A Wiper/washer
F18 20A A/C
F19 5A GPS power supply
F20 30A ECM power supply
F21 15A Power supply for PVC
F22 10A Electromagnetic pump
F23 15A Horn
F24 5A Inner light
F25 5A Overhaul light
F26 10A Oil filling pump
F27 10A Reserved
F28 30A Reserved
K2 24V,20A 5-PIN MICRO Main controller power supply relay
K3 24V,20A 5-PIN MICRO Working light relay
K4 24V,20A 5-PIN MICRO Dome light relay in cab
K5 24V,20A 5-PIN MICRO Warning light (sound) relay
K8 24V,20A 5-PIN MICRO Electromagnetic pump relay
K9 24V,20A 5-PIN MICRO Horn relay
K10 24V,20A 5-PIN MICRO Fuel filtration pump relay
K11 24V,20A 5-PIN MICRO Warning light (light) relay
K12 24V,20A 5-PIN MICRO Flameout delay relay
K15 24V,20A 5-PIN MICRO Oil filling pump relay
K16 24V,20A 5-PIN MICRO Reserved
K17 24V,20A 5-PIN MICRO Reserved

Information contained in table of trouble diagnosis

Trouble information Phenomena occurring to this machine
Relevant information Information about trouble and trouble diagnosis
Standard value in normal state and reference

Causes
value for trouble diagnosis
<Contents contained>
● Standard value of normal state, which can be
used to judge that the assumption is justified.
● Reference value, which can be used to carry
Assumed cause
Estimated of trouble to be out the above-mentioned judgment.
causes discussed <Symptoms of trouble of wire harness >
and (The numbering
standard is for the ● Broken circuit
value in 1 purpose of Same as poor contact in connector or broken wire
normal facilitating the harness.
state writing, and
does not ● Troubles of earthling wire
represent any The wire which may not contact with earthling wire
priority order.)
actually contacts with earthling wire.
● Short circuit
The wire which may not be connected with 24V
circuit actually contacts with such circuit.

E-1 The engine could not be started

The engine can’t be started (The engine does not
Trouble information
rotate)
Relevant information
Causes Standard value in normal state and reference value for trouble diagnosis
The ★ Turn the engine start switch to the position OFF for making preparation, and
capacity of maintain the switch at the position OFF for carrying out trouble diagnosis.
1
battery is Voltage
insufficient Storage battery voltage More than 24V
value
Internal ★ Turn the engine start switch to the position OFF for making preparation, and
trouble of maintain the switch at the position OFF for carrying out trouble diagnosis.
2 starting Position OFF: between wire 22 and wire 11 More than 1MΩ
switch for Resistance
engine Position ON: between wire 22 and wire 11 value Less than 1 Ω
★ Turn the engine start switch to the position OFF for making preparation, and
maintain the switch at the position OFF for carrying out trouble diagnosis.
Trouble of
Unlocking position of locking rod: between wire
3 leading Less than 1M Ω
switch 105 and wire 0 Resistance
Locking position of locking rod: between wire 105 value
More than 1Ω
and wire 0
● Turn the engine start switch to the position OFF for making preparation, ad
make the engine rung during the trouble diagnosis (If the power supply,
Estimated earthling, signal and input of engine are normal and only the output of engine
causes is abnormal, then the engine start motor is in trouble.)
Trouble of
and
4 starting Starting
standard Engine start motor Voltage value
motor switch
value in
normal Power supply: terminal B and earth 20—30V
Start
state Between engine input end S and earth 20—30V
The wire then maintain the switch at the position ON for carrying out trouble diagnosis.
harness is Wire 22 of start switch and terminal B of start
5 Less than 1Ω
open- motor Resistance
circuited Wire 11 of start switch and terminal SW of start value
Less than 1Ω
relay
Trouble of Terminal “+” (wire 20) of battery and wire 22 of Resistance
6 Less than 1Ω
fuse F1 control knob value
The wire ● Turn the engine start switch to the position OFF for making preparation, and
harness is maintain the switch at the position OFF for carrying out trouble diagnosis.
short-
7 Between terminal SW of start relay and earth More than 1 MΩ
connected Resistance
(Earthling value
Between engine input end S and earth More than 1 MΩ
trouble)
Internal ● Turn the engine start switch to the position OFF for making preparation, and
trouble of then maintain the switch at the position ON for carrying out trouble diagnosis.
8
AC Voltage
generator Between terminal P of generator and earth Less than 1V
value

E-3: The engine can’t stop

Trouble information The engine can’t be stopped
When the engine start switch is turned to the position OFF, the
engine will stop without delay
Trouble of
When the engine start switch is operated, if the operating sound is heard from
Estimated 1 storage relay contact of battery, the battery can be judged as normal. Start switch ON-
causes battery
START-ON.
and relay
standard Internal Since this is an internal trouble, no trouble diagnosis can be carried out. (If the
value in 2 trouble of cause of trouble is not the above-mentioned cause, the controller or procedure
normal controller is in trouble)
state 3
Battery relay
BAT-1 battery
Figure 7-6

E-4 The automatic idling does not work

Trouble information The engine has no automatic idling function
In the automatic idling mode, when the handle is at middle
position, the engine speed does not reduce

Causes
trouble diagnosis
● Turn the engine start switch to the position OFF for
making preparation, and then start up the engine and
make it run for carrying out trouble diagnosis.
When the control rod is at
Estimated middle position, the
1 The sensor has trouble 0 KG
causes pressure signal is
Pressure
and transmitted
value
standard When the control rod is
value in operated, the pressure 0～37 KG
normal signal is transmitted
state ● Since this is an internal trouble, no trouble diagnosis can
be carried out. (If it is not for the above-mentioned
2 Controller trouble
reasons, the controller or procedure should be in
trouble)
3
4

E-5 The preheating function does not work

Trouble information The engine preheating function does not work
★ Turn the engine start switch to the position OFF for making preparation,
Trouble of and maintain the switch at the position OFF for carrying out trouble
1 preheating diagnosis.
fuse Between wire 21 and pin 3 (contact) of Resistance
Less than 1 Ω
preheating relay value
Trouble of When the preheating function is activated, if the operating sound can be heard
2 preheating from contact of preheating relay, the relay can be judged as normal. Preheating
Estimated relay switch OFF-ON-OFF.
causes
and
and maintain the switch at the position OFF for carrying out trouble
standard The
diagnosis.
value in preheating
3 The preheating switch is disconnected:
normal switch is in More than 1M Ω
state trouble between wire 16# and wire 17# Resistance
The preheating switch is closed: between wire value
Less than 1 Ω
16 and wire 17
Short- ★ Turn the engine start switch to the position OFF for making preparation,
circuit and maintain the switch at the position OFF for carrying out trouble
4 trouble of diagnosis.
wire Between pin 3 (contact) of preheating relay Resistance
(grounding) and earth More than 1M Ω
value
5
Storage
Starting
battery
switch
Preheating relay
switch
Storage battery relay
Preheating relay
Preheater
Body harness Cab Body harness
Figure 7-7

E-6 All devices could not work

Trouble information After this machine is started, this machine does not act
★ Turn the engine start switch to the position OFF for making
preparation, and then start up the engine and make it run for carrying
out trouble diagnosis.
Trouble of
1 safety locking Safety Resistance
Measurement items
switch control rod value
Locking Less than 1 Ω
Estimated Between wire 105 and wire 41
Loosen More than 1M Ω
causes
and ★ Turn the engine start switch to the position OFF for making
standard Short-circuit preparation, and maintain the switch at the position OFF for carrying
value in 2 trouble of wire out trouble diagnosis.
normal (grounding) Resistance
Between wire 105 and earth More than 1M Ω
state value
The internal coil ★ Turn the engine start switch to the position OFF for making
of PPC locking preparation, and maintain the switch at the position OFF for carrying
3 electromagnetic out trouble diagnosis.
valve is in Between pin 1 and pin 2 of electromagnetic Resistance
trouble About 34 Ω
valve value
Locking relay Start switch
Leading switch
Starting relay
Figure 7-8

E-7: The boom lifting acts slowly and powerlessly

When the excavator is acting, the action of boom is
Trouble information
slow, and the excavation is powerless
When the boom is acting, the pilot pressure signal
can be read from display screen
Estimat then start up the engine and make it run for carrying out trouble diagnosis.
The
ed
1 sensor has When the control rod is at middle position, the pilot pressure will be 0KG
causes
trouble
and
standar When the control rod is operated, the pilot pressure will be 0-37KG
d value Trouble
in relating to Inspect the engine speed and the current of proportional electromagnetic valve.
normal 2
engine If the speed is too low, please re-calibrate the speed.
state speed
Controller Since this is an internal trouble, no trouble diagnosis can be carried out. (If it is
3
trouble not for the above-mentioned reasons, the controller should be in trouble)
Controller
Boom lifting pressure sensor
Signal
Displayer
(CAN bus)
Earthling wire
Figure 7-9

E-8: The bucket arm acts slowly and powerlessly

When the excavator is acting, the action of bucket arm is
Trouble information
slow, and the excavation is powerless
When the bucket arm is acting, the pressure signal can be
read from display screen
The then start up the engine and make it run, so as to carry out trouble
sensor diagnosis.
1
Estimated has When the control rod is at middle position, the pilot pressure will be 0KG
causes trouble
and When the control rod is operated, the pilot pressure will be 0-37KG
standard Trouble
value in relating to Inspect the engine speed and the current of proportional electromagnetic valve.
normal 2
state speed
3
Controller
pressure sensor
Signal
Displayer
(CAN bus)
Earthling wire
Figure 7-10

E-9: The bucket acts slowly and powerlessly

When the excavator is acting, the action of bucket is slow,
Trouble information
and the excavation is powerless
When the bucket is acting, the pressure signal can be
The
sensor then start up the engine and make it run for carrying out trouble diagnosis.
1 When the control rod is at middle position, the pilot pressure will be 0KG
Estimated has
causes trouble
When the control rod is operated, the pilot pressure will be 0-37KG
and
Trouble
standard
relating to Inspect the engine speed and the current of proportional electromagnetic valve.
value in 2
normal
speed
state
3
Controller
Bucket excavation pressure

sensor
Signal
Displayer
(CAN bus)
Earthling wire
Figure 7-11

E-10: The travelling is slow and powerless

Trouble information When the excavator is acting, the travelling is slow
When the machine is travelling, the pressure signal can be
The
sensor then start up the engine and make it run for carrying out trouble diagnosis.
1 When the control rod is at middle position, the pilot pressure will be 0KG
has
Estimated trouble
causes When the control rod is operated, the pilot pressure will be 0-37KG
and Trouble
standard relating to Inspect the engine speed and the current of proportional electromagnetic valve.
value in 2 engine If the speed is too low, please re-calibrate the speed.
normal speed
state
3
Left travelling pressure

sensor
Signal
Controller
Earthling wire
Right travelling pressure

sensor
Displayer Signal
(CAN bus)
Earthling wire
Figure 7-12

E-11 The display screen goes black

After the excavator is powered on, the display
Trouble information
screen is still black
Estimated ★ Turn the engine start switch to the position OFF for making preparation, and
causes then maintain the switch at the position ON for carrying out trouble
Fuse diagnosis.
and 1
trouble Between wire 21 and earth About 24V
standard Voltage
value in Between wire 29 and earth value About 24V
normal
state Trouble of Since this is an internal trouble, no trouble diagnosis can be carried out. (If the
2 display cause of trouble is not the above-mentioned cause, the display screen is in
screen trouble)
To display screen
120ω
Figure 7-13

E-12 The display screen could not display

After the excavator is powered on, the display
Trouble information
screen is lighted, but no information is displayed.
Resistor
1 diagnosis.
trouble
Resistance
Between pin 1 and pin 2 of M09 120 Ω
value
diagnosis.
Estimated The wire is
2 Between pin 78 CN-437M and pin B of CN-
causes disconnected
and
452M/pin 1 of CN-101M Resistance Less than 1 Ω
standard Between pin 60 of CN-437M and pin A of CN- value Less than 1 Ω
value in 452M/pin 2 of CN-101M
normal ★ Turn the engine start switch to the position OFF for making preparation,
state and maintain the switch at the position OFF for carrying out trouble
Short-circuit diagnosis.
3 trouble of Between pin 78 CN-437M and pin B of CN- More than 1M
wire 452M/pin 1 of CN-101M Resistance Ω
Between pin 60 of CN-437M and pin A of CN- value More than 1M
452M/pin 2 of CN-101M Ω
Trouble of
Since this is an internal trouble, no trouble diagnosis can be carried out. (If it is
display
4 not for the above reasons, the display screen or controller
screen or
should be in trouble)
controller
To display screen
120ω
Figure 7-14

E-13 The dual running speed function does not work

During operation, the excavator maintains low
Trouble information
speed, and can’t travel at high speed
Operate the high/low speed travelling button on
Relevant information display screen so as to achieve the changeover
between high/low speed
Trouble of dual
running speed
1 diagnosis.
electromagneti
Resistance
c valve Between wire 607 and wire 0-YV of CN-414F About 34 Ω
value
Estimated ★ Turn the engine start switch to the position OFF for making preparation,
causes and maintain the switch at the position OFF for carrying out trouble
and diagnosis.
The wire is
standard 2 Between wire 607 of CN-414F and pin 82 of
disconnected Less than 1 Ω
value in controller Resistance
normal Between wire 0-YV of CN414F and pin 25 of value
state Less than 1 Ω
controller
Short-circuit
3 diagnosis.
trouble of wire
Resistance More than 1M
Between wire 607 of CN-414F and earth
value Ω
4
Controller
High speed
travelling valve
Position signal High speed

acquisition port travelling signal
Earthling wire Earthling wire
Cab Body harness
Figure 7-15

E-15 The indication of fuel oil level is inaccurate

The fuel level sensor on engine can’t correctly reflect
Trouble information
the current fuel level
Relevant information The fuel level can be read from display screen
diagnosis.
Trouble of oil Pin Fuel oil level Resistance value
1
level sensor
Full (upper limit) About 10 Ω
Estimated Between wire 509 and earth Empty (lower
causes 85-95 Ω
limit)
and
standard
value in The wire is
2 diagnosis.
normal disconnected
Between wire 509 and pin 11 of signal Resistance
state Less than 1 Ω
acquisition port of controller value
Short-circuit
trouble of
3 diagnosis.
wire
Resistance
(grounding) Between wire 509 and earth More than 1M Ω
value
Controller
Fuel throttle sensor
Fuel level
Position signal
signal
acquisition port
Earthling wire Earthling wire
Cab Body harness
Figure 7-16

E-16 The wiper does not work

Trouble information The wiper can’t work
Internal and maintain the switch at the position OFF for carrying out trouble
1 trouble of diagnosis.
wiper motor Resistance
Between wire 25 of wiper and earth More than 10 Ω
value
Estimated ★ Turn the engine start switch to the position OFF for making preparation,
causes and maintain the switch at the position OFF for carrying out trouble
and diagnosis.
standard Between pin 25 of Fuse F17 and pin 2 of CN-
The wire is Less than 1 Ω
value in 2 disconnected 117M
normal Between wire 35L of wiper switch and pin 5 of Resistance
Less than 1 Ω
state CN-1-117M value
Between wire 35H of wiper switch and pin 4 of
Less than 1 Ω
CN-1-117M
Short-circuit
trouble of
3 diagnosis.
wire
Harness between pin 25 of Fuse F17 and pin 2 Resistance
(grounding) More than 1M Ω
of CN-117M value
Washer motor
Wiper motor
Control
Switch Cab
Figure 7-17

Trouble diagnosis for hydraulic and mechanical systems (mode H)

System diagram for hydraulic system and mechanical system
★ This system diagram is drawn after the table of hydraulic oil way is simplified. It can be used as
reference during trouble diagnosis for hydraulic system and mechanical system.
Sa: Safety valve

Su: Oil suction valve
Bucket interflow
valve
S&S: Safety and oil
suction valve
Bucket arm holding
Bucket rod Bucket arm

valve with
Valve of bucket arm 2
valve
regeneration
valve
cylinder
Boom 2
Bucket valve Bucket cylinder
Anti-swing valve
Slewing
motor Boom cylinder
Boom holding valve

Anti-swing valve
Boom valve
Back slewing valve
Standby actuating
Straight
travelling valve
Standby valve element
Servo mechanism
Left traveling
Balance valve
Right traveling
motor
motor
Balance valve
Right travelling
Straight travelling valve valve
mechanism
Servo
Left pilot Traveling Right pilot
valve leading valve valve
Bucket Back Traveling Traveling Boom Bucket

rod swing LEFT RIGHT
Unloading
Excavatin
Excavati
Reverse
Reverse
Forward
Forward
Unloadi
Lowering
Lifting
Right
Left
ng
ng
g
High/low
Stand
travelling speed
by
Secondary
turbocharging
Pilot valve
lock
Figure 7-18

Information contained in table for trouble diagnosis

★ The table for trouble diagnosis and relevant wiring diagrams contain the following information. Please
carry out trouble diagnosis work only after you have fully understood these contents.
Trouble information Phenomena occurring to this machine

Relevant information Information about trouble occurring and trouble diagnosis
The valve given for normal state and reference value for trouble
Causes
Estimated causes and standard value in
diagnosis
1
normal state
2 <Contents>
Estimated causes of trouble
● The standard value in normal state can be used to judge
(The number is given for the
whether the estimated cause is in “good” or “bad” conditions
3 purpose of facilitating the
writing, and does not mean ● The reference value is used to judge whether a component
any priority order) is in “good” or “bad” conditions
4

H-1 The working device acts slowly, or the running and slewing speed is low.
● The working device acts slowly, or the running and slewing
Trouble information
speed is low.
● Set the work mode at position 10 of mode S, so as to carry out
trouble diagnosis.
Causes
diagnosis
★ Turn off the engine for making preparation. When the engine is
Estimated causes and standard value in normal state
running at high idle speed, please carry out the trouble

diagnosis.
Pressure of primary overflow
The main overflow valve is Control rod
valve
1 not adjusted properly or
fails 31.4~33 MPa
Bucket rod excavation
{320~337 kg/cm2}
After the adjustment is carried out, if the pressure still can’t be
resumed to normal state, maybe the main overflow valve fails or
there is trouble in it. In such case, please inspect the valve.
diagnosis.
The leading overflow valve
2 Control rod Pilot control pressure
fails
All control rods are at “middle 3.9~4.1 MPa
position” {40~42 kg/cm2}
Maybe the regulator fails. Please inspect the regulator servo
3 The regulator fails
mechanism
If the above-mentioned causes are not detected, maybe the plunger
4 The plunger pump fails
pump deteriorates, fails or has internal trouble.

H-2: The engine speed obviously reduces or the engine stalls

Trouble information ● The engine speed obviously reduces or the engine stalls.
Relevant information ● Relevant information
Causes
diagnosis
Fuel injection pump has Maybe the fuel injection pump is in trouble. Please inspect the fuel
1
trouble injection pump.
Maybe the regulator fails. Please inspect the regulator servo
2 The regulator fails
mechanism.
normal state
Fuel oil filter core is Maybe the fuel filter element is blocked and thus the oil way is not
3
plugged clear. Please inspect the filter element.
Carbon is accumulated in Maybe carbon is accumulated in the nozzle. Please inspect the
4
nozzle nozzle.
Maybe the air filter is blocked and thus the intake pipeline is not
5 The air filter is blocked
clear. Please inspect the air filter.
The engine is abnormally
6 Maybe the engine is abnormally worn. Please inspect the engine.
worn
The fuel delivery pump Maybe the oil transfer pump is in trouble. Please inspect the oil
7
has troubles transfer pump.
H-3: The working device, travelling or slewing functions can’t be activated

● The working device, travelling and slewing functions can’t be
Trouble information
activated
trouble diagnosis.
Causes The valve given for normal state and reference value for trouble diagnosis
★ Turn off the engine for making preparation. When the engine is running
at high idle speed, please carry out the trouble diagnosis.

Pilot safety rod Pilot overflow pressure
The pilot safety
1 Locking 0 {0}
electromagnetic valve fails
3.9~4.1 MPa
Unlocking
{40~42 kg/cm2}
The leading pump overflow Control rod Pilot overflow pressure
2
valve has trouble
3.9~4.1 MPa
All control rods are at middle position
{40~42 kg/cm2}
Maybe the plunger pump fails or has internal trouble. Please carry out
The hydraulic pump has diagnosis in accordance with the following method.
3
trouble ● Dismantle the oil pressure measuring gauge, and start up the engine. If
there is oil flowing out, then it is normal.
The pump shaft can’t rotate owing to internal trouble of coupling. Please
inspect the coupling.
4
The coupling has trouble ● Loosen the oil outlet way of pilot pump. If no oil flows out, maybe the
coupling is in trouble.

H-4 The hydraulic pump has abnormal noise

Trouble information ● The abnormal noise is heard near hydraulic pump.
Relevant information ―
Causes
diagnosis
The hydraulic oil level

1 Visual inspection
reduces
The hydraulic oil quality is

2 Maybe there is air in oil. Please carry out visual inspection.
normal state
poor
Maybe the vent device on top cover of hydraulic oil tank is blocked
The air breather on the top
up, so that the negative pressure is generated in oil tank. Please
3 of hydraulic oil tank is
press down the air release valve of breather valve, and inspect
plugged
whether the noise disappears.
Maybe the strainer of hydraulic oil tank is blocked up, so that the
The hydraulic oil tank filter
4 negative pressure is generated in oil suction way. Please carry out
screen is plugged
visual inspection.
The plunger pump has Maybe there is trouble in plunger pump. Please inspect the plunger
5
trouble pump.

H-5 The automatic idling could not work.

Trouble information ● The automatic idling could not work.
trouble diagnosis.
Estimated causes and standard value in normal
Every control rod Output Pressure of Pilot Valve
The pressure relay
1 "Neutral position" 0 {0}
fails
3.5~4.1MPa
Operations
{36~42 kg/cm2}
state
Every control rod Output Pressure of Pilot Valve
The leading valve
2 "Neutral position" 0 {0}
fails
3.5~4.1MPa
Operations
{36~42 kg/cm2}
3 Controller trouble Maybe the controller is in trouble. Please inspect the controller.

H-6: The boom moves slowly

Trouble information ● The boom moves slowly.
trouble diagnosis.
Causes
diagnosis
diagnosis.
The right pilot valve (on Boom control rod Output Pressure of Pilot Valve
1
boom oil way) fails "Neutral position" 0 {0}
More than 3.5mpa

“Lifting” or “lowering ”
{36 kg/cm2}
The pressure relay is in running at high idle speed, please carry out the trouble
2 diagnosis.
trouble
Replace the part with a new one and then carry out inspection
The boom control valve
3 Maybe the valve core in boom control valve fails. Inspect the valve.
(valve core) fails
The boom control valve Maybe the holding valve in boom control valve fails. Inspect the
4
(holding valve) fails valve.
(safety valve and oil filling Maybe the safety valve and oil replenishing valve in boom control
5
valve) fails or the sealer has valve fail or the sealing element is in trouble. Please inspect it.
trouble
diagnosis.
Load the bucket by about 2260kg, cut off the oil way on high-
The boom cylinder has pressure side of cylinder, disconnect its connection with main valve,
6
trouble wait until the cylinder is stabilized, and measure the displacement
amount of piston within 15 minutes. If the value is more than 10mm,
then it can be determined that the cylinder seal is in trouble. As for
the detailed measurement method, please refer to “Measurement of
Oil Leakage” (Page 4-26).

H-7: The bucket arm moves slowly

Trouble information ● The bucket arm moves slowly.
trouble diagnosis.
Causes
diagnosis
diagnosis.
The left pilot valve (bucket Boom control rod Output Pressure of Pilot Valve
1
arm oil way) fails "Neutral position" 0 {0}
More than 3.5mpa

“Excavation” or “unloading ”
{36 kg/cm2}
2 diagnosis.
trouble
The bucket arm control Maybe the valve core in bucket arm control valve fails. Inspect the
3
valve (valve core) fails valve.
The bucket arm control
Maybe the regeneration valve in bucket arm control valve fails.
4 valve (regeneration valve)
Inspect the valve.
fails
Maybe the safety valve and oil replenishing valve in bucket arm
(safety valve and oil filling
5 control valve fail or the sealing element is in trouble. Please inspect
valve) fails or the sealer has
it.
trouble
★
Turn off the engine for making preparation. When the engine is
diagnosis.
As for detailed measurement method, please refer to “Measurement
The bucket rod cylinder has
6 of Oil Leakage” (Page 4-26). Cut off the oil way on high-pressure
trouble
side of cylinder, disconnect its connection with main valve, wait until
the cylinder is stabilized, and measure the displacement amount of
piston within 15 minutes. If the value is more than 10mm, then it
can be determined that the cylinder seal is in trouble.

H-8: The bucket moves slowly

Trouble information ● The bucket moves slowly.
trouble diagnosis.
Causes
diagnosis
diagnosis.
Bucket control rod Output Pressure of Pilot Valve
The right pilot valve (bucket

1
oil way) fails "Neutral position" 0 {0}
More than 3.5mpa

{36 kg/cm2}
2 diagnosis.
trouble
The bucket control valve
3 Maybe the valve core in bucket control valve fails. Inspect the valve.
(valve core) fails
The bucket control valve
(safety valve and oil filling Maybe the safety valve and oil replenishing valve in bucket control
4
valve) fails or the sealer has valve fail or the sealing element is in trouble. Please inspect it.
trouble
diagnosis.
The bucket cylinder has pressure side of cylinder, disconnect its connection with main valve,
5
detailed measurement method, please refer to “Measurement of Oil
Leakage” (Page 4-26).

H-9 Single cylinder of working device could not act

● When being operated separately, the boom cylinder does not
act.
● When being operated separately, the bucket arm cylinder does
Trouble information
not act.
● When being operated separately, the bucket cylinder does not
act.
trouble diagnosis.
Causes
diagnosis
diagnosis.
Working device control rod Output Pressure of Pilot Valve
1 The leading valve fails
"Neutral position" 0 {0}
More than 3.5mpa

state
{36 kg/cm2}
2 diagnosis.
trouble
The working device control Maybe the valve core in working device control valve fails. Inspect
3
valve (valve core) fails the valve.

H-10 The settling volume of working device cylinder is too big

Trouble information (1) ● The lowering of boom is too quick.
trouble diagnosis.
Causes
diagnosis
diagnosis.
The boom cylinder has pressure side of cylinder, disconnect its connection with main valve,
1
the detailed measurement method, please refer to “Measurement of
Oil Leakage” (Page 4-26).
The boom holding valve is Maybe the boom holding valve is worn or jammed. Please inspect
2
in trouble it.
The sealing element of
boom control valve (safety Maybe the sealing element of safety valve and oil replenishing
3
valve and oil replenishing valve in boom control valve fails. Please inspect the seal.
valve) fails
The boom valve core is in
4 Maybe the boom valve core is excessively worn. Please inspect it.
trouble
Trouble information (2) ● The lowering of bucket arm is too quick.

trouble diagnosis.
Causes
diagnosis
diagnosis.
As for detailed measurement method, please refer to “Measurement
The bucket rod cylinder has of Oil Leakage” (Page 4-26). Cut off the oil way on high-pressure
1
trouble side of cylinder, disconnect its connection with main valve, wait until
the cylinder is stabilized, and measure the
displacement amount of piston within 15 minutes. If the value is
more than 10mm, then it can be determined that the cylinder seal is
in trouble.
Maybe the sealing element of safety valve and oil replenishing valve
The sealing element of in bucket arm control valve fails. Please inspect the seal.
bucket arm control valve ★ Whether the sealing element fails can be determined by
2
(safety valve and oil replacing the safety valve and oil replenishing valve. (Don’t
replenishing valve) fails replace them with the safety valve and oil replenishing valve for
lowering of boom, because the set pressure is different.)
The bucket arm holding Maybe the bucket arm holding valve and pilot valve are worn or
3
valve is in trouble jammed. Please inspect it.
The bucket arm valve core Maybe the bucket arm valve core is excessively worn. Please
4
is in trouble inspect it.

Trouble information (3) ● The lowering speed of bucket is too high.

trouble diagnosis.
Causes
diagnosis
The bucket cylinder has diagnosis.
1
trouble Bucket control rod Oil leakage in cylinder
normal state
Excavation overflow 20 ml/min

Maybe the sealing element of safety valve and oil replenishing
The sealing element of valve in bucket control rod fails. Please inspect the sealing element.
bucket control valve ★ Whether the sealing element fails can be determined by
2
(safety valve and oil replacing the safety valve and oil replenishing valve.
replenishing valve) fails (Don’t replace them with the safety valve and oil replenishing valve
for lowering of boom, because the set pressure is different.)
The sealing element of
Maybe the sealing element of valve core in bucket control valve
3 bucket control valve (valve
fails. Please inspect it.
core) fails

H-11 The action of working device is lagged

Trouble information ● The action of working device is lagged
trouble diagnosis.
Estimated causes and standard value
Causes
diagnosis
The regeneration
1 valve of bucket rod Maybe the bucket arm regeneration valve fails. Please inspect it.
in normal state
fails
Maybe the safety valve and oil replenishing valve in control valve fail.
Please inspect them.
The control valve
★ As for bucket arm and boom, whether the valve fails can be
2 (safety valve and oil
determined by replacing the safety valve and oil replenishing valve.
filling valve) fails
(Don’t replace them with the safety valve and oil replenishing valve
for lowering of boom, because the set pressure is different.)
H-12 Other working devices move when single oil way is overflowing
● When an oil way of working device is overflowing, other working device
Trouble information
moves.
Relevant information ● Set the work mode as mode S, so as to carry out trouble diagnosis.
Causes
diagnosis
The sealer of control

1 Maybe the control valve seal fails. Please inspect it.
valve fails

H-13: During the slewing +travelling operation, the travelling speed obviously
reduces
● During the slewing +travelling operation, the travelling speed is
Trouble information
obviously reduced.
● If the travelling speed is slow when only the travelling is carried out,
please firstly carry out inspection H-15.
Causes
diagnosis
normal state
The straight travelling If the straight travelling valve does not act, please inspect the valve
1
valve is in trouble core and the oil discharge port of logic oil way

H-14 The excavator deviates when running

Trouble information ● This machine deviates during travelling.
trouble diagnosis.
Causes
diagnosis
running at high idle speed, please carry out the trouble diagnosis.
Running Control Lever Output Pressure of Pilot Valve
The running leading
1 Forward traveling or backward 3.5~3.9 Mpa
valve fails
travelling { 36~40 kg/cm2}
There is difference between output 0.4 Mpa
on right and left sides {4 kg/cm2}
Control the source pressure in oil
The leading overflow Control rod
2 way
valve fails
All control rods are at “middle 3.5~3.9 Mpa

position ” { 36~40 kg/cm2}
The regulator has
3 Please carry out inspection by interchanging the front and rear regulators
trouble
The proportional
Output pressure of proportional
4 electromagnetic valve Running Control Lever
valve
gets clamped
The operation is carried out on both The difference shall be no more
sides than 0.1 MPa
The running valve core
5 Inspect whether the valve core can move smoothly
gets clamped
The central slewing
6 Use the pipeline-inter changing method to carry out inspection
joint internally leaks
7 The running motor fails Running Control Lever Oil leakage in travelling motor
Travelling overflow 27.2 ml/min
Maybe the final transmission is in trouble. Directly inspect the inside of
final transmission.
The final transmission
8 ★ The trouble in final transmission can be determined through internal
is in trouble
abnormal noise, abnormal heating, or emission of metal powder or
debris in oil.
The travelling pilot
Forward traveling or backward
9 pressure relay is in Is the idling cancelled
travelling
trouble
There is difference between output 0.4 Mpa
on right and left sides {4 kg/cm2}
Use the interchange method to carry out inspection

H-15 The excavator runs slowly

Trouble information ● The travelling speed of this machine is too low.
trouble diagnosis.
Causes
diagnosis
The running leading Forward traveling or backward 3.5~3.9 Mpa
1
valve fails travelling { 36~40 kg/cm2}
There is difference between left
Less than 0.4 MPa
and right output or front and rear
{Less than 4 kg/cm2}
output
Control the source pressure in oil
The leading overflow Control rod
2 way
valve fails
All control rods are at “middle 3.5~3.9 Mpa
position ” { 36~40 kg/cm2}
Display screen
Travelling speed Running Control Lever
display- indicator
3 The sensor has trouble
Low speed Operations Is it lighted
High speed Operations Is it lighted

Use the interchange method to carry out inspection.
The running control Maybe the valve core in travelling control valve fails. Please inspect the
4
valve (valve core) fails valve core.
The running control
Maybe the oil replenishing valve in travelling control valve fails. Please
5 valve (oil filling valve)
inspect the valve.
fails
The running motor has
6 Running Control Lever Oil leakage in travelling motor
trouble
Maybe the final transmission is in trouble. Please directly inspect the
final transmission internal.
The final transmission is
7 ★ The trouble in final transmission can be determined through
in trouble
internal abnormal noise, abnormal heating, or emission of metal
powder or debris in oil.

H- 16 It is not easy for the excavator to make a turn or the power is insufficient
Trouble information ● It is not east to steer this machine.
trouble diagnosis.
Causes
diagnosis
The running leading Running Control Lever Output Pressure of Pilot Valve
1
valve fails At “middle position” on both sides 0 {0}
Only carry out operation on one 3.5~3.9 Mpa

side { 36~40 kg/cm2}
Output pressure of
Running Control Lever
The running leading
2 The operation is carried out on 3.5~3.9 Mpa
pressure sensor fails
both sides { 36~40 kg/cm2}
Only carry out operation on one 3.5~3.9 Mpa

side { 36~40 kg/cm2}
The running control Maybe the valve core in travelling control valve fails. Please inspect the
3
valve (valve core) fails valve core.
The running control
Maybe the oil replenishing valve in travelling control valve fails. Please
inspect the valve.
fails
Maybe the sealing element in safety valve in travelling motor fails.
The running motor Please inspect the sealing element.
5
(safety valve) fails ★ Whether the sealing element fails can be determined by
interchanging the front and rear or left and right motors.
Maybe the sealing element in one-way valve in travelling motor fails.
The running motor (one- Please inspect the sealing element.
6
way valve) fails ★ Whether the sealing element fails can be determined by
interchanging the front and rear or left and right motors.

H-17 The running speed could not be changed

Trouble information ● The running speed could not be changed
trouble diagnosis.
Causes
diagnosis
The high/low speed Output pressure of
Travelling speed Running Control Lever
change-over electromagnetic valve
normal state
1
electromagnetic valve Low speed Operations 0 {0}
fails
3.5~3.9 Mpa
High speed Operations
{ 36~40 kg/cm2}
Travelling motor
Maybe the gear-shift unit in travelling motor is in trouble. Please
2 (gear-shift) is in
directly inspect the gear-shift unit.
trouble

H-18 The excavator could not run (only on one side)

Trouble information ● The crawler plate can’t turn (only on one side).
trouble diagnosis.
Causes
diagnosis
The running control
Maybe the valve set for oil replenishing valve in travelling control valve
is in trouble. Please inspect the valve seat.
seat has trouble
The running motor
Maybe the valve set for safety valve in travelling motor is in trouble.
2 (safety valve) seat has
Please inspect the valve seat.
trouble
The running motor (oil
Maybe the valve seat for one-way valve in travelling motor is in trouble.
3 filling valve) seat has
Please inspect the valve seat.
trouble
The speed of travelling
4 Running Control Lever Oil leakage in travelling motor
motor reduces
Maybe the final transmission is in trouble. Please directly inspect the
final transmission internal.
The final transmission is
5 ★ The trouble in final transmission can be determined through
in trouble
internal abnormal noise, abnormal heating, or emission of metal
powder or debris in oil.
The value displayed on display
The leading pressure Forward traveling or backward
6 screen is 3.5-3.9mpa
sensor has trouble travelling
{ 36~40 kg/cm2}
There is difference between output
0.4 MPa {4 kg/cm2}
on right and left sides
Use the interchange method to carry out inspection

H-19 The excavator could not slew

Trouble information (1) ● This machine can’t slow leftwards and rightwards.
● Set the work mode at position 10 of mode S, so as to carry out trouble
diagnosis.
The slewing motor fails

1 Maybe the parking brake of slewing motor fails. Please directly inspect it.
(parking brake)
★ Turn off the engine for making preparation. When the engine is running at
high idle speed, please carry out the trouble diagnosis.
Back slewing control rod Slewing overflow pressure
The slewing motor (safety
2 valve) is not adjusted 25.5~28.5 Mpa
Slewing overflow
properly or fails {260~291 kg/cm2}
If the oil pressure can’t resume to normal state after the adjustment is
completed, maybe the safety valve fails, or there is trouble in it. Please inspect
the valve.
The slewing motor has
3 Back slewing control rod Oil leakage in slewing motor
trouble
Slewing overflow More than 10 ml/min
Maybe the slewing device is in trouble. Please directly inspect slewing device.
The slewing gear has
4 ★ The trouble in slewing device can be determined through internal abnormal
trouble
noise, abnormal heating, or emission of metal powder or debris in oil.
Trouble information (2) ● This machine can’t carry out slewing operation in one direction.
diagnosis.
Left control lever Output Pressure of Pilot Valve
More than 3.5mpa
Slewing operation
state
{More than 36 kg/cm2}
The slewing control valve Maybe the valve core in slewing control valve fails. Please inspect the valve
2
(valve core) fails core
Maybe the sealing element of oil replenishing valve in slewing motor fails.
Inspect the sealing element.
The sealer of slewing
3 ★ Interchange the left and right oil replenishing valve, and observe whether
motor (oil filling valve) fails
the situation changes, so as to determine whether the sealing element
fails.

H-20: The slewing acceleration performance is poor, or the slewing speed slow
● The slewing acceleration performance is poor, or the slewing speed
Trouble information (1)
slow.
diagnosis.
The slewing motor (parking

1 Maybe the parking brake of slewing motor fails. Please directly inspect it.
brake) fails
The slewing motor (safety Back slewing control rod Slewing overflow valve
2 valve) is not adjusted 28.5~30 Mpa
properly or fails Slewing overflow
{291~306 kg/cm2}
state
After the adjustment, if the oil pressure can’t resume to normal level, then
maybe the safety valve fails or is in trouble. Please inspect the valve.
The slewing motor has high idle speed, please carry out the trouble diagnosis.
3
trouble Back slewing control rod Oil leakage in slewing motor
Slewing overflow Less than 10 ml/min
The brake control pipeline is
4 Dismantlement, cleaning and inspection.
plugged
● The slewing acceleration performance is poor only on one side, or the

slewing speed slow.
diagnosis.

Back slewing control rod Output Pressure of Pilot Valve
More than 3.5mpa
Left or right
The slewing motor
Maybe the pressure compensation valve in slewing motor fails. Please inspect
2 (pressure-compensated
it.
valve) fails
Maybe the sealing element slewing in oil replenishing valve in motor fails.
The sealer of slewing motor Inspect the sealing element.
3
(oil filling valve) fails ★ Interchange the left and right oil replenishing valves, and judge whether
the sealing element fails on the basis of the observation result.
The shuttle valve of slewing Back slewing control rod Output Pressure of Pilot Valve
4 leading pressure sensor
leaks from one side "Neutral position" 0 {0}
3.5~3.9Mpa
Left or right
{36~40 kg/cm2}

H-21 The overrunning is too big when the slewing stops.

● When the slewing stops, the working device goes beyond the
stroke excessively.
trouble diagnosis.
Causes
diagnosis
Back slewing control rod Slewing overflow pressure
The running motor
normal state
1 (safety valve) is not 28.5~30 Mpa

Slewing overflow
adjusted properly or fails {291~306 kg/cm2}
After the adjustment, if the oil pressure can’t resume to normal level,
then maybe the safety valve fails or is in trouble. Please inspect the
valve.
The slewing motor has
2 Control rod Oil leakage in slewing motor
trouble
Slewing overflow Less than 10 ml/min
● The slewing acceleration performance on one side is poor, or

the slewing speed is slow.
trouble diagnosis.
Causes
diagnosis
Back slewing control rod Output Pressure of Pilot Valve
normal state

More than 3.5mpa
Left or right
The slewing control valve
2 Maybe the valve core in slewing control valve fails. Please inspect it.
(valve core) fails
Maybe the sealing element of oil replenishing valve in slewing motor
The sealer of slewing fails. Please inspect the sealing element.
3 motor (oil filling valve) ★ Interchange the left and right oil replenishing valves, and judge
fails whether the sealing element fails on the basis of the observation
result.

H-22 The impact is too big when the slewing stops

● When the slewing stops, the relatively large impact may be
Trouble information
generated.
trouble diagnosis.
Causes
diagnosis
The slewing leading Back slewing control rod Output Pressure of Pilot Valve
normal state
1
valve fails "Neutral position" 0 {0}
More than 3.5mpa
Left or right
The slewing anti-swing Maybe the slewing anti-swing valve fails. Inspect the valve.
2
valve fails ★ Determine whether the valve fails by replacing it with a new one.
The slewing overflow

3 The slewing overflow valve is worn or jammed.
valve fails
H-23 The abnormal noise is too high when the slewing stops
Trouble information ● When the slewing stops, there is high abnormal noise.
trouble diagnosis.
Causes
diagnosis
The counterbalance
1 Maybe the backpressure valve fails. Please inspect it.
valve fails
The slewing motor
2 Maybe the safety valve in slewing motor fails. Please inspect it.
(safety valve) fails
normal state
Maybe the sealing element of oil replenishing valve in slewing motor

The slewing motor (oilfails. Please inspect the sealing element.
3
filling valve) fails★ Interchange the left and right oil replenishing valves, on the basis
of the result determine sealing element whether fails.
Maybe the slewing mechanical device is in trouble. Please inspect the
inside of mechanical device.
The slewing mechanical
4 ★ The trouble in slewing device can be determined through internal
device fails
abnormal noise, abnormal heating, or emission of metal powder or
debris in oil.

H-24: The natural drifting during slewing is too large

● The natural drifting during slewing is too large (when the parking
brake acts).
● When the slewing is carried out and the parking brake acts, the
slewing will be locked by disc brake.
Causes
diagnosis
The slewing brake

Maybe the slewing braking control pipeline and rake pilot valve are in
in normal state
1 control pipeline has

trouble. Please inspect them.
trouble
The slewing motor Maybe the park unit of slewing motor fails or is in trouble. Please
2
(parking brake) fails inspect it.
● The natural drifting during slewing is too large (when the parking
brake is released).
● The slewing and parking brake is released, and the slewing can
only be held by hydraulic pressure.
Causes
diagnosis
The slewing control valve Maybe the sealing element of valve core in slewing control valve fails.
1
(valve core) fails Please inspect it.
in normal state
The slewing motor

Maybe the sealing element of overflow valve in slewing motor fails.
2 (overflow valve) has
Please inspect it.
trouble
The slewing motor (oil Maybe the sealing element of oil replenishing valve in slewing motor
3
filling valve) has trouble fails. Please inspect it.

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SY750H Hydraulic Excavator Disassembling and Assembling

Notices for Operation................................................................................................................................... 8-3
Dismantlement and installation of start motor assembly ............................................................................. 8-6
Dismantlement and installation of fuel injection pump assembly ................................................................ 8-7
Dismantlement and installation of rear oil seal of engine .......................................................................... 8-13
Dismantlement and installation of cylinder head assembly....................................................................... 8-16
Disassembling and assembling of cylinder head assembly ...................................................................... 8-19
Dismantlement and installation of radiator assembly ................................................................................ 8-29
Dismantlement and installation of engine and hydraulic pump assembly ................................................. 8-34
Dismantlement and installation of final transmission assembly ................................................................ 8-40
Disassembling and assembling of final transmission assembly................................................................ 8-42
Dismantlement and installation of slewing motor and slewing mechanism assembly .............................. 8-51
Disassembling and assembling of slewing motor and slewing mechanism assembly.............................. 8-53
Disassembling and assembling of guiding wheel assembly ..................................................................... 8-63
Dismantlement and installation of sprocket ............................................................................................... 8-67
Dismantlement and installation of crawler assembly ................................................................................ 8-68
Dismantlement and Installation of Back slewing Bearing Assembly ......................................................... 8-71
Dismantlement and installation of slewing table assembly ....................................................................... 8-73
Dismantlement and installation of central slewing joint assembly............................................................. 8-76
Disassembling and assembling of Central Back slewing Joint Assembly ................................................. 8-78
Dismantlement and Installation of Hydraulic Oil Tank Assembly .............................................................. 8-80
Dismantlement and Installation of Control Valve Assembly ...................................................................... 8-83
Dismantlement and installation of hydraulic pump assembly.................................................................... 8-87
Dismantlement and installation of oil seal in hydraulic pump input shaft .................................................. 8-91
Dismantlement and installation of independent oil disperser .................................................................... 8-92
Disassembling and assembling of working device pilot valve assembly .................................................. 8-94
Disassembling and assembling of travelling pilot valve assembly ............................................................ 8-95
Disassembling and assembling of hydraulic cylinder assembly................................................................ 8-96
Dismantlement and Installation of Working Device Assembly ................................................................ 8-106
Dismantlement and installation of A/C device assembly ......................................................................... 8-109
Dismantlement and installation of balance weight assembly .................................................................. 8-113
Dismantlement and installation of cab assembly .................................................................................... 8-115
Dismantlement and installation of display screen ................................................................................... 8-119
Dismantlement and installation of controller assembly ........................................................................... 8-120
Dismantlement and installation of radio .................................................................................................. 8-121

Disassembling and Assembling SY750H Hydraulic Excavator
Removal and Installation of Storage Battery ........................................................................................... 8-124

Dismantlement and installation of key switch .......................................................................................... 8-126
Dismantlement and installation of fuse box ............................................................................................. 8-129
Dismantlement and installation of wiper .................................................................................................. 8-130
Dismantlement and installation of relay ................................................................................................... 8-133
Installation and dismantlement methods for terminal of plug-in part ....................................................... 8-135

Notices for Operation

When dismantling or installing device, please comply with the following notices.
1. Notices for Dismantlement
● If the engine coolant contains anti-freezing agent, please dispose of it correctly.
● After disconnecting a hose or steel pipe, please cover it or mount a blind plug in it, so as to avoid
the entry by dirt or dust.
● When draining the oil, please prepare an appropriate container to collect the oil.
● Before the dismantlement, please leave the mating marks on necessary locations, so as to
prevent mistake during re-assembling.
● In order to prevent the wire from getting disconnected, don’t pull the wire. In order to avoid too
much force applied onto wire, please hold the connector when dismantling the wire.
● Label the wires and hoses, so as to determine the installation position and avoid mistake during
re-installation.
● Record and inspect the number of gaskets of different thickness, and store them in a safe place.
● When lifting up a component, the lifting equipment selected shall have sufficient capacity and
safety.
● When using the thrust screws to dismantle the component, please evenly tighten up the screws in
order.
● Before dismantling a device, please clean up the surrounding area. After the dismantlement,
please cover the device, so as to prevent dust or dirt from entering it.
★ Notices for Handling of Pipeline during Disassembling
During disassembling operation, after a pipeline id disconnected, please mount the following blind
plugs into pipes.
A. Use the threaded hose
Inside diameter of
Code Name
hose (mm)
Light thread connect
6 B210780001189 End plug of pipe
22 60056667 End plug of pipe
Heavy thread connect
16 60002397 End plug of pipe

B. Use the threaded transition joint (The front and rear parts form a set)
Inside
diameter
Code Name Code Name
of hose
(mm)
Light thread connect
6 B210780000903 Bevel hole plug 23002925 Nut
8 B210780001146 Blind plug B210770000011 Nut
10 B210780000088 Blind plug B210334000011 Nut
12 B210780000089 Blind plug B210334000012 Nut
15 B210780000882 Blind plug B210334000004 Nut
20 B210780000090 Blind plug B210334000010 Nut
22 B210780000091 Blind plug B210780000112 Nut
Heavy thread connect
12 B210780001143 Blind plug B210780000406 Nut
16 A820205001523 Blind plug B210780000405 Nut
20 B210780000902 Blind plug B210780000904 Nut
25 B210780001172 Blind plug B210334000006 Nut
2. Notices for Installation

● Tighten up all bolts and nuts (sleeve nut) to the specified torque.
● During installation, the hose may not be twisted or interfered with.
● The bushing, O-ring, split pin and locking plate shall be replaced with new ones.
● Firmly bend the split pin or locking plate.
● Before applying the adhesive, please clear away the oil and dust on parts so as to ensure that the
part is clean, and then drip two or three drops of adhesive on thread.
● Before applying the gasket sealant, please clear away the oil and dust on surface, and inspect
whether there is dirt or damage, and then even apply the gasket sealant.
● Clear away the damage, dent, burr or rust from parts.
● Apply the engine oil onto rotating parts and sliding parts.
● When installing any snap ring, please inspect whether the snap ring is correctly installed in groove.
● Before connecting any wire connector, please clear away the oil, dirt or water on connector, and
then connect it firmly.
● Before using any eye bolt, inspect whether the eye is deformed or deteriorated, and then fully
screw it in and align it with lifting hook.
● When tightening up any split flange, please evenly tighten it up in order, so as to prevent it from
being excessively tightened up on one side.
★ After the cylinder, main pump or hydraulic equipment which has been repaired is re-assembled, when
the hydraulic cylinder is operated for the first time, it is necessary to bleed the air. The operation is
detailed as follows:
● Start up the engine and make it run at low idle speed.
● Operate the working device control rod, make the hydraulic cylinder moves for 4-5 times, and stop
the cylinder at the position which is 100mm away from end of its stroke.

● Continue to operate the hydraulic cylinder for 3-4 times, until it reaches the end of its stroke.
● After the operation is completed, make the engine run at normal speed.
★ When this machine is used for the first time after being repaired or stored for long time, please
follow the same procedure.
3. Notices for Completion of Operation
● After draining the engine coolant, please tighten up the drain valve, and fill the coolant to the
specified level. Run the engine so as to make the coolant circulate in system, and then inspect
the level again.
● After dismantling and then installing the hydraulic equipment, please fill the hydraulic oil to the
specified oil level. Run the engine so as to make the hydraulic oil circulate in system, and then
inspect the oil level again.
● After dismantling, repairing and re-installing any pipe or hydraulic equipment, please bleed the air
from system.
★ Please refer to the contents about air bleeding in the Section “Testing and Adjustment”.
● Add the grease (molybdenum disulfide grease) of specified amount into relevant component of
working device.

Dismantlement and installation of start motor assembly

● Dismantlement sequence
1 Nut
2 Nut
3 Starter relay
4 Bolt
5 Nut
6 Starter
*a Flywheel housing
B: Terminal B
S: Terminal S
Figure 8-1
Attention
● Before dismantling the starter 6, please
disconnect the negative terminal of battery,
and wrap it with insulated tape.
● It is dangerous not to disconnect the negative
terminal of battery, because there is always
the battery voltage on every terminal B.
● Installation sequence
Carry out the installation in accordance with the reversed dismantlement sequence.

Dismantlement and installation of fuel injection pump assembly
Dismantlement
Disconnect battery negative (-) terminal.
1. Open the top cover on balance weight side.
Figure 8-2
2. Dismantle the air intake pipe (1).
Figure 8-3

3. Dismantle the fuel oil return pipe (2).
Figure 8-4
4. Dismantle the nozzle oil discharge pipe (3).
Figure 8-5

5. Dismantle the fuel oil return pipe (4).
Figure 8-6
6. Dismantle the fuel pipe (fuel feed pump – public

oil groove) (5).
Figure 8-7

7. Loosen the fuel injection pipe clamp, and

dismantle the fuel injection pipe 1 (6), fuel
injection pipe 2 (7), fuel injection pipe 3 (8), fuel
injection pipe 4 (9), fuel injection pipe 5 (10),
and fuel injection pipe 6 (11).
Figure 8-8
8. Dismantle the fuel pipe clamp brackets (12,

(13), (14) and dismantle the oil groove (15).
Figure 8-9

9. Dismantle the fuel supply pipe (17) and fuel

return pipe (18) of fuel feed pump (16).
Figure 8-10
10. Turn the crankshaft, align it with the

compression TDC of cylinder 1, and align the
punching mark on flywheel with indicating
needle.
Figure 8-11

11. Loosen the coupling locking bolt and dismantle

the fuel feed pump.
Figure 8-12
Installation
Carry out the installation in accordance with the
reversed dismantlement sequence.

Dismantlement and installation of rear oil seal of engine
Figure 8-13
1. NE sensor 5. Flywheel housing support
2. Washer 6. Flywheel housing
3. Flywheel 7. Flywheel housing
4. Oil seal

Dismantlement
1. Dismantle the hydraulic pump assembly.
Please refer to the Section “Dismantlement and
Installation of Hydraulic Pump Assembly” in this
Manual.
2. Dismantle the NE sensor (1)
3. Dismantle the washer (2)
4. Dismantle he flywheel (3)
5. Dismantle the flywheel housing support (5)
6. Dismantle the flywheel housing (6)
7. Dismantle the oil seal (4)
Note: When dismantling the oil seal, please be
careful not to damage or scratch the surface of oil
seal of flywheel housing. Meanwhile, when
replacing the oil seal, please always also replace
the oil baffle. Figure 8-14
8. Use the oil baffle dismantler to dismantle the oil

baffle (7)
Installation
1. Install the flywheel housing.
Note: Firstly tighten up the bolt close to thrust
pin. Please apply sufficient liquid sealant onto
the connection between cylinder and
crankcase, and don’t let the liquid sealant enter
the bolt hole.
2. Install the flywheel housing support.
3. Install the oil seal.
Note: Inspect that the dust lip is fixed in outer
race of oil baffle.
1) Apply a thin layer of new engine oil on
inside of oil seal.
2) Use the installer to install the oil seal and
oil baffle at the same time.
3) Tighten up the central bolt until the sleeve
contacts with the joint.
4) After pressing in the part, wipe away all oil
stain.
5) After installing the oil seal, measure the
size (2) from top of crankshaft to surface of
oil seal.
Basic size: 7.0±0.3 mm
Figure 8-15
4. Install the flywheel.

5. Install the washer and tighten up the bolt.

Apply the molybdenum disulfide onto bolt thread
and bearing surface, and fix them in accordance
with the numbering sequence in figure. The
tightening torque is 79N.m.
6. Install the NE sensor onto flywheel housing.
Note: Please install the sensor only after the
flywheels assembled.
Figure 8-16
Table of torque for dismantlement and installation of rear oil seal of engine
Figure 8-17

Dismantlement and installation of cylinder head assembly
Figure 8-18
1. Cylinder head cover 8. Rocker arm assembly
2. Cylinder head cover sealing gasket 9. Camshaft
3. Fuel injector harness 10. Transverse arm
4. Fuel discharge pipe of nozzle 11. Fuel injector and thimble
5. Lower cover of cylinder head 12. Cylinder head assembly
6. Harness connector 13. Cylinder head sealing gasket
7. Sealing gasket for lower cover of cylinder head 14. Idler C

Dismantlement
1. Dismantle the vent hose, and then dismantle
the cylinder head cover (1)
2. Dismantle the cylinder head cover sealing
gasket (2)
3. Dismantle the fuel injector harness (3)
4. Dismantle the fuel discharge pipe (4) of nozzle
5. Dismantle the harness connector (6)
6. Dismantle the lower cover (5) of cylinder head
7. Dismantle the sealing gasket (7) on lower cover
of cylinder head
8. Dismantle the rocker arm assembly (8), keep
the bracket balanced, and loosen and
dismantle the fixing bolt from both sides of
rocker arm assembly bracket
9. Dismantle the transverse arm (10)
Note: Please label every cylinder in transverse arm.
10. Dismantle the camshaft (9)
Before dismantling the camshaft, measure the axial

clearance of camshaft.
Clearance in direction of camshaft (mm)
Standard Extreme
0.085~0.170 0.25
Measure the Clearance between camshaft journal
and bracket
Clearance between shaft journal and bracket (mm)
Selection of reference
Extreme
points
0.065~0.125 0.15
11. Dismantle the fuel injector and thimble (11)

Note: Before dismantling the fuel injectors,
please number them.
12. Dismantle the cylinder head assembly (12),
dismantle the fixing bolts (27) and (28), and
then loosen and dismantle the fixing bolts from
outside in a balanced manner in accordance
with the sequence indicated in the figure.
13. Dismantle the cylinder head sealing gasket (13) Figure 8-19

Installation
● Assembling sequence
Carry out the installation in accordance with the
● When installing the cylinder head cover, please
fix it in accordance with the sequence indicated
in the figure.
Figure 8-20
Table of tightening torque for engine cylinder head
Figure 8-21

Disassembling and assembling of cylinder head assembly
Figure 8-22
1. Spacing sleeve 13. O-ring
2. Sealing ring 14. Valve seat gasket
3. Sealing ring 15. Valve
4. Exhaust pipe bracket 16. Heater plug
5. Exhaust manifold assembly 17. Preheating plug connector
6. Slotted washer 18. Thermal sensor
7. Spring sleeve (upper) 19. Intake manifold
8. Valve spring 20. Idler shaft C
9. Valve rod oil seal 21. Idler
10. Spring sleeve (lower) 22. Gear box
11. Valve guide 23. O-ring
12. Air nozzle sleeve 24. Transverse arm guide

Disassembling
1. Dismantle the preheating plug connector (17)
2. Dismantle the preheating plug (16)
3. Dismantle the thermal sensor (18) Axial clearance (mm)
4. Dismantle the gear box (22) Standard Extreme
0.05~0.14 0.25
Before dismantling the gear, measure the axial
clearance of idler shaft C.
5. Dismantle the gear box O-ring (23)
6. Dismantle the idler shaft C (20)
7. Dismantle the idler C (21)
Note: Be careful not to damage the idler shaft
bushing.
8. Dismantle the intake manifold (19)
9. Dismantle the exhaust pipe bracket (4)
10. Dismantle the engine bracket (front)
11. Dismantle the exhaust manifold assembly (5)
Note: Don’t reuse the locking nut.
12. Dismantle the sealing ring of exhaust manifold
13. Dismantle the slotted washer (6)
14. Dismantle the spring sleeve (upper) (7)
Place the cylinder head on a piece of wood plate,
use the compressor to dismantle the slotted washer,
and then dismantle the spring seat, valve spring
and valve, and label every cylinder.
15. Dismantle the valve spring (8)
16. Dismantle the spring sleeve (lower) (10)
17. Dismantle the valve (15)
18. Dismantle the valve rod oil seal (9)
19. Dismantle the valve guide (11)
20. Dismantle the transverse arm guide (24)
Note: Don’t dismantle the guide of transverse
arm guide, unless it is worn.
21. Dismantle the valve seat gasket (14)
22. Dismantle the nozzle sleeve (12)
23. Dismantle the nozzle sleeve O-ring (13)

Assembling
1. Apply engine oil onto O-ring and insert it into
sleeve.
2. Apply the sealant onto outside diameter surface
of nozzle sleeve and end face of bearing, and
make then mate with cylinder head forcibly.
Note: Insert the O-ring, make the red portion
face upwards, and make the black portion face
downwards.
Figure 8-23
3. Clean up the installation surface of valve seat

bushing, and apply pressure to the valve seat
bushing.
Figure 8-24

4. Install the transverse arm guide onto cylinder

head.
Apply the engine oil onto the outside diameter of
guide. Use the installer to forcibly press the
transverse arm guide into cylinder head, and ensure
that the guide extrudes from upper surface of
cylinder head by 49mm.
Figure 8-25
5. Install the valve guide bush.

Apply the engine oil onto the whole outside of valve
guide bush. Use the installer to press in the valve
guide bush, and ensure that the distance between it
and the surface of cylinder head is the standard
height.
The distance between intake pipe and surface of
cylinder head is the standard height: 27mm The
distance between exhaust pipe and surface of
cylinder head is the standard height: 29mm
Figure 8-26

6. Use the installer to mount the valve sleeve onto

valve rod seal.
Figure 8-27
7. Install the valve.
Figure 8-28

8. Install the spring seat (lower).

9. Install the valve spring.
10. Install the spring seat (upper).
Figure 8-29
11. Install the split washer.
Figure 8-30

12. Install the sealing ring onto exhaust manifold.
Figure 8-31
13. Install the exhaust manifold.

Fix the sealing gasket, install the manifold onto
cylinder head, and fix it in accordance with the
sequence as indicated in the figure. When
fixing the flange, please start with lower side of
flange and fix it anticlockwise.
Figure 8-32

14. Install the exhaust pipe bracket.
Figure 8-33
15. Install the engine bracket (front bracket).

16. Install the intake manifold.
Figure 8-34

17. Apply the engine oil onto idler C and insert it

into idler shaft.
18. Mount the idler C in idler shaft C, and assemble
and fix the cylinder head.
Figure 8-35
19. Install the O-ring onto gear box.

20. Install the gear box onto cylinder head and
tighten up the bolt.
Figure 8-36

21. Install the thermal sensor onto cylinder head.
Figure 8-37
22. Install the preheating plug onto cylinder head.

23. Insert the ignition connector between ignition
nut and flat washer and tighten up the nut.
Figure 8-38

Dismantlement and installation of radiator assembly

Before the dismantlement, please pay attention to
the following matters:
1) In order to avoid scalding, please drain the
coolant only after it has fully cooled down.
2) If the pressure cover (2) in Figure 8-39 is
randomly opened when the coolant is hot, the
coolant may spout out.
When opening the pressure cover, please use
wiping cloth to wrap the pressure cover 2, slowly
loosen pressure cover 2 so as to release the
pressure, and then fully open it.
Figure 8-39
Dismantlement
1. Dismantle the hood (1) and crossbeam (2).
Figure 8-40
2. Dismantle the crossbeam (3).
Figure 8-41

3. Open the pressure cover (2), and drain the

engine coolant via water drain valve on lower
portion of cooling water tank.
Coolant: about 47L
Figure 8-42
4. Dismantle the air inlet pipe (4) of intercooler.
Figure 8-43
5. Dismantle the air outlet pipe (5) of intercooler.
Figure 8-44

6. Dismantle the engine exhaust gas circulation

exhaust pipe (6), engine water filling pipe (7)
and engine exhaust pipe (8).
Figure 8-45
7. Dismantle the cooling water return pipe (9).
Figure 8-46
8. Drain the refrigerant, dismantle the 2 bolts (10)
and 4 bolts (11) on A/C radiator, dismantle the
A/C radiator, place it at appropriate position,
and dismantle the fuel inlet/return pipes (12),
(13)of fuel cooler.
Figure 8-47

9. Dismantle the crossbeam (14).
Figure 8-48
10. Dismantle the water inlet pipe (15) of radiator.
Figure 8-49
11. Dismantle the four fixing bolts (16) for support
of radiator assembly.
12. Lift up and mount the radiator assembly.
Figure 8-50

13. Dismantlement of radiator assembly
Figure 8-51
● Dismantlement sequence
1 Damping block 2 Sleeve 3 Fuel cooler 4 Mooting leg
5 Dust mat 6 Dust mat 7 Protective mat 8 Shroud
9 Expansion water tank 10 Sponge strip 11 Mooting leg 12 Mooting leg
13 Mooting leg 14 Intercooler 15 Mooting leg 16 Mooting leg
17 Sponge strip 18 Hose 19 Spring clamp 20 Water cooler
● Installation sequence
Carry out the installation in accordance with the reversed dismantlement sequence.

Dismantlement and installation of engine and hydraulic pump

assembly
Dismantlement
Lower down the working device onto ground so
as to ensure safety, turn off the engine, and
dismantle the cable from negative pole (-) of
battery.
Screw off the butterfly nut of breather valve,
and press down the air bleeding button, so as
to release the internal pressure.
★ Mark the pipeline, so as to avoid mistake during
re-installation.
1. Dismantle the oil suction filter of hydraulic oil
tank, and block up the oil outlet port.
2. Drain the engine coolant.
Coolant: about 47 L
3. Dismantle the hood
Figure 8-52
4. Dismantle the pipelines (1), (2), (3), (4).
Figure 8-53

5. Dismantle the pipelines (5), (6), (7), (8), (9),

(10),
6. Dismantle the sensors A and B
Figure 8-54
7. Dismantle the sensor harness clamps and
cables.
Figure 8-55
8. Dismantle the connecting cables (12), (13) on
starter.
Figure 8-56

9. Dismantle the cables (14), (15) and pipes (16),

(17) from compressor.
Figure 8-57
10. Dismantle the hoses (18), (19), (20) which
connect engine with radiator.
Figure 8-58
11. Dismantle the intercooler hose (21) and air
suction hose (22).
Figure 8-59

12. Close the engine fuel cut-off valve, and

dismantle the fuel inlet/outlet pipes (23), (24),
(25), (26) of engine.
Figure 8-60
13. Dismantle the bottom cover plate on platform
under engine, and dismantle the earthling wire
(27) of engine.
Figure 8-61
14. Dismantle the engine harness fixing clamps
(28), (29), (30).
Figure 8-62

15. Dismantle the engine harness mouthpieces

(31), (32), (33), (34) connected with controller.
Figure 8-63
16. Dismantle the pedal (35).
Figure 8-64
17. Dismantle the engine oil inlet/outlet pipes (36)
and (37).
Figure 8-65

18. Dismantle the radiator fan cover (38).
Figure 8-66
19. Dismantle the fixing bolts (39) on 4 damper
mounting plates, and lift up the engine and
main pump assembly.
Engine and hydraulic pump

assembly: 1636 kg
Figure 8-67
Installation
● Carry out the installation in accordance with the reversed dismantlement sequence.
● Open the radiator water tank cover, and re-fill the coolant into water tank;
Engine coolant: About 47 L.
● Re-fill the hydraulic oil into hydraulic oil tank;
Hydraulic oil tank: About 440 L.
★ Start up the engine and make the coolant circulate so as to release the bubble, and then inspect the
level of coolant.
★ Start up the engine to make the oil circulate in hydraulic system, and then inspect the oil level again
● Bleed the air
Please refer to “Air Bleeding for Every Device” in the Section “Testing and Adjustment” in this Manual
(Page 6-31).

Dismantlement and installation of final transmission assembly

Dismantlement
1. Dismantle the sprocket. Please refer to the
Section “Dismantlement of Sprocket” in this
Manual.
as to ensure safety, turn off the engine, and
operate the breather valve to release the
internal pressure.
2. Dismantle the motor cover plate (1).
Figure 8-68
3. Dismantle the 4 travelling motor hoses (2) and

the pipe joints connected with them.
Figure 8-69

4. Dismantle the 40 fixing bolts on final

transmission assembly (3), and then lift it up so
as to dismantle it.
★ Be careful not to damage the seal surface
on hose seat.
★ When lifting up the final transmission
assembly, don’t use the threaded hole to lift
up the hood.
Final transmission assembly: 430

kg
Figure 8-70
Installation
● Carry out the installation in accordance with the
Final transmission assembly fixing bolt:

860~1030 Nm {87.7~105 kgm}
● Re-filling of hydraulic oil

Re-fill hydraulic oil via oil filling port to the
specified oil level, start up the engine to make
the oil circulate in hydraulic system, and then
inspect the oil level.
● Bleed the air
Please refer to “Air Bleeding for Every Device”
in the Section “Testing and Adjustment” in this
Manual (Page 6-31).

Disassembling and assembling of final transmission assembly

Disassembling
1. Drainage of oil
Screw off the drain plug, and drain the oil in
final transmission box.
Final transmission box: about 9 L
2. Hood
Dismantle the fixing bolt, and then use the eye
bolt ① to dismantle the hood (1).
Figure 8-71
3. Spacing plate
Dismantle the spacing plate (2).
Figure 8-72

4. Planet carrier assembly 1

1) Dismantle the planet carrier assembly 1
(3).
Figure 8-73
2) Disassemble the planet carrier assembly 1.
i) Dismantle the pin (5), and remove the
axis pin (4) from planet carrier (9).
ii) Dismantle the thrust washer (6), gear
(7), bearing (8) and thrust washer (6).
Figure 8-74
5. Sun wheel shaft 1
Dismantle the sun wheel shaft 1 (10).
Figure 8-75

6. Sun gear 2
Dismantle the sun wheel shaft 2 (11).
Figure 8-76
7. Disassemble the planet carrier assembly 2.

1) Dismantle the pin (13), and dismantle the
axis pin (18) and planet wheel (16) from
planet carrier (12).
2) Dismantle the thrust washer (17), gear
(16), bearing (15) and thrust washer (14).
3) Dismantle the fixing screw, and remove the
planet carrier (12) from body.
Figure 8-77
8. Hub assembly
1) Use the eye bolt ② to dismantle the hub
assembly (19) from travelling motor.
Figure 8-78

2) Disassemble the hub assembly as follows.

i) Dismantle the floating seal (20).
ii) Dismantle the bearings (22) and (21)
from hub (23).
★ When dismantling the bearing (22),
don’t damage the carrier of bearing.
Figure 8-79
3) Dismantle the floating seal (25) from

travelling motor (24).
Figure 8-80
Assembling
★ Clean up all parts and inspect whether there is
dirt or damage. Before the installation, please
apply the engine oil onto sliding surface of
parts.
1. Hub assembly
1) Press the bearings (22) and (21) onto hub
(23).
Figure 8-81

2) Install the floating seal (24)

★ Clear away the oil and dust on contact
surface between O-rings, and before
installing the floating seal, dry up the
part.
★ After installing the floating seal, inspect
whether the corner of floating seal is
within 1mm.
★ After installing the floating seal, apply
a thin layer of engine oil onto sliding
surface. Figure 8-82
3) Install the floating seal (25) onto travelling

motor (24).
★ The installation procedure is as same
as the above-mentioned Step 2.
Figure 8-83
4) Use the eye bolt ② to place the hub

assembly (19) onto travelling motor, and
carefully knock in the bearing.
Figure 8-84

2. Calculation of thickness of adjusting gasket

1) Measure the height H of boss on planet
carrier 2 (12).
Figure 8-85
2) Measurement of bearing
Apply the load of 3,000kg on bearing, and
then measure the length H of extrusion
portion of bearing.
★ Before applying the force, please turn
Apply the load of
the hub for 2-3 times. 3000Kg
★ Don’t use spray gun to apply gasket
for bearing.
★ Don’t push or knock the holding valve.
3) Thickness of adjusting gasket: C=H-h.
Figure 8-86
4) Place the adjusting gasket on body, insert

the lock pin, press the planet carrier into
lock pin, use the screw to fix it, and apply
the thread adhesive onto thread.
Tension
Thread adhesive (Kesaixin meter
1277).
★ Use the tensimeter to measure the
tangential force applied by hub on
motor box in rotating direction.
● tangential force: maximum 297 N
{30kg}
● The maximum tangential force
appears at the beginning of Figure 8-87
steering.

3. Assemble the planet carrier assembly 2

1) Assemble the planet carrier assembly 2 in
accordance with the following steps.
★ The pin (13) shall be replaced with a new
one.
i) Install the bearing (15) onto gear (16),
assemble the baffles (14) and (17) on
top and bottom, and place the gear
assembly into planet carrier (12).
ii) Use the axis pin (18) to lock it, and
then knock in the pin (13)
★ After assembling the planet carrier
assembly, please inspect whether the
gear (16) rotates smoothly. Figure 8-88
4. Sun gear 2
Install the sun gear 2 (11).
Figure 8-89
5. Sun wheel shaft 1

Install the sun wheel shaft 1 (10)
Figure 8-90


1) The planet carrier assembly 1 is detailed
as follows.
★ The pin (5) shall be replaced with a
new one.
i) Mount the bearing (8) onto gear (7),
assemble the washers (6) on top and
bottom, and mount the gear assembly
into planet carrier (9).
ii) Use the axis pin (4) to fix the gear
assembly onto planet carrier (9).
Figure 8-91
2) Install the planet carrier assembly 1 (3).
Figure 8-92
7. Spacing plate
Install the spacing plate (2).
Figure 8-93

8. Hood
Use the eye bolt ① to assemble the hood (1),
and then use the torque spanner to tighten up
the fixing bolts.
Fixing bolt:
88.6±6.66 Nm {7±0.7 kgm}
9. Re-fill the oil
Torque
Tighten up the drain plug and fill the engine oil.
spanner
Final transmission box: about 9 L
★ After installing the final transmission

assembly onto chassis, finally inspect
whether the oil level is at the specified
position.
Figure 8-94

Dismantlement and installation of slewing motor and slewing

mechanism assembly
Dismantlement
Release the residual pressure in hydraulic
circuit. Please refer to “Release of Residual
Pressure in Hydraulic Oil Way” in the Section
“Testing and Adjustment” in this Manual (Pages
6-25).
as to ensure safety, turn off the engine, press
down the exhaust valve of breather valve so as
to release the residual pressure in oil tank, and
set the safety locking rod at the locking
position.
1. Respectively dismantle the hoses No. 1-9.

1) Between main valve and slewing motor (oil
port M)
2) Between oil tank and slewing motor (oil
port Dr)
3) Left slewing motor and right slewing motor
(oil port DL) Figure 8-95
4) Between slewing motor and port Px of

main valve (oil port SH)
5) Between slewing motor and
electromagnetic valve block (oil port PG)
6) Left slewing motor and right slewing motor
(oil port M)
7) The left slewing motor SH is connected
with right slewing motor SH connect
8) The left slewing motor PG is connected
with right slewing motor PG connect
2. Dismantle the 11 fixing bolts (9).
3. Lift up the slewing motor and slewing
mechanism assembly (10), so as to carry out
dismantlement.
● When lifting up the slewing motor and
slewing mechanism assembly, please act
slowly and be sure not to damage the hose
and other parts.
Back slewing motor and back slewing

mechanism assembly: 280 kg

Installation
Back slewing motor and back slewing

mechanism assembly install bolt:
490~608 Nm {50~62 kgm}
Re-fill hydraulic oil via oil filling port to the
specified oil level, start up the engine to make
the oil circulate in hydraulic system, and then
inspect the oil level.
● Bleed off the air
Manual (Pages 6-31).

Disassembling and assembling of slewing motor and slewing

mechanism assembly
Disassembling
1. Drainage of oil
Screw off the drain plug, and drain the oil from
slewing mechanism box.
Slewing mechanism box: about 4 L
2. Back slewing motor assembly

1) Place the slewing motor and slewing
mechanism assembly onto carrier, and be
careful not to get the driving gear damaged
or contact with ground.
2) Dismantle the 4 fixing bolts so as to
dismantle the slewing motor assembly (1).
Back slewing motor assembly: 70 kg
Figure 8-96
3. Sun gear 1
1) Dismantle the sun wheel 1 (2).
Figure 8-87


1) Remove the planet carrier assembly 1 (3)
and backing plate (4).
Figure 8-98
2) Disassemble the planet carrier 1
Firstly break the riveted portion on shaft
(8), remove the shaft (8), and remove the
gear (6), bearing (9) and backing plate (7)
in order.
Figure 8-99
5. Tooth ring
Dismantle the fixing bolt and dismantle the
tooth ring (10).
Figure 8-100

6. Sun gear 2
Dismantle the sun wheel 2 (11).
Figure 8-101
1) Dismantle the planet carrier assembly 2
(12).
Figure 8-102

2) Manually disassemble the planet carrier

assembly 2 in accordance with the
following method.
i) Knock in the pin (13) until it fully
enters the shaft (14), and push out the
shaft (14) from planet carrier (19).
★ After dismantling the shaft, pull out the
pin (13).
ii) Dismantle the thrust washer (16), gear
(17), thrust washer (19). Figure 8-103
iii) Knock in the pin (15) from shaft,
remove the bearing (18), and pull out
the pin (15).
8. Snap ring
Dismantle the snap ring 20.
Figure 8-104
9. Disassembling of main shaft

Pressure (out)
1) Place the shaft housing assembly on press
machine, and push out the shaft assembly
(21) from shaft housing assembly (22).
Figure 8-105

2) Disassemble the shaft assembly in Press out

Dismantle the bearing (23) from shaft (24).
Figure 8-106
10. Bearing
Take out the bearing (25) and oil seal (26) from
housing (27).
Figure 8-107

Assembling
★ Clean up all parts, inspect whether any part is
dirty or damaged, and apply the engine oil onto
sliding surface of parts before assembling.
1. Bearing
Press the bearing (23) into housing (27).
Figure 8-108
2. Oil seal
Press the oil seal (26) into housing (27).
Installation surface of oil seal: gasket
sealant (Loctite 515).
Figure 8-109
3. Housing assembly
1) Place the plate (28) on shaft (24).
2) Place the housing assembly (22) on shaft
(24), and press in the bearing.
Figure 8-110

4. Bearing
Press in the bearing (25).
★ When pressing in the bearing, please
simultaneously press the inner and outer
rings of bearing, and don’t press the inner
ring only.
★ After pressing the bearing, inspect whether
the housing can rotate smoothly.
Figure 8-111

1) Re-assemble the planet carrier 2 in
i) Assemble the backing plate (16) onto
planet carrier (19).
ii) Place the gear (17) into planet carrier
(19). Put the bearing (18) onto shaft
(14), align the pin hole, gently knock in
the pin (15) with rubber hammer, and
make sure that the pin (15) is not Figure 8-112
higher than bearing (18).
iii) Push the shaft assembly into planet
carrier (19), and don’t damage the
gear and backing plate. Align the pin
holes on shaft and planet carrier,
install pin (13), and use a rubber
hammer to carefully knock them in.
★ When installing the shaft, please turn
the planet wheel. Please don’t damage
the thrust washer.

6. Mount the snap ring (20), planet carrier 2 and Planet carrier 2
sun wheel 2 (11) in order.
Figure 8-113
7. Mount the tooth ring
Apply the sealant onto the mating face as
indicated by C, and then fix it with screw. Be
sure not to apply the sealant onto tooth ring
(10).
Mating face: sealant (Loctite 515).
Figure 8-114
1) Assemble the planet carrier 1 in
i) Place the backing plate (7) on planet
carrier (5).
ii) Mount the bearing (9) onto gear, and
then place the gear (6) on backing
plate. Figure 8-115
iii Press in the shaft (8) into gear (6) and
planet carrier (5), and rivet one end of
shaft.
★ Inspect whether the gear can rotate
smoothly.

2) Install the planet carrier assembly 1 (3)

and backing plate 4.
Figure 8-116
9. Sun wheel assembly 1

Install the sun gear 1 (2).
Figure 8-117

10. Install the back slewing motor assembly

After applying the sealant onto contact faces of
tooth ring and motor cover, install the slewing
motor assembly.
Mating face: sealant (Loctite 515)
Back slewing motor assembly: 55 kg
Slewing motor fixing bolt:

156±5 Nm {16±0.5 kg}
★ The 14 fixing bolt holes of slewing motor
and slewing mechanism assembly are
distributed unevenly, and their mating
direction is unique, as indicated in right
figure. When installing the slewing motor,
please align the thread hole and ensure
that the installation direction is correct.
Figure 8-118
11. Re-filling of lubricating oil
Screw in the drain plug and re-fill the lubricating
oil via oil filling port to the specified oil level
(high level mark on oil dipstick).
Slewing mechanism box: about 6.6 L

Disassembling and assembling of guiding wheel assembly

Disassembling
1. Dismantle the locating pin (1) and support (2).
2. Dismantle the floating seal (3) from support (2)
and guide wheel (4).
3. Dismantle the O-ring (11), and then dismantle
guide wheel (4) from shaft (5) and support
assembly (7).
★ The guide wheel contains 80ml of oil.
Before disassembling it, please drain the
oil. In order to prevent the floor from getting
dirty, please lay a layer of cloth on floor.
Figure 8-119
4. Dismantle the floating seal (6) on the other side

from guide wheel (4), shaft (5) and support
assembly (7).
Figure 8-120
5. Dismantle the locating pin (8), so as to
dismantle the support (7) from shaft (5).
6. Dismantle the bushing (9) and (10) from guide
wheel (4).
Figure 8-121

Assembling
1. Press the bushings (9) and (10) in to guide
wheel (4).
Figure 8-122
2. Assemble the O-ring, and use the locating pin

(8) mount the support (7) onto shaft (5).
Figure 8-123
3. Mount the floating seal (6) onto the assembly of

guide wheel (4), shaft (5) and support (7).
★ Floating Seal
Before installing the floating seal, please
fully clear away the grease on contact
surface of O-ring and floating seal (dashed
area in figure). In addition, don’t let any
dust stick to the contact surface of floating
seal.
Figure 8-124

★ After installing the floating seal, make sure

that the inclination of seal is less than 1
mm, and the protrusion of seal is 5-7 mm.
Figure 8-125
4. Mount the shaft (5) & support (7) assembly

onto guide wheel (4).
Figure 8-126

5. Mount the floating seal (3) onto guide wheel (4)

and support (2).
★ Apply the oil onto sliding face of floating seal,
and don’t let any dirt or dust stick onto it.
★ Clear away the oil and dust on contact face of
O-ring and floating seal.
Figure 8-127
Figure 8-128
6. Install the O-ring, and then use the locating pin

(1) to install the support (2).
7. Add the oil and screw in the screw plug.
Oil: About 80ml (hypoid gear oil No. 18)
Plug: 205.8±49 Nm {21±5 kgm}
Figure 8-129

Dismantlement and installation of sprocket

Dismantlement
1. Dismantle the crawler plate assembly. For
details, please refer to “Dismantlement of
Crawler Plate Assembly”.
2. Slew the working device for 90°, and then use
the working device to push up the chassis, and
place the cushion block ① between crawler
carrier and crawler plate.
3. Dismantle the sprocket (1).
Sprocket wheel: 106 kg
Figure 8-130
Installation
Thread of sprocket fixing bolt:

Thread sealant (Kesaixin 1277).
Sprocket wheel fixing bolt:
945±85Nm{95±8kgm}

Dismantlement and installation of crawler assembly

Special tools
Necessi Quanti
Mark Part name
ty ty
Hydraulic crawler
M dismantling/installing ● 1
machine
Dismantlement of crawler assembly

1. Select a place where there is sufficient space to
lay down the crawler, and stop the machine
when the main pin is located at the middle
position between guiding wheel and supporting
wheel.
2. Lower down the working device, and then
screw off the oil nozzle (1) and release the
tension of crawler.
The cylinder is under very high pressure.
Don’t screw off the oil nozzle for more than
one round. If no oil flows out, please move Figure 8-131
this machine forwards and backwards.
3. Use the tool M to pull out the main pin (2).
Figure 8-132

4. Dismantle the tool M, move this machine

forwards until the temporary pin ② is located in
front of guiding wheel, and place the cushion
block ①.
5. Dismantle the temporary pin ②, dismantle the
dust seal, and then move this machine
backwards so as to lay down the crawler (3).
Figure 8-133
Installation
★ Please refer to “Inspection and Adjustment of Crawler plate

Corner
Crawler Plate Tensioning Device” in the Section nut (square)
“Testing and Adjusting” in this Manual (Page 4-
14).
● Installation procedure for bolts and nuts for
Corner
crawler plate
1) Turn the side R of crawler plate nut (1) to Corner
the surface of connecting rod seat. When
assembling the crawler plate, please make
the two seat surfaces contact with each
other closely.
The surface of
★ If the crawler plate bolt is installed in seat shall
reversed direction, the corner of nut may contact closely
interfere with the surface of connecting rod
seat, so that the nut will rise and then the
bolt may get loosened.
2) Tighten up the crawler plate bolt to the
following torque.
Crawler plate bolt:
1369±49Nm{140±5kgm}
Figure 8-134

★ Use the tool M to press in the main pin, and

ensure that the extrusion amount of main pin
meets the size a.
Extrusion amount a of main pin: 4.4±1 mm
Figure 8-135
★ Before installing the dust seal, apply the grease

(lithium-based grease No. 2) onto it and contact
surface of bushing.

Dismantlement and Installation of Back slewing Bearing Assembly

Dismantlement
1. Dismantle the slewing table assembly. Please
refer to “Dismantlement of Slewing Table
Assembly”.
2. Dismantle the 60 fixing bolts (1), so as to
dismantle the slewing support assembly.
Figure 8-136
3. Lift up the slewing support assembly (2).
Back slewing bearing assembly: 1030

kg
Figure 8-137
Installation
Thread on fixing bolt of slewing support:

Thread adhesive (Tianshan adhesive 1277)

Slewing support fixing bolt:

Step 1:
Use the pneumatic spanner to tighten up the bolt.
Step 2:
Tighten it up to the torque of 1350±150 Nm
{138±15kgm}
1) When using the torque spanner to tighten
up bolts, please firstly tighten up the bolts
on four corners, and then leave the mark.
2) The remaining bolts shall be tightened up
in the clockwise or anticlockwise order.
First tighten up a bolt, and then tighten up
the opposite bolt, and leave the mark.
3) Tighten up bolts in this way, until the work
is completed.
★ As indicated in the figure, make the side

with mark S of soft area on inner race
towards right side, and then install it onto
crawler carrier.
★ Apply the grease onto inside of tooth ring
of slewing support.
● Apply the grease onto tooth.
Slewing bearing: Soft area of
inner race
Grease (molybdenum disulfide based
lubricating grease) 30 L
Figure 8-138

Dismantlement and installation of slewing table assembly

Dismantlement
Fully extend the bucket arm and bucket, lower
down the working device onto ground, and set
the safety locking rod at locking position.
1. Dismantle the working device assembly. Please
refer to “Dismantlement and Installation of
Working Device Assembly” in this Manual.
2. Dismantle the balance weight assembly.
Please refer to the Section “Dismantlement of
Balance Weight Assembly” in this Manual.
3. Dismantle the 4 boom cylinder hoses (1).
★ Block up the hose so as to prevent the oil
from flowing out.
Figure 8-139
4. Lift up the boom cylinder assembly (2).
Figure 8-140

5. Dismantle the plate (3) and pin (4), and lift up

the boom cylinder assembly (2) so as to
dismantle the it.
★ Dismantle the boom cylinder assembly on
the other side in accordance with the same
method.
Boom cylinder assembly: 645 kg
6. Dismantle the plate (5).
Figure 8-141
★ When dismantling the slewing table,

please dismantle the other parts which
affect the lifting operation.
Figure 8-142
7. Dismantle the 6 hoses above rotation joint

assembly on slewing joint side.
(8): Central slewing joint (oil port A) - left
travelling control valve (oil port BTL)
(9): Central slewing joint (oil port C) - left
travelling control valve (oil port ATL)
(10): Central slewing connector (oil port F) -
(11): Central slewing joint (oil port G) -
Slewing motor (oil port T)
(12): Central slewing joint (oil port D) - Right
travelling control valve (oil port ATR)
(13): Central slewing joint (oil port B) - Right Figure 8-143
travelling control valve (oil port BTR)
8. Dismantle the fixed bolt (14).

9. Dismantle the 32 slewing table fixing bolts and

dismantle the slewing table assembly (15), and
then lift it away.
★ Firstly dismantle the two fixing bolts in front
and behind the slewing table, use the
lever-type trolley to adjust the slewing table
until it is balanced, and then dismantle the
remaining two bolts.
When dismantling the slewing table
assembly, please don’t make it collide with
central slewing joint assembly. Figure 8-144
Slewing table assembly (excluding

balance weight and working device)
Only slewing table

Assembly
(reference value)
SY750H 17575 kg 13800 kg
Installation
Air intake hose fixing screw:

5.4~6.4 Nm {0.55~0.65 kgm}
Mating surface of back slewing bearing:

Plane sealant (Tianshan 1596)
Thread on fixing bolt of slewing table
install bolt thread:
Thread adhesive (Tianshan 1277)
Slewing table fixing bolt:
Step 1: Use the pneumatic spanner to
tighten up the screw
Step 2: Re-tighten up the screw
1200~150 Nm {120~150 kgm}
Re-fill the hydraulic oil via oil filling port until the
level reached the specified level, start up the
engine to make the oil circulate in hydraulic
system, and then inspect the oil level again.
Bleed the air from travelling motor. Please refer
to “Air Bleeding for Every Device” in the Section
“Testing and Adjustment” in this Manual (Page
6-31).

Dismantlement and installation of central slewing joint assembly

Dismantlement
circuit. Please refer to the contents about
release of residual pressure in hydraulic circuit
Manual.
★ All pipelines shall be attached with label so as
to prevent incorrect installation position.
1. Dismantle the 8 hoses (1) through (8) from
central slewing joint of travelling motor.
● (1): Central slewing joint (oil port T) - left
travelling motor (oil port T)
● (2): Central slewing joint (oil port T) - right
travelling motor (oil port T)
● (3): Central slewing joint (oil port B) - left
travelling motor (oil port PA)
● (4): Central slewing joint (oil port D) - Right
travelling motor (oil port PB)
Figure 8-145
● (5): Central slewing joint (oil port A) - left
travelling motor (oil port PB)
● (6): Central slewing joint (oil port C) - right
travelling motor (oil port PA)
● (7): Central slewing joint - left travelling motor
(oil port P)
● (8): Central slewing joint - right travelling motor
(oil port P)
2. Dismantle the 6 hoses (9) through (14).

● The four rubber hoses (9) through (12) are
connected to main oil port of main valve
● (13) Connected to oil port A2 of
electromagnetic valve group
● (14) Connected to oil return port of oil
discharge filter element
Figure 8-

3. Dismantle the fix bolt (15) and T-shaped anchor

ear (16), and remove the rubber pad assembly
(17).
4. Dismantle the fix bolt (18).
Central slewing connector: 56kg
Figure 8-147
Installation
Install the central slewing joint and make it face Central slewing
in the direction as indicated in the figure. connector
(The vertical view of this machine is given in Sproc

ket
the figure) wheel
● Refilling of oil (hydraulic oil tank)
★ Fill oil to the specified level via oil filling
port. Start up the engine, make the oil
circulate in system, and then inspect the oil
level.
★ Bleed the air from travelling motor, For Figure 8-148
details, please refer to the contents about
bleeding air from components in the
Section “Testing and Adjustment”.

Disassembling and assembling of Central Back slewing Joint

Assembly
Disassembling
1. Dismantle the fixing bolt (1).
2. Dismantle the cover (2).
3. Dismantle the O-rings (3), (5) and blind plug
(4).
4. Dismantle the circlip (7).

5. Dismantle the slewing shaft (12) from slewing
body (6)
● Be careful not to damage the sliding face
of seal of slewing shaft (12).
6. Dismantle the spacing sleeve (8) and gasket
(9) from slewing body (6). Figure 8-213
7. Dismantle the dust ring (11) from slewing shaft
(12).
8. Dismantle the O-ring (10) from slewing body
(6).

Assembling
1. Mount the dust ring (11) onto slewing shaft Dust Seal
(12).
2. Mount the O-ring (10) onto slewing body (6).
Lip
3. Fix the slewing shaft (12) onto the working
bench, and install the slewing body (6) onto
slewing shaft (12).
Slewing body
4. Use the rubber hammer to knock the slewing
body (6), until it properly mates with slewing
shaft (12).
5. Mount the spacing sleeve (8) and gasket (9) Figure 8-150
into slewing body (6).
6. Mount the circlip (7) onto slewing shaft (12).
7. Mount the O-ring (3), (5) and plug (4) onto
slewing shaft.
8. Install the cover (2), and tighten up the fixing
bolt (1)
Fixing bolt: 49 Nm{5 kgm}

Dismantlement and Installation of Hydraulic Oil Tank Assembly
Dismantlement
1. Drain the oil from hydraulic oil tank
Hydraulic oil: About 400 L
2. Open the hood.

3. Dismantle the hood (1), cover plate (2) and
control valve cover (3).
4. Dismantle the hood mooting bracket (4).
Figure 8-215

5. Dismantle the 3 rubber hoses.

(6): Oil return from electromagnetic valve
(7): Oil discharge pipe of rear pump
(8): Oil discharge pipe of front pump
● Paste the identification label onto hose.
● Use the sleeve nut to protect pipe joint and
bevel seal, so as to prevent them against
damage.
6. Dismantle the 6 hose clamps.

(9): Oil return from main valve
(10): Oil return from main valve Figure 8-216
(11): Oil return from T block

(12): Oil return from slewing joint
(13): Oil return from slewing motor
(14): Oil return from main valve
● Paste the identification label onto hose,
use the sleeve nut to protect pipe joint and
bevel seal, so as to prevent damage.
7. Lift up the hydraulic oil tank assembly and
dismantle the 6 fixing bolt (20).
8. Lift away the hydraulic oil tank assembly and

dismantle it.
Hydraulic oil tank assembly: 256 kg
Figure 8-217

Installation
Hydraulic oil tank drain plug:

58.8~78.5 Nm {6.0~8.0 kgm}
Screw
★ After tightening up the fixing screw of hose,
inspect whether the screw is located in the
area as indicated in the figure.
Hose fixing screw: Upper
side
8.8±0.5 Nm {0.9±0.05 kgm} Lower
side
Figure 8-155
★ As indicated in the right figure, install the

hose clamp and tighten up the fixing Pipe
Clamp Hose
screw.
Fixing bolt:
245.2~308.9 Nm {25~31.5 kgm}
Boss on
● Re-fill the oil (hydraulic oil tank) clamp

port. Start up the engine, make the oil Figure 8-156
level.
★ Please refer to “Air Bleeding for Every
Device” in the Section “Testing and
Adjustment”.

Dismantlement and Installation of Control Valve Assembly

Dismantlement
as to ensure safety, turn off the engine, release
the pressure in oil tank via breather valve, and
then set the safety locking rod at locking
position.
★ Every pipeline is attached identification label,
so as to avoid wrong installation position.
1. Open the hood (1), and dismantle the cover (2)
on control valve.
Figure 8-157
2. Dismantle the 8 pilot pipes (from left to right),

and paste the label.
● (3) Boom lowering hose
● (4) Boom lifting hose
● (5) Bucket excavation hose
● (6) Bucket unloading hose
● (7) Bucket arm excavation hose
● (8) Bucket arm unloading hose
● (9) Left slewing hose
● (10) Right slewing hose
Figure 8-158
3. Dismantle the 2 rubber hoses on control valve,

and properly paste the label.
● (11) Left forward traveling hose
● (12) Right forward traveling hose
Figure 8-159

4. Dismantle the rubber hose (13) - (18), and

properly paste the label.
● (13) Oil outlet hose of front pump
● (14) Oil outlet hose of rear pump
● (16) Hose from main valve to cooler
● (18) Oil adding port of slewing motor
5. Dismantle the pipe clamps (15), (17).
● (15) Fixing clamp of oil inlet steel pipe of
main valve
● (17) Fixing clamp of oil return steel pipe of
main valve
6. Dismantle the 4 high-pressure pipelines on
control valve and properly paste the label
● (19) Right backward traveling hose Figure 8-160
● (20) Right forward travelling hose
● (21) Left backward traveling hose
● (22) Left forward travelling hose
Figure 8-161
7. Dismantle the rubber hoses (23) - (26), and
properly paste the label.
● (23) Port A of left slewing motor
● (24) Port B of right slewing motor
● (25) Port A of left slewing motor
● (26) Port B of right slewing motor
Figure 8-162

8. Dismantle the 5 rubber hose s and properly

paste the label
● (27) Bucket unloading oil transfer pipe
● (28) Bucket excavation oil transfer pipe
● (29) Bucket arm excavation oil transfer
pipe
● (30) Bucket arm excavation oil transfer
pipe
● (31) Bucket arm unloading oil transfer pipe
Figure 8-163
9. Dismantle the pipe clamps (32a), (32b), (33).
Figure 8-164
10. Dismantle the steel pipe connected to boom.

● (34) Steel pipe connected to large
chamber of boom cylinder
● (35) Steel pipe connected to small
chamber of boom cylinder
● (36) Clamp on steel pipe of boom cylinder
Figure 8-165

11. Dismantle the oil-return steel pipe (37).
Figure 8-166
12. Dismantle the fixing bolt of control valve

assembly (38), and lift up the assembly so as to
dismantle it.
Control valve assembly: 337 kg
Figure 8-167
Installation
● Re-fill the oil (hydraulic oil tank)
port. Start up the engine, make the oil
level.
★ Bleed the air from circuit between valve
and hydraulic cylinder. For details, please
refer to “Air Bleeding for Every Device” in
the Section “Testing and Adjustment”,.

Dismantlement and installation of hydraulic pump assembly

Dismantlement
Lower down the working device onto ground,
turn off the engine, and then press down the
air-bleeding button on breather valve of
hydraulic oil tank, so as to release the pressure
in tank.
Before carrying out the work, dismantle the
cable on negative pole (-) terminal of battery.
● Label all pipelines, so as to avoid mistake
during installation.
1. Dismantle the oil suction filter element of Oil guard
hydraulic oil tank and use the oil guard to
prevent the hydraulic oil from flowing out.
● If the oil guard is not used, please
dismantle the drain plug and drain the oil
from hydraulic oil tank and pipeline.
Hydraulic oil tank: About 440 L Figure 8-231
2. Dismantle the hoods (1), (2), (3).

3. Dismantle the brackets (4) and (5).
Figure 8-232

4. Dismantle the proportional valve oil inlet rubber

hose (5) and pilot pump oil outlet rubber hose
(6) and seal up the oil ports.
Figure 8-233
5. Dismantle the right door (8).

6. Dismantle the hydraulic pump hood (9).
Figure 8-234
7. Dismantle the oil discharge rubber hose (10)

and seal up the oil port.
8. Dismantle the high-pressure rubber hoses (11),
(12) from control valve and seal up the oil ports.
9. Dismantle the pressure sensor harness (13).
10. Dismantle the oil suction rubber hose (14) of
pilot pump and seal up the oil port.
11. Dismantle the oil suction pipe (15) of hydraulic
pump and seal up the oil port.
Figure 8-235

12. Dismantle the electromagnetic valve harness

(16), (17) and harness clamps (18), (19).
Figure 8-236
13. Dismantle the hydraulic pump 4 个 fix bolt (20),

lift up the hydraulic Dismantle the pump
assembly (21).
Hydraulic pump assembly: 184 kg
Figure 8-237

Installation
Screw
★ After tightening up the fixing screw of hose,

Upper
inspect that the screw is located in the side
area as indicated in the right figure.
Lower
Fixing screw of suction hose: side
8.8±0.5 Nm {0.9±0.05 kgm}
Figure 8-175
★ Install the hose clamp and tighten up the fixing

screw, as indicated in the right figure. Clamp Hose
Pipe
Mating surface of hydraulic pump

housing:
Gasket sealant (Loctite 515)
● Re-fill the oil (hydraulic oil tank)
Fill oil to the specified level via oil filling port.
Start up the engine, make the oil circulate in Boss on
clamp
system, and then inspect the oil level.
Hydraulic oil tank: About 440 L Figure 8-176

Manual.

Dismantlement and installation of

oil seal in hydraulic pump input
shaft
Dismantlement
1. Dismantle the hydraulic pump assembly.
Please refer to the Section “Dismantlement of
Hydraulic Pump Assembly”. Circlip
2. Use the long needle-nose pliers to dismantle

the circlip.
3. Use the screwdriver to pry out the oil seal and
its front cover (the oil seal is mounted in front
cover).
★ When prying out the oil seal, be careful not
to damage the shaft.
Figure 8-177
Installation
Front cover
reversed dismantlement sequence. Oil seal
Lip of oil seal: grease (calcium-based

lubricating grease No. 1)
Circumference of oil seal: grease
(calcium-based lubricating grease No.
1)
★ Apply a thin layer of grease onto
circumference of oil seal.
Figure 8-178

Dismantlement and installation of independent oil disperser

Before the dismantlement, please pay attention to
the following matters:
1. In order to avoid scalding, please drain the
hydraulic oil only after it has fully cooled down.
2. When dismantling the independent oil
disperser, please dismantle the covering parts
near it.
Dismantlement
1. Dismantle the oil inlet pipe (1) and oil return
pipe (2) of radiator; dismantle the oil pipes (3)
(4) (5) of motor.
★ Please pay attention to keep the pipeline,
motor and oil port of radiator clean.
Figure 8-179
2. Dismantle the protective mat (6), dismantle the

fan (7), dismantle the motor (8), dismantle the
bracket (9), and dismantle the fixing bolt and
damping pad (10) of radiator.
★ When dismantling the fixing bolt, please lift
up the radiator, and prevent it from tilting.
Figure 8-180

3. Lift out and lower down the hydraulic oil

radiator (11).
Figure 8-181
Installation

Disassembling and assembling of working device pilot valve assembly

★ This Section only discusses the notices which must be complied during assembling of working device
pilot valve assembly.
Figure 8-182
Assembling ★ As indicated in the figure below, apply
● Re-assemble the working device pilot valve thread adhesive (Tianshan 1277) onto
assembly. inner thread at two points, about 0.02g for
every point.
1. Install the connecting plate (9) of oil port onto
the housing (8) with O-ring, and tighten up the Joint (3):
hexagonal screw (10). 98~133 Nm {10~13.5 kgm}
Hexagonal screw: ★ Strictly tighten up the joint in accordance
25~33 Nm {2.55~3.36 kgm} with the specified torque.
2. Place the spring (7) into valve core hole on

housing (8), place the valve core (6) into spring,
install the push rod (5) on upper portion of
valve core, and manually press the push rod (5)
into valve core hole.
3. Install the mounting plate (4) onto push rod (5),
and tighten up the joint (3).
4. Install the round plate (2), adjust it to
appropriate position, and tighten up the fixing
nut (1).
Fixing nut:
Figure 8-183
98~133 Nm {10~13.5 kgm}
★ The position of every oil port is punched on
lower portion of valve body. Contact face of push rod (5) and round
disc (2):
Circumference of push rod (5):
Grease 0.3-0.8cc (calcium-based lubricating
Grease (calcium-based lubricating grease No. 1) grease No. 1)
Movable surface of joint (3): ★ After assembling the round plate, please
Grease (calcium-based lubricating grease No. 1) refer to “Adjustment of Working Device
and Slewing Pilot Valve” in the Section
Thread in housing: “Testing and Adjustment” in this Manual
Thread adhesive (Tianshan 1277) (Page 4-22).

Disassembling and assembling of travelling pilot valve assembly

★ This Chapter only discusses the notices to be complied with during re-assembling of travelling pilot
valve assembly.
Push Rod
Figure 8-184
Assembling
● Re-assemble the travelling pilot valve assembly.
1. Mount the spring (8) into valve core hole on body (9), mount the valve core (7), place the body (6) on
valve core, and hold the body (6) with hand.
2. Align the hole, install the cover plate (4), and tighten up the hexagonal screw (1).
Hexagonal screw: 98~114 Nm {10~11.6 kgm}
3. Mount the dust proof ring (3) onto push rod, install the cam (2), and fix it with camshaft (5).
Contact between push rod and dust ring (5): Grease (calcium-based lubricating grease No. 1)

Disassembling and assembling of hydraulic cylinder assembly

Special tools
Name of Tool Schematic diagram Necessity Quantity
Used to pull out

and press in ■ 1
bushing
Used to press in
■ 1
dust ring
Used to correct
■ 1
sealing ring
Insertion tool Correction

tool
Used to insert
■ 1
cylinder cover
Used to insert
■ 1
piston

Disassembling
1. Drain the oil, and dismantle the pipe.
2. Fix the cylinder.
★ Please fix the cylinder vertically or
horizontally. The vertical state will make
the dismantlement and installation easy.
★ Please use the pin hole on large chamber
to carry out fixing, and use the axis pin to
prevent rotation.
★ During the fixing, if any pipe interferences
with it, please dismantle such pipe.
Fix the cylinder
Figure 8-185

3. Dismantlement of cylinder head

About 1.5m
★ Please use the hexagonal spanner to
screw off and dismantle the fixing bolt.
★ As indicated in the right figure, connect the
extended rod with hexagonal spanner, so
as to facilitate the operation.
Figure 8-186
4. Pull out the piston rod.

★ Please confirm that the cover of pipe has
been dismantled.
★ Please prepare a container to collect the
oil flowing out from oil hole.
★ Please pull out the piston rod (1) to the
longest position, and then slowly loosen
and pull out the cylinder head.
Sleeper
★ Pull out the piston rod (1) and cylinder
head (2) together, and then place them on
sleeper.
Figure 8-187
5. Fix the piston rod.

★ Please use the pin hole on rod head or the
plane on ear ring to fix it, so as to prevent it
Fixing
from rotating.
Figure 8-188

6. Dismantlement of piston nut (5) Drill bit

1) Dismantle the fixing screw (3) of piston nut.
★ Two position on circumference of
fixing screw must be punched so as to
prevent the screw from getting
loosened. Please use the hand-
operated drill to remove the riveted
portion, and then loosen and
dismantle the fixing screw (3).
2) Please dismantle the steel ball (4) in fixing
screw.
3) Dismantle the piston nut (5).
★ The tightening torque of piston nut (5)
Figure 8-189
is relatively high. In order to loosen the
piston nut (5), please prepare the
hydraulic jack or power spanner for
hydraulic cylinder. When manually
dismantling it, please prepare the
extended rod.
Hydraulic jack
Hydraulic
cylinder
Figure 8-190
7. Dismantle the components such as piston.
Please dismantle the piston (7), cushion collar
(6) and cylinder head (2) in accordance with the
sequence.
Figure 8-191

8. Dismantlement of cushion collar (8) on no-rod Thread

chamber side
1) Please firstly dismantle the piston nut (5),
otherwise the dismantlement can’t be
Piston rod
carried out.
2) Under the precondition that the piston rod
and cushion collar (8) will not be damaged,
use the tool such as rubber hammer to
gently knock the elastic retaining ring (9),
so as to dismantle it.
3) Slid the cushion collar (8) towards the
There is a (Two-plate type)
thread on piston, and then dismantle the
gap
spacing ring (two-plate type).
4) Dismantle the cushion collar (8). Figure 8-192
5) There is a gap on cushion seal (10).
Please use this gap to dismantle it.
9. Dismantle the piston seal.

Screw driver
1) The sliding ring (12) and protective ring
(13) can be dismantled easily with hand.
Piston
2) Please use hammer to knock the vertically-
placed flat screwdriver, so as to cut off and
dismantle the sealing ring (14).
Bench clamp
4) Please use the crowbar to takeout the O-
ring (15).
★ The dismantled sealing element may not
be re-used.
Figure 8-193
10. Dismantlement of cushion ring (16).

★ There is cushion ring (16) mounted in
groove on inside wall of cylinder head.
When dismantling it, please use sharp tool
to prick it and lift it up, and then insert the
scraper so as to take it out.
11. Dismantle the U-ring (17) and dust ring (18).
1) Please use the tool such as screwdriver to
dismantle the U-ring (17).
dismantle the dust ring (18).
★ The dismantled sealing element may not
be re-used.
Figure 8-194

12. Dismantlement of bushing (19)

1) Please use the screwdriver to take out the Press machine
elastic retainer ring (20), and dismantle it
from cylinder head (2).
2) Please use the fixture and press machine Cushion block
to push out the bushing (19).
13. Dismantlement of pin bushing (21)

dismantle the dust ring (22) on the side of
cylinder bore and piston rod. The method Support
is as same as the dismantlement method
for dust ring of cylinder head.
Figure 8-195
2) Please use the appropriate cushion block
to dismantle the pin bushing (21).
Assembling
1. Installation of axis pin bushing (21) Press
machine
1) Please use the installing tool to press it
into the bushing on the side of piston rod Installing
and cylinder bore (which is previously tool
Cushion
applied with hydraulic oil). block
Piston rod
2) Please use the cushion block to install the
dust ring (22).
Figure 8-196
2. Assembling of cylinder head assembly (2) Hydraulic press machine

1) Please use the pressing tool to press in the
bushing (19).
★ Apply the hydraulic oil onto inside of Tool
cylinder cover, and confirm whether
the shoulder of bushing (19) which
has been pressed in is raised.
Pressed face
Figure 8-197

2) Please use the pressing tool to press in the

dust ring (18).
3) Please in the order of protective ring and
U-ring (17), mount them into the U-ring Tool
groove. U-ring groove
★ Please confirm that the U-ring (17) is

Please use the
not damaged, and then install it in press machine
accordance with the correct direction. to press it in.
★ The installation in reversed direction
may lead to leakage of oil.
★ After the installation is completed,
please confirm whether the U-ring (17)
is free from corrugation or permanent
deformation.
Figure 8-198
4) Please install the buffer ring (16).
★ When carrying out installation, please
pay attention to direction of sealing
ring. If it is installed in reversed
direction, very high pressure will be
generated between it and U-ring (17),
which may deform or damage the
cylinder.
5) In order to prevent the bushing (19) from
falling off, please install the elastic retainer
ring.
3. Assembling of piston assembly
1) Install the sealing ring (14).
★ Please mount the O-ring and
protective ring (13) of one side onto
the piston, place them on press
machine, and use the tool to install the Figure 8-199
sealing ring (14) as indicated in the
right figure.
2) Please correct the sealing ring (14). Please use the press Cushion
Please use the press
machine to press it in. block
machine to press it in.
★ After installing the sealing ring (14)
and the protective ring (13) on the Tool
other side, in order to prevent the
sealing ring (14) from staying in
expanded state, please immediately Correction
Tool
tool
use the correction tool to correct the
sealing ring (14). The sealing ring (14) Piston
is prolonged during installation, and if
it is not corrected in time, the piston O-ring
rod can’t be inserted into cylinder
bore.
3) Install the sliding ring (12).
★ Please separate the cross section
slightly with two hands, and carry out Figure 8-200
installation from the direction of shaft.
If it is separated too large, the
installation can’t be carried out.

4. Assembling of piston rod assembly

1) Fix the piston rod (1). Tool used for
assembling
2) Install the cylinder head (2) onto piston
rod.
★ Make sure that the lip of dust ring or
U-shaped ring is not hung up by any
shoulder. Please use the tool to install
the cylinder head and piston rod.
Figure 8-201
3) If there is cushion on no-rod chamber side

The opened side faces
(none for bucket cylinder), please install towards thread direction
the cushion bearing and cushion seal in Thread
accordance with the following sequence.
i) Make the side of cushion seal (10)
there is a gap face towards the piston,
Piston rod
and mount it into groove.
ii) Please install the plane of cushion
collar (8) as indicated in the right
figure.
iii) Place the spacing ring (11) into
groove. Press the cushion collar (8)
towards spacing ring to the end, and
then install the elastic retaining ring. In There is a gap (Two-plate type)
order to prevent the piston rod and
cushion bearing from getting Cushion on no-rod
damaged, please use the tool such as chamber side
rubber hammer to knock them gently.
Figure 8-202

4) If there is cushion on rod chamber side,

please install the cushion collar (6) and
cushion seal (23) in accordance with the
following sequence.
i) Before installing the piston nut, please
install the cushion bearing; otherwise,
the cushion bearing can’t be installed.
ii) Make the side of cushion seal (23)
with gap face towards the piston, and
install it in groove.
iii) Please install the machined plane of The opened side faces towards
piston side
cushion collar (6) in accordance with
the right figure. Cushion on rod chamber side
5) Fix the piston nut (5).
Piston nut (bucket arm): Figure 8-203
9600 Nm {979.6 kgm}

Piston nut (boom and bucket):
6200 Nm {632.6 kgm}
★ If the tightening torque is insufficient,
the oil may internally leak, the nut may
get loosened, and then thread may get
damaged. In addition, if the tightening
torque is too high, the cushion bearing
may expand, or the side in contact
with piston will get deformed.
★ Please fully cleanup and degrease the
thread on piston, nut and piston rod
(banana oil and etc.), and then fix the
nut.
6) Carry out the anti-loosening treatment for
piston.
★ After tightening up the piston nut (5), Punch
Riveted
mount the steel ball (4), tighten up the
fixing screws (3), and rivet 2 locations
on circumference.
Fixing screw (3):
66.9 Nm {6.8 kgm}
Figure 8-204

5. Insert the piston rod into cylinder.

Tool
1) Vertically or horizontally fix the cylinder. Nylon sleeve (two-
plate type)
2) Insert the piston rod into cylinder.
★ As for vertical fixing, the piston rod will
enter the cylinder by virtue of its dead
weight. (Please make the
gap misaligned by
★ When the piston enters the cylinder, 180 degrees)
make sure that the sliding ring will not
fall off.
Figure 8-205
6. Tightening of cylinder head.

Please fix the bolts by reference to the position
indicated in the assembling diagram of cylinder
head and in accordance with the sequence as
indicated in the right figure.
Fixing bolt: 267 Nm {27.2 kgm}
7. Install the pipes.
Fixing sequence of bolts
Figure 8-206

Dismantlement and Installation of

Working Device Assembly
Dismantlement
Fully extend the bucket arm and bucket, lower
down the working device onto ground, and set
the safety locking rod at locking position.
circuit. Please refer to “Release of Residual
Pressure in Hydraulic Oil Way” in the Section
4-25).
1. Disconnect the grease pipe (1).
2. Lift up the boom cylinder assembly (2), and
dismantle the locking bolt (3).
3. Dismantle the plate (4), and then dismantle the
axis pin (5).
★ Since there are gaskets, please inspect the
number and thickness of gasket, and store
them in a safe place.
4. Start up the engine and retract the piston rod.
★ Use a steel wire rope to fix the piston rod
to prevent it from sliding off, and lower
down the cylinder onto bench or place a Figure 8-207
support under cylinder so as to support up
the oil cylinder. In the latter case, firstly
dismantle the grease pipe joint on bottom.
★ Dismantle the boom cylinder on the other
side in accordance with the same method.
5. Dismantle the two bucket cylinder hoses (6)
and three bucket arm cylinder hoses (7).
★ Block up the hose so as to prevent the oil
from flowing out, and fix it on one side of
valve.
6. Dismantle the middle connector (8) used for
working light.
Figure 8-208

7. Dismantle the decorative cover (9), pedal (10)

and ladder (11), lift up the working device and
dismantle the axis pin baffle (12), and then
dismantle the axis pin (13) on bottom.
★ Since there are gaskets installed, please
don’t forget to inspect the number and
installation positions of gaskets.
8. Dismantle the working device assembly and
disassemble it.
Working device assembly:
Model Weight
Figure 8-209
SY750H 17500 kg
Installation
★ When tightening up the bolt, please ensure

that the clearance between backing plate
and piston rod is 0.5-1.0mm.
After assembling the pin, apply the
grease onto it:
Grease (molybdenum disulfide based lubricating
grease)
When aligning the pin hole, be sure not to
insert your finger into the pin hole.
Figure 8-210

★ Adjust the thickness of gaskets, until the

clearance a between cylinder piston rod (14)
and plate (4) meets the condition: 0.5＜a＜1
mm.
★ Standard thickness of gasket: 1.0 mm - 2.0
mm.
After assembling the pin, apply the

grease onto it:
Grease (molybdenum disulfide based lubricating
grease)
When aligning the pin hole, be sure not to Figure 8-211
insert your finger into the pin hole.
● Supplement hydraulic oil
Add the hydraulic oil to the specified oil level,
start up the engine so make the oil circulate in
hydraulic system, and then inspect the oil level
again and add the hydraulic oil.
Bleed the air from travelling motor. Please refer
to “Air Bleeding for Every Device” in the Section
6-31).

Dismantlement and installation of A/C device assembly

Special tools
Mark Part name Model Necessity Quantity

Refrigerant-
Robin Nell
filling ● 1
34711-2K
machine
S
Refrigerant-
Inoue
filling ● 1
tsinghua
machine
Dismantlement
Firstly dismantle the negative (-) cable of
battery.
1. Drain the cooling water.
Cooling water: about 22.5 L
2. Use the tool S to recover the refrigerant from

A/C system.
Figure 8-212
3. Dismantle the base plate gasket (1).
Figure 8-213

4. Use the key of start switch to open the cover on

left rear portion of cab, and dismantle the air
filter element (2).
Figure 8-214
5. Dismantle the lower covers (3) and (4) of

monitor.
★ When dismantling the cover (3), firstly
dismantle the M19 wire of cigarette lighter.
6. Dismantle the right wind pipe (5).
Figure 8-215
7. Dismantle the rear hood (6).
Figure 8-216

8. Dismantle the rear air pipe (7).

9. Dismantle the left air pipe (8).
10. Dismantle the baffle (9).
11. Dismantle the right wind pipe (10).
Figure 8-217
12. Dismantle the hood (11).

13. Dismantle the middle connector (12) of cab.
14. Dismantle the radio antenna (13).
Figure 8-218
15. Dismantle the air pipe (14), dismantle the

connector (15), dismantle the A/C wire
connector (16), dismantle the 4 fixing bolts,
dismantle the controller assembly (17), and
dismantle the hood (18).
Figure 8-219

16. Dismantle the A/C water pipes (19), (20) under

base plate, and dismantle the water dripping
pipe (21).
Figure 8-220
17. Dismantle the A/C unit (22).
★ When dismantling the A/C unit, don’t forget
to connect the 2 A/C hoses on bottom.
Figure 8-221
Installation
★ When installing any A/C hose, please don’t let dirt, dust or water enter the hose.
★ Please install the A/C hose only when the O-ring is at the connected position.
★ Inspect whether the O-ring is damaged or deformed.
★ Apply the compressor oil (ND8#) onto the thread of connection part of refrigerating pipeline, and
then tighten up the pipeline with double-end spanner.
Hose fixing screw: 8.83~14.7 Nm {0.9~1.5 kgm}
Compression plate bolt: 13.5±1.2 Nm {1.38±0.12 kgm}
● Fill the A/C refrigerant
Use the tool S to fill the refrigerant (HFC-134a) into the A/C circuit.

Dismantlement and installation of balance weight assembly

Dismantlement
Steel wire rope
1. Attach the lifting hook onto the lug on balance
weight.
Lifting bolt
Figure 8-222
2. Dismantle the 8 fixing bolt (2).

3. Use the steel wire rope or chain pulley to
horizontally lift up the balance weight.
★ Be careful not to collide with engine,
radiator and cooler.
Balance weight assembly: 10950 kg
Figure 8-223

Installation
Thread of counterweight fixing bolt:

Thread adhesive (Tianshan adhesive 1277)
Counterweight fixing bolt:
4500-5000Nm{460-510kgm}
★ Installation and adjustment of balance

weight Door Unit: mm
1) Use a crane to lift up the balance

weight onto appropriate position on Counterweight
this machine.
2) Push the balance weight, mount the
fixing bolt and adjust it to the following
size.
● Clearance from slewing table:
10±5 mm (left and right)
Slewing table
● Clearance from door on
excavator:
Figure 8-224
10±5 mm (left and right)
● Step difference b of slewing table
on body of excavator in left and
right directions: maximum 5 mm
● Step difference a of door on body
of excavator in left and right
directions: 10±4
● Step difference c of top cover on
body of excavator in left and right
directions: maximum 5 mm

Dismantlement and installation of cab assembly

Dismantlement
battery.
1. Dismantle the floor mat (1).
Figure 8-225
2. Dismantle the back plates (2) and (3).
Figure 8-226
3. Disconnect the left harness (4), display harness
connector (5) and wind field washer harness
(6).
4. Dismantle the right air duct (7).
Figure 8-227

5. Dismantle the external air filter element (8).
Figure 8-228
6. Dismantle the external air duct (9).
Figure 8-229
7. Dismantle the armrest box (10).
Figure 8-230

8. Disconnect the radio connector (11).

9. Dismantle the radio harness (12).
Figure 8-231
10. Dismantle the wind field washer reservoir (13).
Figure 8-232
11. Dismantle the water pipe (14) of wind field

washer.
Figure 8-233

12 Dismantle the decorative cover (15).
Figure 8-234
13. Dismantle the 5 fixing bolts (16) and 4 fixing
nuts (17)
。
★ Firstly inspect the length of bolt
Figure 8-235
14. Lift up and dismantle the cab assembly (18).
Cab assembly: 432.5 kg
Figure 8-236
Installation
Fixing bolt: 200 Nm {20.4 kgm}

Fixing nut: 210 Nm {21.4 kgm}

Dismantlement and installation of display screen

Dismantlement
battery.
1. Dismantle the 3 fixing bolts (4), and dismantle
the fixing plate and display subassembly from
mounting bracket (3).
2. Loosen the fixing nut (1) and gasket (2), and
dismantle the display (5) from mounting plate.
Figure 8-237
Installation

Dismantlement and installation of controller assembly

Dismantlement
battery.
1. Dismantle the back plates (1), (2).
Figure 8-238
2. Dismantle the wire connectors (3), (4) of

controller.
3. Dismantle the 4 fixing bolt and dismantle the
controller assembly (5).
Figure 8-239
Installation

8-121
Radio Antenna
The black is output of left
sound track
The white is output of left
sound track
Rear panel of machine
Service Manual 03-2017

The grey black is output of
right soundtrack
Dismantlement and installation of radio
The grey is output of

right sound track
Power supply, earth and audio

The black is earthling wire
The yellow is the power supply
output
for BSTT
The red is the ACC ignition wire
The white is input of right
SY750H Hydraulic Excavator
sound track
Audio input
The red is input of left sound
Main structure track
Figure 8-240
Figure 8-241
Wiring
Structure
1)
2)
Installation and dismantlement

Dismantlement
Armrest
1) Dismantle the armrest box cover. box cover
Attention
● Before the dismantlement, please turn off the
power supply.
Radio
Figure 8-242
2) Dismantle the plug-in part CN-112M of radio
Plug-in part CN- Cab harness

112M
Figure 8-243
3) Dismantle the four fixing screws and washers,

and dismantle the radio and radio mounting
bracket from armrest box hood. Armrest box
4) Dismantle the four fix screws and washers, and
dismantle the radio from mounting bracket.
Installation
Radio
Radio mounting Washer
bracket Screw
Figure 8-244

Model and wiring of plug-in part
Harness socket terminal

Binding terminal of radio Model: Deutsch DJ7072-3-21
Figure 8-245

Removal and Installation of Storage Battery

Attention
● Before the dismantlement, please turn the key switch to the position OFF
1) Disconnect thenegative pole cutoff switch (2).

● Open the tool box cover, and turn the negative
pole cutoff switch (1) to the position OFF.
Warning
● The battery gas may cause explosion. Don’t
let any spark or flame get close to battery.
2) Dismantle the tool box fixing bolt, and take out

the tool box (2).
Figure 8-246
3) Dismantle the tool box bracket fixing bolt, and

take out the tool box bracket (3).
4) Dismantle the fixing nut on protective cover of
battery, and take out the protective cover (4) of
battery.
5) Open the rubber protective cap, dismantle the
fixing bolt for earthling wire on negative pole of
battery, and dismantle the terminal from binding
post of battery.
6) Dismantle the connecting wire of battery.
7) Dismantle the fixing nut of compression plate of
battery, and dismantle the compression plate
(5) of battery. Figure 8-247
8) Take out the battery (6).
Installation

Replacement
This machine is equipped with two 12V batteries of which the negative pole (-) is earthed. If a battery in the
24V system fails and the other battery is in good conditions, please replace the failing battery with a battery
of the same type. The charging rate of different type of battery will be different. Owing to this difference, a
certain battery may get overloaded and then fail.
Attention
● During installation, please apply the vaseline onto terminals of battery so as to avoid corrosion.

Dismantlement and installation of key switch

Structure
Figure 8-248
1- Casing 2- Key 3- Key ring 4- Key knob 5- Nut

6- Barrel 7- End cap 8- Door 9- Door pin 10- Door spring
11- Rotating disc 12- Rotating disc 13- Plug 14- Rotation body 15- Spring cover
spring
16- Resetting spring 17- Ball 18- Ball spring 19- Contact SPR-B 20- Contact A
21- Terminal seat 22- Contact SPR-A 23- Contact B 24- Terminal 25- Bolt
26- O-ring 27- Harness assembly 28- Washer


Dismantlement
1) Dismantle the locking screw, and dismantle the
armrest box cover.
Key switch Armrest box Locking screw

cover
Figure 8-249
2) Dismantle the two locking screws, and Armrest box cover

dismantle the mounting plate and key switch
Locking screw
from armrest box hood.
Attention
● Before the dismantlement, please disconnect
the plug-in part of key switch.
Install the plate Key switch
Figure 8-250
3) Dismantle the nut, and dismantle the key switch

from mounting plate.
Installation
Nut
Key switch Install the plate
Figure 8-251

Internal principle and wiring of key switch

Internal principle
Conductivity
Electrical Heater plug

Gear Storage battery Storage battery Starting relay
accessories
relay(BR)
Wiring
Harness plug terminal

Connecting terminal of key switch Model of protective sleeve: Yazaki 7123-7464-30
Model of protective sleeve: Yazaki
7222-7464-30
Figure 8-252

Dismantlement and installation of fuse box

Dismantlement
1) Open the door of electrical control cabinet.
Hood
Figure 8-253
2) Pull out the electrical plug of fuse box, and
dismantle the terminal.
Figure 8-254
3) Dismantle the fix bolt, and dismantle the fuse
box.
Figure 8-255
Installation

Dismantlement and installation of wiper

Structure and composition
Wiper blade
Rotating
mechanism
Wiper arm
Wiper motor
Plug-in
elements
Mounting
bracket
Figure 8-256
Internal Schematic Diagram
Green wire (low

speed)
Yellow wire
(resetting)
Blue wire (high
speed)
Red wire (power
supply +)
Black wire (power

supply -)
Figure 8-257


Dismantlement
1) Dismantle the interior trim clamp, and then Interior tri
dismantle the interior trim. clamp
Interior
trim
Figure 8-260
2) Dismantle the action mechanism and motor
● Dismantle the fixing bolt, and dismantle the
wiper motor and action mechanism from cab. Fixing bolt
Action
mechanism
Wiper motor
Locking bolt
Figure 8-261
3) Dismantle the arm and wiper blade
● Loosen the fixing nut, and dismantle the wiper
arm and wiper blade from cab.
Arm mounting
bracket
Protective
Installation cover
● Carry out the installation in accordance with the Fixing nut

reversed dismantlement sequence,
Figure 8-262

Adjustment of angle of wiper arm

● Before the wiper blade reaches the mechanical
Mechanical
limit, the arm shall stop. limit
● If the arm continues to act when the wiper
blade reaches the mechanical limit or the arm Wiper blade
stops before the wiper blade reaches the
mechanical limit, please adjust the action angle
of wiper, so as to prevent the wiper from getting
damaged.
Arm
● The adjustment method is to loosen the locking
nut, and adjust the work angle leftwards or
rightwards on the basis of the actual situations,
so as to ensure when the wiper blade reaches
the mechanical limit, the wiper motor will just
stop.
Fixing nut
Figure 8-261

Dismantlement and installation of relay

Engine relay
1) Inspection on starter relay
● Carry out the inspection on conductivity and
action. If any trouble is found, please replace
the relay.
Figure 8-262
2) Inspection on main power relay
the relay.
(+) Terminal of battery
Figure 8-263
3) Heating plug relay
the relay.
Figure 8-264

Other load relay

Function and position
● Other load relays are install in the electrical
control box behind the cab.

Dismantlement
1) Pull out the relay from relay seat.
Installation
Figure 8-265

Installation and dismantlement methods for terminal of plug-in part

Installation of terminal
1. Hold the wire at the position about 25mm
behind the pressed portion of terminal.
Figure 8-266
2. Hold the connector, and make the sealing ring

on its rear end face towards you.
Figure 8-267
3. Alight the terminal with the hole on sealing ring

and insert it vertically to the end. Gently pull
back the wire in opposite direction, so as to
confirm whether the terminal is locked in place.
Figure 8-268

Removal of terminal
1. Make the rear end of connector face towards
you, select the tool suitable for the wire, and
wrap the wire.
Figure 8-269
2. Push the tool into connector along the wire, and

use it to expand the locking shoulder of
terminal, so as to reach the terminal flange.
Figure 8-270
3. Pull outwards the tool, so as to take out the

wire together with terminal.
Figure 8-271

SY750H Hydraulic Excavator Hydraulic & Electrical Diagram
Hydraulic & Electrical Diagram

Start and preheating control ........................................................................................................................ 9-2
Auxiliary function control 1........................................................................................................................... 9-3
Auxiliary function control 2........................................................................................................................... 9-4
Main controller 1 .......................................................................................................................................... 9-5
Main controller 2 .......................................................................................................................................... 9-6
Display screen and GPS ............................................................................................................................. 9-7
Engine control .............................................................................................................................................. 9-8
A/C control ................................................................................................................................................... 9-9
Principle 1 for fuse box .............................................................................................................................. 9-10
Cab harness .............................................................................................................................................. 9-14
Control switch harness .............................................................................................................................. 9-15
Tool box harness ....................................................................................................................................... 9-16
Pump chamber harness ............................................................................................................................ 9-17
Body harness ............................................................................................................................................. 9-18
Body harness ............................................................................................................................................. 9-19
Hydraulic Schematic Diagram ................................................................................................................... 9-20
SY485H 9-1
Start and preheating control
Storage Contact of battery relay Start relay contact circuit fuse Main circuit fuse Charging indicator light Preheating relay Always-on circuit fuse Angle contact of flameout delay Ignition key switch
battery relay
From FU2
To ECM
To preheating relay To ECM To ECM To controller To ECM

To controller
Negative pole Contact of start relay Starting motor Alternator Heater plug Storage battery relay Power-on signal Starting signal
breaking switch
Figure 9-1
9-2 SY485H
Auxiliary function control 1
Radio Radio Antenna Contact of warning light relay Oil filling pump relay Contact of fuel filtration Working light switch Dome light Wiper switch Wiper controller Washer switch
relay switch
From indoor
light fuse
Intermittent Single speed Positive pole Washing Negative pole

of power of power
supply supply
Wiper controller
Resetting Negative Positive Positive Negative
control control rotation rotation
Warning light Left side Right

Platfor Left Right Rear
Left speaker Right Oil filling pump Oil filling Fuel filtration pump Working light relay side Dome light license Wiper motor Washer motor
pump Boom working m light
speaker Light Sound switch relay Dome light light
light
Figure 9-2
SY485H 9-3
Auxiliary function control 2
Electrical socket Power supply

Main controller A/C power GPS power ECM power Electromagnetic Horn button Inner light switch
of cigarette for display
lighter power supply supply supply supply pump switch
screen
To radio
To display To A/C
screen
To display
screen
To main
controller
To ECM To ECM To ECM
ECM main relay Start cutoff relay Electromagnetic Electrom Horn relay
Cigar Main controller power PCV power High-pitch Low-pitch Light in cab Inspection lamp
pump relay agnetic
lighter supply relay supply horn horn socket
pump
Figure 9-3
9-4 SY485H
Main controller 1
+5V OUT of Operating Work pressure Boom lifting Boom lowering Bucket arm Bucket arm Bucket Bucket Left travelling Right travelling Slewing pilot
Main controller power Fuel oil level Earth of sensor power supply Throttle knob pressure of of large Pressure of Pressure of pilot pressure pilot pressure unloading pilot excavation pilot unloading pilot excavation pilot pilot pressure pilot pressure pressure
supply for sensor cooling pump chamber of pump 1 pump 2 pressure pressure pressure pressure
boom
4-88ω
+24V power supply
V-BCU (Kawaski KC-MB-20 controller)

Earth for power supply
Fuel filter Warning light Flameout Start motor Warning light Proportional Proportional Cooling pump Pilot locking Dual running Standby Boom-slewing Boom-bucket Interflow
Earth for power supply Hydraulic oil relay (light) relay delay relay relay (sound) relay Earth of electromagnetic valve valve of pump 2 valve of pump 1 proportional electromagnetic speed electromagnetic priority priority electromagnetic
temperature Electromagnetic Electromagnetic electromagnetic valve electromagnetic valve proportional proportional valve of pump 2
valve valve valve valve valve valve
Figure 9-4
SY485H 9-5
Main controller 2
The fuel The water level
Air filter filtration in oil water Pilot locking Starting Power-on GPS
blocking system is separator is too signal signal detection
abnormal high
V-BCU (Kawaski KC-MB-20 controller) 120ω 120ω
ACNO-I (Terminal ACNO-H (Terminal ACN1-L (Terminal ACN1-H (terminal

resistor) resistor) resistor) resistor)
To ECM To display screen
LAN communication (MAINTENANCE TOOL) CAN communication 0 CAN communication 1
Figure 9-5
9-6 SY485H
Display screen and GPS
Power supply for GPS power Video Earth of
Video signal GPS GPRS antenna
display screen supply camera video
connected to 1 antenna
camera
From FU19 From FU7
Topology
GPS antenna GPRS antenna
+12V output
I-ECU (Huaxing SECD-710F-02 display screen) Main controller KC-MB-20

120ω
Engine controller
Display CAN module CAN module
screen 1 0
To main
controller
To main controller
Dismantlement Resetting of
Earth for power -proof CAN
structure of display
supply screen communication
display screen
Figure 9-6
SY485H 9-7
Engine control
Power- Starting Hour Start cutoff Preheati Diagnosi Engine oil Heating Turboch PCV1 relay PCV2 relay Exhaust Fuel filter Turbocharg EGR position Fuel oil Crankshaft Common Intake Camshaft Turbocharg Engine oil
on signal signal meter relay ng relay s pressure indicator arging temperatur pressure ing sensor temper position rail temperatur position ing pressure
ECM power supply
relay indicator indicator light indicator e sensor pressure ature sensor pressure e sensor sensor temperatur sensor
sensor e sensor
Ecm----isuzu
Atmospheric Engine Speedo Trouble Trouble Terminal Terminal

Throttle position pressure sensor Fuel injector Fuel injector Fuel injector Fuel injector Fuel injector Fuel injector stop meter Earthling wire of clearing selectio Main relay Diagnosis port resistor resistor
control 1# 3# 2# 5# 6# 4# signal controller n
Figure 9-7
9-8 SY485H
A/C control
Compressor clutch relay Main relay contact of Compressor clutch Thermostat box Main relay of blower Internal/external air servo
contact- blower relay motor
Refrigerant Water Internal air

Electromagnetic Blower motor high/low- temperatur thermal resistor A/M servo motor Blower servo motor
clutch pressure switch e thermal
resistor
Figure 9-8
SY485H 9-9
9-10
Figure 9-9
Charging indicator
Principle 1 for fuse box
Power supply for

display screen
Manual/automatic
Radio
Cigar lighter
+24V power supply
Wiper/washer
A/C
Fuel filling relay
Dome light in cab

in cab
Dome light relay
relay
Travelling
warning light
SY485H
Working light Fuel filtration Warning light Main controller Flameout delay
relay pump relay (light) relay power supply relay relay
light
Working
Figure 9-10
SY485H 9-11
9-12
Figure 9-11
Horn
Horn relay
Electromagn
etic pump
pump relay
Electromagnetic
Starting loop
GPS power
supply
ECM power
supply
Inner light
Overhaul
light
SY485H
SY485H
Figure 9-12
Power-on signal
Starting signal
PCV power supply
Reserve the input of fuse 1
Reserve the output of fuse 1
Reserve the input of fuse 2
Reserve the output of fuse 2

Relay
Reserved 1
Relay
Reserved 2
9-13
Cab harness
To body harness CN-431M

Deutsch DRC 12-40P
To wiper harness
To control switch
harness CN-110F
To horn
button
To A/C
Yazaki 7123-1720 58-S 12PF

To control switch
harness CN-111M
To self-provided harness of cab
Seven-wire electrical
socket sleeve D J7072-3-
21 to radio
To pilot locking rod
Wire Wire Wire Wire Wire Wire

no. diameter color no. diameter color
To emergency
stop switch
To self-provided harness of cab
Figure 9-13
9-14 SY485H
Control switch harness
To key switch
Yazaki 7123-7464-30
HL1: Yellow charging indicator

plug-in part 735075-0
To throttle knob
Three-wire protective
sleeve 282105-1
HL2: Engine trouble indicator
735075-0
To cab harness CN-110F

HL3: Red low engine oil pressure
indicator plug-in part 735075-0
HL3: Yellow preheating

indicator plug-in part 735075-0
TP-100M (4pcs) fixed, without corrugated

pipe
Wire Wire Wire Wire Wire Wire Wire Wire Wire

no. diameter color no. diameter color no. diameter color
To cab harness CN-111F
Plug-in part H8JA713631 to

working light switch

wiper switch

washer switch

dome light switch
Figure 9-14
SY485H 9-15
Tool box harness
Connector CN-458M Wire Wire diameter Wire
no. color
Wire Wire diameter Wire This dotted-line portion is fixed onto

no. color main harness with tape
To oil filling Yazaki 7123-4220-30
pump The harness in this dotted-line box is protected To start relay contact
The position of hole is decided by
by black braid, and the distance between end
direction of diode To start relay coil
of braid and sheath shall be at least 60 This dotted-line portion is fixed onto
Yazaki 7123-1424-40
main harness with tape
Connector CN-457M
Plug-in part 174 352-
2 connected with (AMP) sealed diode IN5406
diode
Wire Wire diameter Wire
no. color Plug-in part 174 352-2
(AMP sealed diode IN5406)
This dotted-line portion is fixed onto The position of hole is decided by
main harness with tape direction of diode
Connector CN-472M Y4-1.5, wire diameter: 1.5mm2

To battery relay coil terminal C
Wire Wire diameter Wire
no. color
Yazaki 7323-2228
To preheating relay
coil
Plug-in part 174

352-2 connected (AMP) sealed diode IN5406 This dotted-line portion is fixed onto Yazaki 7323-3010
To fuel filtration pump with diode main harness with tape Wire diameter: 6mm2
To preheating relay
(AMP sealed diode IN5406) contact input
The position of hole is To oil filling pump switch
decided by direction of
diode Yazaki 7323-3010
Wire diameter: 6mm2
To preheating relay
contact output
To fuel level sensor of fuel Y4-1.5, wire diameter: 1.5mm2 Plug-in part 174 352-2
tank To terminal D of battery relay Connected to diode
coil
To body harness CN-459F
Y6-6, wire diameter:

6mm2
To preheating fuse output
Y10-6, wire diameter: 6mm2
To platform earthling point
Y6-1.5, wire diameter: 1.5mm2 Y6-10, wire diameter:
To earthling bolt of fuel level 10mm2
sensor of fuel tank To always-on fuse output
Y6-16,
Y6-16,wire
wire diameter: 16mm2 2
diameter: 16mm
Toalways-on
To always-on fuse
fuse input
input Y10-6, wire diameter: 6mm2
2
C8-16, wire diameter: 16mm To platform earthling point
To battery relay contact output
Y6-6, wire diameter: 6mm2
To start relay fuse output
Y6-16, wire diameter:

C8-16, wire diameter: 16mm2 C8-16, wire diameter: 16mm2 16mm2
To battery relay contact input To main circuit fuse input To main circuit fuse output
To slewing table working light EL6
The corrugated pipe at

This means that at this location, the harness is wrapped and marked by white tape, and the locating size only indicates the
this location is inserted
into protective sleeve
mark position rather than length of harness.
on tail of plug-in part
To body harness CN-

458F
To body harness CN-

457F
Figure 9-15
9-16 SY485H
Pump chamber harness
To left pump (pump 1) proportional valve
To left pump (pump 2)

proportional valve
To cooling pump proportional valve
The harness in this dotted-line box is To left pump (pump 1) pressure To left pump (pump 2) pressure
protected by black braid, and the distance sensor sensor
between end of braid and sheath shall be at
least 60
DELPHI protective sleeve 12129615, terminal To hydraulic oil temperature sensor

12045773
Terminal 12048086, sleeve 12052845
To oil water separator water level sensor
To body harness CN-401F
Connector CN-401M Wire Wire Wire Wire Wire Wire

no. diameter color no. diameter color
Wire Wire Wire
no. diameter color
Figure 9-16
SY485H 9-17
Body harness
Figure 9-17
9-18 SY485H
Body harness
Figure 9-18
SY485H 9-19
Hydraulic Schematic Diagram

Shop Manual Sany SY 750H

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SY750H

Service Manual 03-2017 III

IV Service Manual 03-2017

Service Manual 03-2017 1-1

Reading Method of Service Manual

1. Composition of Service Manual

1-2 Service Manual 03-2017

2. Amendment and Issuance

Symbols Items Remarks

Safety The special safety notices are required during operation.

This symbol indicates the relevant provisions and notices

Locations to which the adhesive must be applied during

Lubricant This symbol indicates the lubricant to be used.

Locations where the oil or water must be added, and

Locations where the oil or water must be drained, and

Service Manual 03-2017 1-3

Explanation on Terms for

● The tolerance may be expressed in the form of

1-4 Service Manual 03-2017

2. Standard Clearance and Standard Value 5. Clearance limit

Service Manual 03-2017 1-5

Handling of Electrical Component and Hydraulic Components

1-6 Service Manual 03-2017

4) The high-pressure water enters into connector

5) Oil or oil sludge sticking to connector

Service Manual 03-2017 1-7

3. Dismantle, install and blow dry the connector

● When dismantling a connector from a clip

When dismantling a connector from a clip, please

1-8 Service Manual 03-2017

● Measures to be taken after a connector is

Service Manual 03-2017 1-9

● Correct the situation that the protective cover

1-10 Service Manual 03-2017

4) Dry up the harness

Service Manual 03-2017 1-11

5. Matters to be Remembered During Diagnosis

1-12 Service Manual 03-2017

Precautions when Treating Hydraulic Parts

Service Manual 03-2017 1-13

5. Replace the hydraulic oil at high temperature

1-14 Service Manual 03-2017

Type of Pipe Joint

Service Manual 03-2017 1-15

Tightening Torque of Pipe Joint

1-16 Service Manual 03-2017

Dimension of wrench mm Dimension of wrench mm Tightening torque

Service Manual 03-2017 1-17

Bolt and nut

Thread Dimension of Hexagonal bolt Inner hexagonal bolt

1-18 Service Manual 03-2017

Tightening Sequence of Bolts Tighten them up Tighten them up

Service Manual 03-2017 1-19

Maintenance of Split Flange

2. Be sure to use the designated O-ring, inspect

3. Please gently tighten up the split flange, locate

Table of Tightening Torque for Split Flange Bolt

1-20 Service Manual 03-2017

Millimeter to inch (B) 1mm=0.03937in

Service Manual 03-2017 1-21

1-22 Service Manual 03-2017

Liter to gallon (Britain)

Service Manual 03-2017 1-23

1-24 Service Manual 03-2017