SY365H Shop Manual 20210823

Quality Changes the World
Crawler Hydraulic
Excavator
SY365H(BH)-10
Shop Manual
SY365H(BH)-10 Hydraulic Excavator
SY365H(BH)-10 Hydraulic
Excavator
Service Manual
WARNING
This manual is prepared for professional technicians and aims to provide technical information
required for maintenance and repair of the machine.
This manual may involve work equipment and optional devices not available in your region. You
may consult local dealers authorized by Sany Heavy Machinery Co., Ltd. for ordering of these
parts. Materials and technical specifications are subject to change without prior notice.
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Sany Group
Sany Heavy Machinery Co., Ltd.
SANY Industrial Park, Economic and Technological Development Zone, Kunshan,
Suzhou, China
Postcode: 215300
Service hotline: 4008 28 2318
Inquiring and Complaint Number: 4008 87 9318
http://www.sanygroup.com
With constant updating of our technologies and products, materials and technical specifications are
subject to change without prior notice. Copyright © 2013 Sany Group No part of this manual may be
reproduced, transmitted, sold or altered without the written permission of Sany Group.
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SY365H(BH)-10 Hydraulic Excavator Table of Contents
Table of Contents
1 Foreword..............................................................................................................................1-1
1.1 How to read this manual ......................................................................................................1-3
1.2 Notes on standard terminology for maintenance .............................................................1-5
1.3 Treatment of electrical and hydraulic components ..........................................................1-8
1.3.1 summarize .....................................................................................................................1-8
1.3.2 Precautions for treatment of electrical components ...............................................1-8
1.3.3 Precautions for treatment of hydraulic components ............................................ 1-16
1.4 Pipe connector.................................................................................................................... 1-19
1.4.1 Type of pipe connector ............................................................................................. 1-19
1.4.2 Tightening torque of pipe connector ....................................................................... 1-20
1.4.3 Connection with O-ring ............................................................................................. 1-20
1.5 Bolts and nuts ..................................................................................................................... 1-21
1.5.1 Table of tightening torques of bolts and nuts ......................................................... 1-21
1.5.2 Bolt type ...................................................................................................................... 1-23
1.5.3 Bolt tightening sequence .......................................................................................... 1-23
1.6 Maintenance of split flange ............................................................................................... 1-24
1.6.1 summarize .................................................................................................................. 1-24
1.6.2 Table of tightening torques of split flange bolts ..................................................... 1-24
1.7 Conversion table ................................................................................................................ 1-25
2 Safety.....................................................................................................................................2-1
2.1 Instructions for safety signs .................................................................................................2-5
2.2 General precautions .............................................................................................................2-6
2.2.1 summarize .....................................................................................................................2-6
2.2.2 Safety rules....................................................................................................................2-6
2.2.3 Keep working area tidy ................................................................................................2-7
2.2.4 Liquid storage................................................................................................................2-7
2.2.5 Part washing..................................................................................................................2-8
2.2.6 Machine cleaning..........................................................................................................2-8
2.2.7 Decent clothing .............................................................................................................2-9
2.2.8 Personal protective equipment (PPE) .......................................................................2-9
2.2.9 Correct use of tools ................................................................................................... 2-10
2.2.10 Fire extinguisher and emergency exit .................................................................. 2-10
2.3 Preparations before maintenance ....................................................................................2-11
2.3.1 Preparations before working.....................................................................................2-11
2.3.2 WARNING decals...................................................................................................... 2-12
2.3.3 Self-preparation ......................................................................................................... 2-13
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Table of Contents SY365H(BH)-10 Hydraulic Excavator
2.4 Precautions for maintenance............................................................................................ 2-14

2.4.1 Work during engine running..................................................................................... 2-14
2.4.2 Dismantling accessories of machine ...................................................................... 2-15
2.4.3 Working under machine............................................................................................ 2-15
2.4.4 Adding or changing fluid ........................................................................................... 2-16
2.4.5 Parts alignment.......................................................................................................... 2-16
2.4.6 When a hammer is used........................................................................................... 2-17
2.4.7 When compressed air is used ................................................................................. 2-17
2.4.8 Welding ....................................................................................................................... 2-17
2.4.9 Tension spring............................................................................................................ 2-18
2.4.10 Safe operation for high pressure hoses ............................................................... 2-18
2.4.11 Be careful when you work with high-pressure fluid ............................................ 2-19
2.4.12 Be careful when you work with hot coolant ......................................................... 2-20
2.4.13 A/C system ............................................................................................................... 2-20
2.4.14 Electrical safety ....................................................................................................... 2-21
2.4.15 Switching power off................................................................................................. 2-21
2.4.16 Battery operation ..................................................................................................... 2-22
2.4.17 Accumulator ............................................................................................................. 2-22
2.4.18 Reducing fire and explosion risks ......................................................................... 2-23
2.4.19 Proper disposal for waste....................................................................................... 2-24
2.5 Miscellaneous..................................................................................................................... 2-24
2.5.1 Miscellaneous ............................................................................................................ 2-24
2.5.2 Precautions for using mobile crane ........................................................................ 2-27
2.5.3 Precautions for using bridge crane ......................................................................... 2-27
2.5.4 Selection of wire ropes ............................................................................................. 2-28
3 Technical Specifications.............................................................................................3-1
3.1 Specified dimension..............................................................................................................3-3
3.1.1 Dimension......................................................................................................................3-3
3.1.2 Working range...............................................................................................................3-4
3.2 Technical specifications .......................................................................................................3-5
3.3 Weight table ...........................................................................................................................3-7
3.4 Oil, fuel and coolant ..............................................................................................................3-8
3.5 Engine curve ..........................................................................................................................3-9
4 Structure and Function................................................................................................4-1

4.1 Engine and cooling system..................................................................................................4-5
4.1.1 Engine-related parts.....................................................................................................4-5
4.1.2 Radiator and intercooler ..............................................................................................4-6
4.2 Powertrain ..............................................................................................................................4-7
4.2.1 Powertrain .....................................................................................................................4-7
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4.2.2 Travel reducer assembly .............................................................................................4-8

4.2.3 Swing reducer mechanism....................................................................................... 4-10
4.2.4 Swing bearing ............................................................................................................ 4-12
4.3 Lower structure................................................................................................................... 4-13
4.3.1 Track frame and tension mechanism ..................................................................... 4-13
4.3.2 Idler.............................................................................................................................. 4-15
4.3.3 Carrier roller ............................................................................................................... 4-16
4.3.4 Track roller.................................................................................................................. 4-17
4.3.5 Crawler........................................................................................................................ 4-19
4.3.6 Three-teeth track shoe.............................................................................................. 4-21
4.4 Hydraulic system, part 1.................................................................................................... 4-22
4.4.1 Layout of hydraulic parts .......................................................................................... 4-22
4.4.2 Hydraulic tank and filler ............................................................................................ 4-24
4.4.3 Hydraulic pump.......................................................................................................... 4-25
4.4.4 Regulator .................................................................................................................... 4-32
4.4.5 Adjustment of the regulator...................................................................................... 4-36
4.5.1 Main control valve...................................................................................................... 4-46
4.6.1 Swing motor ............................................................................................................... 4-78
4.6.2 Swing retention brake ............................................................................................... 4-82
4.6.3 Central swivel joint .................................................................................................... 4-88
4.6.4 Travel motor (Nabtesco)........................................................................................... 4-89
4.7 Control system.................................................................................................................... 4-99
4.7.1 summarize .................................................................................................................. 4-99
4.7.2 Manual pilot valve.................................................................................................... 4-100
4.7.3 Travel pilot valve...................................................................................................... 4-106
4.7.4 Solenoid valve...........................................................................................................4-110
4.7.5 PPC accumulator......................................................................................................4-111
4.7.6 Pilot oil filter ...............................................................................................................4-112
4.7.7 Hydraulic cylinder .....................................................................................................4-113
4.8 Work equipment ................................................................................................................4-115
4.8.1 Part size .....................................................................................................................4-115
4.8.2 Arm size .....................................................................................................................4-117
4.8.3 Bucket size ................................................................................................................4-119
4.9 A/C system........................................................................................................................ 4-121
4.9.1 summarize ................................................................................................................ 4-121
4.9.2 Layout of A/C elements .......................................................................................... 4-122
4.9.3 A/C control panel ..................................................................................................... 4-123
4.9.4 Schematic circuit diagram ...................................................................................... 4-124
4.9.5 A/C cooling principle ............................................................................................... 4-125
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4.9.6 Compressor.............................................................................................................. 4-127

4.9.7 Clutch ........................................................................................................................ 4-129
4.9.8 Condenser ................................................................................................................ 4-129
4.9.9 Expansion valve....................................................................................................... 4-130
4.9.10 Evaporator.............................................................................................................. 4-130
4.9.11 Dryer........................................................................................................................ 4-131
4.9.12 Pressure switch ..................................................................................................... 4-132
4.9.13 Fresh air sensor..................................................................................................... 4-133
4.9.14 Refrigerant.............................................................................................................. 4-133
4.10 Engine control................................................................................................................. 4-150
4.10.1 summarize.............................................................................................................. 4-150
4.10.2 System operation .................................................................................................. 4-151
4.10.3 System components ............................................................................................. 4-151
4.10.4 Controller ................................................................................................................ 4-153
4.11 Electrical control system ............................................................................................... 4-156
4.11.1 Control functions.................................................................................................... 4-156
4.11.2 Machine control system diagram ........................................................................ 4-157
4.11.3 Engine - pump combination control function ..................................................... 4-159
4.11.4 Pump control function ........................................................................................... 4-164
4.11.5 Valve control function............................................................................................ 4-168
4.11.6 High/low speed travel control............................................................................... 4-170
4.11.7 Engine warm-up/overheating alarm.................................................................... 4-172
4.11.8 Excessively low oil pressure alarm ..................................................................... 4-173
4.11.9 Automatic idling/acceleration control.................................................................. 4-174
4.11.10 System parts ........................................................................................................ 4-175
4.12 Display system ............................................................................................................... 4-179
4.12.1 summarize.............................................................................................................. 4-179
4.12.2 Display .................................................................................................................... 4-180
4.12.3 Display panel ......................................................................................................... 4-182
4.12.4 Operation of display interfaces............................................................................ 4-184
5 Standard values of components ............................................................................5-1

5.1 Table of Standard Values of Engine Related Components.............................................5-3
5.2 Table of Standard Values of Body Related Components ................................................5-4
6 Test and adjustment ......................................................................................................6-1

6.1 Exhaust smoke color measurement...................................................................................6-3
6.2 Valve clearance adjustment.................................................................................................6-4
6.3 Inspection and adjustment of A/C compressor belt tensioner ........................................6-7
6.4 Measurement of swing bearing clearance.........................................................................6-8
6.5 Inspection and adjustment of track tensioner ...................................................................6-9
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6.6 Inspection and adjustment of hydraulic oil in the work equipment, swing and travel
hydraulic lines............................................................................................................ 6-10
6.7 Inspection and adjustment of oil pressure in control oil line ........................................ 6-15
6.8 Measuring the output pressure of solenoid valve.......................................................... 6-16
6.9 Measuring the output pressure of pilot valve ................................................................. 6-18
6.10 Adjustment of work equipment and swing pilot valve ................................................. 6-20
6.11 Inspection of the drift of hydraulic cylinder for work equipment................................. 6-20
6.12 Release of residual pressure from hydraulic lines ...................................................... 6-23
6.13 Leakage measurement ................................................................................................... 6-24
6.14 Bleeding air from each system....................................................................................... 6-28
7 Fault diagnosis and troubleshooting...................................................................7-1

7.1 Precautions during fault diagnosis......................................................................................7-5
7.2 Inspection before fault diagnosis ........................................................................................7-7
7.3 Fault-Find out the symptoms and fault diagnosis numbers ............................................7-8
7.4 Fault diagnosis of electrical system................................................................................. 7-14
7.5 Circuit Diagram of Electrical Control System ................................................................. 7-18
7.6 SWP connector................................................................................................................... 7-25
7.7 A/AMP connector ............................................................................................................... 7-26
7.8 DT connector....................................................................................................................... 7-27
7.9 Fault diagnosis with DTC displayed ................................................................................ 7-28
7.9.1 Information of the fault diagnosis table................................................................... 7-28
7.9.2 DTC E006 (Internal failure of controller) ................................................................ 7-29
7.9.3 DTC E007 (Controller internal temperature abnormality alarm)......................... 7-30
7.9.4 DTC E008 (Sensor power abnormality) ................................................................. 7-31
7.9.5 DTC E043 (Memory error) ....................................................................................... 7-32
7.9.6 DTC E047 (CPU error) ............................................................................................. 7-33
7.9.7 DTC E001 (Power voltage too low)......................................................................... 7-34
7.9.8 DTC E002 (Power voltage too high) ....................................................................... 7-35
7.9.9 DTC H010 (hydraulic oil temperature too high) .................................................... 7-36
7.9.10 DTC P013 (Engine oil pressure too low).............................................................. 7-37
7.9.11 DTC P086 (Coolant temperature too high) .......................................................... 7-38
7.9.12 DTC P070 (Fuel level too low)............................................................................... 7-39
7.9.13 DTC P072 (Air cleaner clogged) ........................................................................... 7-40
7.9.14 DTC P197 (Water separator water level too high).............................................. 7-41
7.9.15 DTC H011 (Pump 1 pressure abnormal) ............................................................. 7-42
7.9.16 DTC H012 (Pump 2 pressure abnormal) ............................................................. 7-43
7.9.17 DTC H015 (Pump 1 proportional valve abnormal) ............................................. 7-44
7.9.18 DTC H016 (Pump 2 proportional valve abnormal) ............................................. 7-45
7.9.19 DTC E004 (Throttle knob abnormality) ................................................................ 7-46
7.10 Fault diagnosis of electrical system (mode E) ............................................................. 7-46
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7.10.1 Fuse box wiring table.............................................................................................. 7-46

7.10.2 Information of the fault diagnosis table ................................................................ 7-49
7.10.3 E-1 The engine cannot be started......................................................................... 7-49
7.10.4 E-2 Irregular fluctuation of engine speed............................................................. 7-52
7.10.5 E-3 Automatic idle is disabled ............................................................................... 7-53
7.10.6 E-4 The preheating function is disabled............................................................... 7-53
7.10.7 E-5 No equipment works........................................................................................ 7-55
7.10.8 E-6 The boom lifting is slow and powerless ........................................................ 7-56
7.10.9 E-7 The arm movement is slow and powerless .................................................. 7-58
7.10.10 E-8 The bucket movement is slow and powerless ........................................... 7-59
7.10.11 E-9 The traveling is slow and powerless............................................................ 7-60
7.10.12 E-10 The display is blank..................................................................................... 7-61
7.10.13 E-11 The display has no display ......................................................................... 7-62
7.10.14 E-12 The high/low traveling speed is disabled ................................................. 7-64
7.10.15 E-13 The display of fuel level is inaccurate ....................................................... 7-66
7.10.16 E-15 The wiper doesn’t work............................................................................... 7-67
7.11 Table of Hydraulic and Mechanical System (mode H)................................................ 7-68
7.11.1 summarize ................................................................................................................ 7-68
7.11.2 Information of the fault diagnosis table................................................................. 7-70
7.11.3 H-1 The work equipment or carrier and superstructure work slowly................ 7-71
7.11.4 H-2 The engine speed significantly drops or engine stalls ................................ 7-71
7.11.5 H-3 The work equipment has no movement, and traveling or swing function
is disabled .............................................................................................................. 7-72
7.11.6 H-4 The hydraulic pump has unusual noise ........................................................ 7-73
7.11.7 H-5 Automatic idling is disabled ............................................................................ 7-74
7.11.8 H-6 The boom moves slowly.................................................................................. 7-75
7.11.9 H-7 The arm moves slowly..................................................................................... 7-76
7.11.10 H-8 The bucket moves slowly.............................................................................. 7-77
7.11.11 H-9 The single cylinder of the work equipment has no movement................. 7-78
7.11.12 H-10 The cylinder drift of the work equipment is too large .............................. 7-78
7.11.13 H-11 The work equipment moves slowly ........................................................... 7-80
7.11.14 H-12 Other work equipment moves when a single oil line has an
overflow.................................................................................................................. 7-81
7.11.15 H-13 The traveling speed drops obviously during swing+traveling ............... 7-81
7.11.16 H-14 The machine has off-tracking during traveling ........................................ 7-82
7.11.17 H-15 The machine travels at low speed............................................................. 7-83
7.11.18 H-16 The machine is hard to turn or powerless ................................................ 7-84
7.11.19 H-17 The traveling speed cannot be shifted...................................................... 7-85
7.11.20 H-18 It cannot travel (only on one side) ............................................................. 7-86
7.11.21 H-19 The machine cannot swing ........................................................................ 7-87
7.11.22 H-20 It has low swing acceleration performance or low swing speed ........... 7-88
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7.11.23 H-21 The overrun is too large when swing stops.............................................. 7-90
7.11.24 H-22 The impact is too large when swing stops ............................................... 7-91
7.11.25 H-23 The unusual noise is too loud when swing stops.................................... 7-91
7.11.26 H-24 The natural drift during swing is too large ................................................ 7-92
8 Removal and Installation ............................................................................................8-1

8.1 Tips..........................................................................................................................................8-5
8.2 Precautions during operation ..............................................................................................8-6
8.3 Removal and installation of starter motor assembly ........................................................8-9
8.4 Removal and installation of flywheel ............................................................................... 8-10
8.5 Removal and installation of cylinder head cover ........................................................... 8-12
8.6 Removal and installation of oil pan.................................................................................. 8-13
8.7 Removal and installation of rear oil seal of crankshaft ................................................. 8-14
8.8 Removal and installation of fuel injector ......................................................................... 8-16
8.9 Removal and installation of EGR valve and EGR cooler ............................................. 8-20
8.10 Removal and installation of radiator assembly............................................................ 8-22
8.11 Removal and installation of engine and hydraulic pump assembly ......................... 8-27
8.12 Removal and installation of final drive assembly ........................................................ 8-32
8.13 Disassembly and reassembly of final drive assembly ................................................ 8-34
8.14 Removal and installation of swing motor and swing mechanism assembly............ 8-46
8.15 Disassembly and reassembly of swing motor and swing mechanism
assembly.................................................................................................................... 8-47
8.16 Disassembly and reassembly of idler assembly ......................................................... 8-58
8.17 Removal and installation of driving wheel .................................................................... 8-62
8.18 Removal and installation of track assembly................................................................. 8-62
8.19 Removal and installation of swing bearing assembly................................................. 8-65
8.20 Removal and installation of turntable assembly.......................................................... 8-66
8.21 Removal and installation of center swivel joint assembly .......................................... 8-70
8.22 Disassembly and reassembly of center swivel joint assembly.................................. 8-73
8.23 Removal and installation of hydraulic tank assembly................................................. 8-75
8.24 Removal and installation of control valve assembly ................................................... 8-78
8.25 Removal and installation of hydraulic pump assembly .............................................. 8-84
8.26 Removal and installation of oil seal in the input shaft of hydraulic pump................. 8-89
8.27 Disassembly and reassembly of pilot valve assembly of work equipment.............. 8-90
8.28 Disassembly and reassembly of travel pilot valve assembly..................................... 8-91
8.29 Disassembly and reassembly of hydraulic cylinder assembly .................................. 8-92
8.30 Removal and installation of work equipment assembly ........................................... 8-103
8.31 Removal and installation of A/C assembly................................................................. 8-107
8.32 Removal and installation of counterweight assembly ...............................................8-111
8.33 Removal and installation of cab assembly ..................................................................8-113
8.34 Removal and installation of cab windows....................................................................8-117
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8.35 Removal and installation of front window assembly ................................................. 8-132

8.36 Removal and installation of display screen................................................................ 8-141
8.37 Removal and installation of controller assembly ....................................................... 8-142
8.38 Radio................................................................................................................................ 8-143
8.39 Battery ............................................................................................................................. 8-145
8.40 Ignition key switch.......................................................................................................... 8-148
8.41 Fuse box.......................................................................................................................... 8-151
8.42 Wiper................................................................................................................................ 8-152
8.43 Relay................................................................................................................................ 8-155
8.44 Sensor ............................................................................................................................. 8-157
8.45 Terminal insertion and removal.................................................................................... 8-159
9 Hydraulic and Electrical Diagrams........................................................................9-1

9.1 Hydraulic oil circuit diagram.................................................................................................9-3
9.2 Electrical diagram of body....................................................................................................9-4
9.3 Electrical diagram of control switch ....................................................................................9-5
9.4 Electrical diagram of cab......................................................................................................9-6
9.5 Electrical diagram of A/C group ..........................................................................................9-7
9.6 Electrical diagram of display screen...................................................................................9-8
VIII -
SY365H(BH)-10 Hydraulic Excavator Foreword
Foreword
1 Foreword..............................................................................................................................1-1
1.1 How to read this manual ......................................................................................................1-3
1.2 Notes on standard terminology for maintenance .............................................................1-5
1.3 Treatment of electrical and hydraulic components ..........................................................1-8
1.3.1 summarize....................................................................................................................1-8
1.3.2 Precautions for treatment of electrical components ..............................................1-8
1.3.3 Precautions for treatment of hydraulic components .......................................... 1-16
1.4 Pipe connector.................................................................................................................... 1-19
1.4.1 Type of pipe connector ............................................................................................ 1-19
1.4.2 Tightening torque of pipe connector...................................................................... 1-20
1.4.3 Connection with O-ring............................................................................................ 1-20
1.5 Bolts and nuts ..................................................................................................................... 1-21
1.5.1 Table of tightening torques of bolts and nuts........................................................ 1-21
1.5.2 Bolt type..................................................................................................................... 1-23
1.5.3 Bolt tightening sequence......................................................................................... 1-23
1.6 Maintenance of split flange ............................................................................................... 1-24
1.6.1 summarize................................................................................................................. 1-24
1.6.2 Table of tightening torques of split flange bolts.................................................... 1-24
1.7 Conversion table ................................................................................................................ 1-25
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Foreword SY365H(BH)-10 Hydraulic Excavator
WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.
1-2 -
1.Foreword
1.1 How to read this manual
• Some accessories and optional parts covered in this manual may not be transported to partic-
ular areas. Please consult your dealers authorized by Sany if required.
• Materials and technical specifications are subject to change arising from technological im-
provement without prior notice. For latest relevant technical information, please consult your
dealers authorized by Sany.
1. Constitution of the manual
This manual contains technical information necessary for maintenance in workshops. To facilitate
the understanding, this manual is divided into the following.
Foreword
This chapter introduces the main content of this manual, how to use it, basic principles for mainte-
nance, and other basic information.
Safety
This chapter covers the meanings of safety signs contained herein and the basic safety informa-
tion involved in equipment maintenance.
Technical specifications
This chapter introduces the basic data of the machine, such as the overall dimensions, working
range, weight table and engine curve.
Structure, function and maintenance standard
This chapter is divided into two sections. The structure and function section introduces the struc-
ture and function of each component. It not only assists users to be familiar with the structure, but
also is used as the reference during fault diagnosis. The maintenance section introduces the
standards and measures for disassembly and maintenance.
Standard values of components
This chapter introduces the standard values of a new machine and the judgment standards for
testing, adjustment and fault diagnosis, which can used as guidance for testing, adjustment and
troubleshooting.
Test and adjustment
This chapter introduces the measuring instruments and methods for testing and adjustment, and
adjusting method for each part.
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Fault diagnosis and troubleshooting
This chapter introduces the methods to find and repair faulty parts. Fault diagnosis falls into sev-
eral fault modes.
Disassembly and reassembly
This chapter introduces special tools, the procedures for removal, refitting, disassembly and as-
sembly of each component, as well as relevant cautions. In addition, relevant information such as
tightening torques, coating materials, oil, grease and coolant required for operation is introduced.
Hydraulic and electrical diagrams
This chapter mainly gives the hydraulic circuit diagram and the circuit diagram.
2. Revision and distribution
Any additions, modifications or changes to other precautions will be forwarded to dealers author-
ized by Sany Heavy Machinery Co., Ltd. Make sure to obtain the latest information before you be-
gin any work.
3. Symbols
Important sections relating to safety and quality are marked by the following symbols to make this
manual more practicable.
1-4 -
Symbol Description Remarks

Safety Special safety precautions in operation.
This symbol means the relevant provisions
Note and cautions to be abode by during refit-
ting of parts.
Weight of parts, which shall be considered
for selection of hoisting wire ropes, or
Weight
when the working posture is of great
importance.
Locations where the tightening torque re-
Tightening torque quires particular attention during
assembly.
Locations where adhesive, etc. shall be
Coating
applied during assembly.
Lubricant This symbol means the required lubricant.
Locations where oil, water, etc. shall be

Oil, coolant
added, and the filling capacity.
Locations where oil, water, etc. shall be
Discharge
discharged, and the discharge quantity.
4. Units
The international system of units (SI) is used in this manual. The gravitational system of units in { }
used by convention is provided for reference only.
1.2 Notes on standard terminology for maintenance

The standard values for maintenance of products and parts are described as follows.
1. Standard size and tolerance
• To be exact, the machining dimensions of

parts are slightly different from each other.
• To specify the machining dimension of a
part, we need to set a temporary standard
size and indicate the allowable deviation
from it.
• The abovementioned temporary dimension
is referred to as the ”standard dimension”,
and the range of deviation from the stand-
ard value is referred to as the ”tolerance”.
- 1-5
• he tolerance with + or - is indicated on the

right of standard size.
For example:
Standard size Tolerance

—0.022
120
—0.126
• A tolerance may be indicated by a “stand-

ard value (upper/lower limit)” in a text or ta-
ble. For example: 120 (-0.022/-0.126)
• Generally, the dimensions of a hole and its
fitting shaft are indicated by the same
standard dimension and the tolerance be-
tween them. The tightness of installation is
determined by the tolerance.
• Dimension indication of the rotating shaft
and the hole, and dimension relation
diagram.
For example: Fig.1-1
Tolerance
Standard size
Shaft Hole
—0.030 +0.046
φ60
—0.076 0
2. Standard clearance and standard value
• The clearance occurring in assembly of a

new part is referred to as the “standard
clearance”, expressed by the range from
the minimum to the maximum clearance.
• During repair of parts, the clearance is gen-
erally adjusted to be a standard value.
• The value or an equivalent of performance
and function of a new product is referred to
as the “standard value”, expressed by a
range or target value.
• During repair of parts, the performance/
function value is set as the standard value.
3. Standard interference
1-6 -
• If the size of a hole is less than that of a

shaft fitted to it due to the standard value
and the tolerance, such difference is re-
ferred to as the “interference”.
• The range (A-B) from the difference (A) be-
tween the minimum shaft size and the maxi-
mum hole size to the difference (B)
between the maximum shaft size and the
minimum hole size is referred to as the
“standard interference”.
• After repair or replacement of parts, it is
necessary to check the sizes of their holes
and shafts, and whether the interference is
within the standard range.
4. Repair limit and allowable value
• Changes will occur to the sizes of parts dur-

ing the use due to wear and deformation.
The limit of size change is referred to as the
“repair limit”.
• A part worn to the repair limit must be re-
placed or repaired.
• The product performance and function will
degrade if such a part is used. The value
below is referred to as the ”allowable value”
at which products can be used without
problems.
• A product worn to the allowable value must
be inspected or repaired, because the al-
lowable value is just estimated from tests or
based on many situations. However, no
judgment can be made until the operating
conditions and customer requirements are
taken into account.
5. Clearance limit
• Parts can be used until the clearance be-

tween them exceeds a certain limit. The lim-
it at which these parts can no longer be
used is referred to as the “clearance limit”.
- 1-7
• These parts must be replaced or repaired if

the clearance between them exceeds such
a limit.
6. Limit of interference
• The maximum allowable interference be-

tween the hole of a part and the shaft of a
part to be fitted is referred to as the “limit of
interference”.
• The limit of interference indicates the repair
limit of a part with a smaller tolerance.
• These parts must be replaced or repaired if
the interference between them exceeds
such a limit.
1.3 Treatment of electrical and hydraulic components

1.3.1 summarize
After long-time running, it is necessary to maintain the machine to keep its performance and pre-
vent faults or other troubles. It is a must to carry out correct “operation” ,”maintenance and inspec-
tion” ,” fault diagnosis” and ”repair”. This part especially discusses correct repair procedures and
aims to improve the repair quality. For this purpose, the “treatment of electrical components” and
“treatment of hydraulic components” (especially for gear oil and hydraulic oil) sections are
provided.
1.3.2 Precautions for treatment of electrical components
1. Handling of wires and connectors.
A harness consists of wires from a component

to another, connectors connecting two wires
or disconnecting a wire from another and a
cover or tube protecting wires.
Compared to electrical components in boxes

or cases, as shown in Fig. 1-2 (1), harnesses
are more likely to be directly affected by rain,
water, heat or vibration. Furthermore, they are
frequently removed and refitted during inspec-
tion and repair, so they may be easily de-
Fig.1-2
formed or damaged. Wrong plugging and
unplugging methods are shown in Fig. 1-2 (2).
1-8 -
For this reason, harnesses must be handled

with great care.
2. Main faults in harness
1） Poor contact between connectors (poor

contact between male and female
connectors)
Poor contact may occur when a male connec-

tor is not inserted in a female connector cor-
rectly, or disalignment is made due to
deformation, or corrosion and oxidation ap-
pear on the contact surface.
2）Edge curling or brazing fault
When the pins (1) of male and female connec-

tors make contact with an edge-curling termi-
nal or welding position (2), if wires come
under much stress, the plating at the connec-
tor will peel off, thereby causing incorrect con-
nection or fracture, as shown in Fig. 1-3.
3） Disconnection of wires
If you hold the wire while pulling out the con-

nector, or use a crane to lift the part still con-
nected to the connector, or use a weight to Fig.1-3
strike the wire, the curled edge of the connec-
tor may be separated, or the weld and the wire
may be damaged.
4）High pressure water in the connector
The connector is of a waterproof structure, but

water may enter it in the water injected direc-
tion when high pressure water is directly in-
jected onto it. Therefore, take care not to
make water splash onto the connector. The
connector is of waterproof construction but
hard to drain off water if any (as shown in Fig.
1-4). If water enters the connector and there-
fore causes short circuit in its pin, it is a must
to immediately dry it or take other appropriate
measures before applying power to it. Fig.1-4
- 1-9
5） Oil or sludge on the connector
Contact fault may occur when oil or grease

sticks to the connector and forms an oil film
on the mating surface between male and fe-
male pins, making it impossible for passage of
current. When oil or grease sticks to the con-
nector, wipe it off with a dry cloth (as shown in
Fig. 1-5) or dry it with compressed air which
must be injected from a contact restorer.
• When wiping the mating part of the connec-

tor, take care not to exert excessive force or Fig.1-5
deform the pin.
• he contact will get even dirtier if com-
pressed air contains oil or water, therefore,
the compressed air must be clear of oil and
water before cleaning.
2. 3. Removal, refitting and drying of connec-

tor and harness
1） Disconnection of the connector
• Hold the connector when disconnecting it.
For connectors fixed by screws, loosen the

screws completely and disconnect the male
connector (1) and female connector (2) while
holding them with two hands. For connectors
with a locking spring, depress the spring (3)
with your thumb and pull out he connector, as
shown in Fig. 1-6. Note: never pull out the Fig.1-6
connector with only one hand.
1-10 -
• Removal from the clamp
Both the connector (1) and the clamp (2) have

a stop (3), and they will mesh with each other
when the connector (1) is being installed, as
shown in Fig. 1-7.
Fig.1-7
To remove a connector (1) from a clamp, pull

it out n the direction parallel to the clamp (2)
to take apart the stop (3), as shown in Fig. 1-
8.
Note: If the connector is twisted up and down

or side to side, the casing may be damaged.
Fig.1-8
• Measures to be taken after removal of the

connector
After removal of any connector, cover it with a

polythene bag to prevent ingress of dust,
sludge, oil or water, as shown in Fig. 1-9.
Poor contact may easily occur when the ma-

chine remains decoupled for a long time,
therefore, the connector must be wrapped up
with the bag mouth fastened.
2） Connection of the connector

Fig.1-9
• Visual checking the connector
Check that no oil, sludge or water sticks on

the connector pins (mating part).
- 1-11
Check that the connector pins have no defor-

mation, contact fault, rust or damage.
Check that the connector has no damage or

cracks on the outside.
If any, wipe off the oil, water or sludge on the

connector with a dry cloth. If water enters the
connector, heat the inside of wires with a dry-
er, taking care not to make it too hot as this
can cause short circuit.
Replace the connector with any damage or

cracks.
• Fixing the connector
Align the connector (1) with its intended loca-

tion and then insert it in place. For connectors
(1) with a locking spring (2), push the connec-
tor in until the spring (2) clicks and gets in
place, as shown in Fig. 1-10.
Fig.1-10
1-12 -
• Correcting the budge of shield and mis-

alignment of harness.
For connectors (1) with a shield (2), correct its

budge. Besides, adjust the misaligned har-
ness or the clamp not in place to the correct
position.
If the connector cannot be easily corrected,

remove the clamp (1) and adjust the position,
as shown in Fig. 1-11.
If the connector clamp (1) is removed, make Fig.1-11

sure to return it to the normal position. And
check that the clamp (1) is not loose, as
shown in Fig. 1-12.
Fig.1-12
3） Connection of DT connector
Since the high-power wire connectors of DT8

pins and 12# pins respectively have two keys
which shall be pushed in until two clicks are
heard, as shown in Fig. 1-13.
• Male connector: 1
• Female connector: 2
• Normally locked (horizontal): a, b, d
• Partly locked (diagonal): c
Fig.1-13
- 1-13
4） Drying of harness
If any oil or sludge on the harness, wipe it off

with a dry cloth. Do not use water or steam for
washing. If you must wash the connector in
water, do not apply high pressure water or
steam to the harness. If water is directly ap-
plied to the connector, proceed as follows.
• Disconnect the connector and wipe off

water with a cloth.
Remove oil and water thoroughly before purg-

Fig.1-14
ing with compressed air because the oil in the
air can cause contact fault.
• Dry the inner side of the connector with a

dryer.
If water enters the connector, dry it with a

dryer.
Watch out the working time of the dryer to pre-

vent overheating the connector or relevant
parts, as this can cause deformation or dam-
age of the connector.
• Conduct the continuity test of the Fig.1-15

connector.
After drying, keep the harness disconnected

and carry out continuity test to check whether
short circuit occurs between pins due to water
ingress.
Fig.1-16
1-14 -
4. Treatment of controller
1） he controller contains a microcomputer

and an electronic control circuit. The controller
must be handled with great care because it
controls all the electronic circuits in the
machine.
2） Do not put items on the controller, as

shown in Fig. 1-17.
3） Cover the control connector with a strap

or polythene bag. Never touch the connector
contact. Fig.1-17
4） on rainy days, do not put the controller in

a place exposed to rain splash.
5） Do not put the controller in oil, water or

soil, or any hot place even for a short time.
(Put it on a suitable dry rack.) See Fig. 1-18.
6） Precautions for arc welding. Before arc

welding on the excavator body, disconnect all
the harness connectors from the controller. In-
stall an arc welding GND next to the welding
spot.
5. Considerations for diagnosis of circuit fault Fig.1-18
1） Switch off the power before disconnecting

or connecting the connector.
2） Before fault diagnosis, check that all the

associated connectors are correctly inserted.
Disconnect or connect the related connectors
several times for checking.
3） Always connect all the disconnected con-

nectors before going to next step of operation.
When the power is turned on with connectors
disconnected, undesired abnormal indication
will occur.
4） When circuit fault diagnosis (measure-

ment of voltage, resistance, continuity or cur-
rent) is undergoing, move related wires and
connectors several times and check whether
- 1-15
the meters readings change. If the readings

change, contact failure may exist in the circuit.
1.3.3 Precautions for treatment of hydraulic components
The most common fault cause is the sludge (foreign matter) in the hydraulic circuit due to the pres-
sure increase and accuracy improvement of hydraulic components. Take special care when adding
hydraulic fluid, disassembling or reassembling hydraulic components.
1-16 -
1. Operating environment
Do not add hydraulic oil, replace the filter or

repair the machine on a rainy or windy day or
at a dusty place.
2. On-site disassembly and maintenance
On-site disassembly and maintenance of hy-

draulic components may cause ingress of
dust. It is also difficult to check the perform-
ance after repair, so you’d better replace the
component with an assembly unit. Disassem-
Fig.1-19
bly and maintenance of hydraulic components
shall be carried out in a specially prepared
dust-proof workshop, and the performance
shall be checked by special test equipment.
3. Sealing of openings
After removal of a pipe or component, seal

the opening with a cover, strap or polythene
bag to prevent ingress of sludge or dust. Don’t
do that because sludge may enter or the pe-
ripheral area may be contaminated by leaked
oil if openings are left uncovered or blocked
with rags. Do not simply discharge oil to the Fig.1-20
ground, instead, dispose it by environmental
protection measures.
4. Do not make any sludge, pollutant or dust

entered during refilling.
Take care to prevent ingress of any sludge or

dust when adding hydraulic oil. Make sure to
keep cleanliness of the oil filter and the area
around it, and use a clean pump and an oil
container. An oil cleaning device, if used, is a
more effective means for filtering out the
sludge accumulated in storage process.
Fig.1-21
5. Change of hydraulic oil at high temperature
Hydraulic oil or other oil is easy to move when

warm. Besides, sediments may be easily ex-
pelled from the oil circuit together with oil.
Therefore, it is best to change the oil while
- 1-17
hot. When changing oil, drain the used hy-

draulic oil as much as possible. (Drain from
hydraulic oil tank; and drain from the filter and
the drain plug in the oil circuit.) The impurities
and sediments in the used oil, if any, will be
mixed with the new oil and thereby shorten
the service life of hydraulic oil.
6. Flushing
When disassembling and reassembling the

device or changing the oil, remove the impur-
ities, sediments and old oil in hydraulic circuits
with flushing oil. Flushing shall generally be
done twice: main flushing with flushing oil,
supplemental flushing with the specified hy-
draulic oil.
7. Cleaning
Perform oil flushing to remove sediments or

impurities from the hydraulic circuit after repair Fig.1-22
of hydraulic components (pump, control valve,
etc.) or during the operation of hydraulic exca-
vator. The oil cleaning device is highly effec-
tive because it is used for removing ultra fine
particles of about 3μ to make it unnecessary
to remove the filter built in the hydraulic
component.
Fig.1-23
1-18 -
1.4 Pipe connector

1.4.1 Type of pipe connector
The pipe connector is used for connecting

small-diameter pipes. The metallic sealing
surfaces (4) and (5) of the connector (1) and
the hose (2) fit together to enclose the pres-
sure oil.
CAUTION
• The nut (3) shall not be overtightened. The
nut (3) must be tightened to the technical
specification as excessive force will act on
the metallic sealing surfaces (4) and (5)
and may thereby make the connector (1) Fig.1-24
broken.
• Scratches or other damage on the sealing
surfaces (4) and (5) can cause oil leak at
the junction. Take care not to damage the
sealing surfaces during connection/
removal.
Type of pipe connector
Fig.1-25
- 1-19
1.4.2 Tightening torque of pipe connector
CAUTION
• The torques in the table are for routine use only.
• Use the specified torques other than those given in the table in special occasions.
1.4.3 Connection with O-ring
The O-ring (6) fits with the end face of the

connector (7) to ensure the tightness of high
pressure oil.
Fig.1-26
1-20 -
CAUTION
• When reconnecting the pipe, make sure to replace the O-ring (6).
• Before tightening the nut (9), check that O-ring (6) is correctly placed in its groove (8). If the O-
ring (6) moves when the nut (9) is being tightened, the O-ring (6) will be damaged and cause an
oil leak.
• Take care not to damage the O-ring groove (8) or the sealing surface (10). Damage to the O-
ring (6) will cause an oil leak.
• If the nut (9) is loose and causes an oil leak, do not stop the leak by tightening the nut (9), in-
stead, replace the O-ring (6) and check that it is reliably put in place, and then tighten the nut
(9).
1.5 Bolts and nuts

1.5.1 Table of tightening torques of bolts and nuts
★ Except as otherwise specified, the nuts and bolts shall be tightened to the torque values below
(when a torque wrench is used).
- 1-21
CAUTION
The following items apply to fine and coarse threads.
• Apply lubricant (zinc white B dissolved in spindle oil) to the nuts and bolts to reduce their friction
coefficients. Lubricants are not required for thrust bolts.
• The tolerance of torques is ±10%.
• Be sure to use bolts of correct length. An overlong bolt cannot be screwed tight, as its top
touches the bottom of bolt hole. A too short bolt cannot be tightened enough.
• The torques given above are only applicable for general purpose. Use the specified torques
other than those given in the table in special occasions.
• Before installing a nut or bolt, check that the thread is clean. Remove dirt or rust if any.
1-22 -
1.5.2 Bolt type
• The nuts or bolts shall be correctly tight-

ened to the specified torque. The bolt type
and grade are as shown at right.
• When assembling the machine or compo-
nents, make sure to use correct bolts and
correctly tighten them.
Fig.1-27
1.5.3 Bolt tightening sequence
When tightening two or more bolts, tighten

them alternately, as shown on the right figure,
to ensure the force is uniform.
CAUTION
• The tools used shall be suitable for the op-
eration. Casual use of inappropriate tools
or rules may cause a safety hazard.
• Use a properly sized tool to loosen or tight-
en the nuts and bolts, otherwise, personal
injuries can occur if the tightening device
slips. Fig.1-28
Fig.1-29
- 1-23
1.6 Maintenance of split flange

1.6.1 summarize
1. Wipe clean the sealing surface and do an

inspection. Scratches/roughness will cause a
leak or wear of seals. Unevenness will make
seals squeezed out; parts shall be replaced if
these defects cannot be removed.
2. Make sure to use a specified O-ring and

check whether it is damaged. Do not file its
surface, and fix its position with lubricating
grease when placing it in its groove.
Fig.1-30
3. Gently tighten the split flange, with its open-

ing at the center and the plane perpendicular
to the oil port, and tighten the bolt by hand to
keep the part in place.
Fig.1-31
1.6.2 Table of tightening torques of split flange bolts
★ Except as otherwise specified, the bolts of split flange shall be tightened to the torque values
below.
Thread diameters of
Widths across flats Tightening torque
bolts
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
1-24 -
1.7 Conversion table

How to use the conversion table
This part provides a conversion table for simple numeric conversion. For example: conversion from
mm to in.
1. Conversion of 55 mm by inch
1） Locate the figure 50 in the left column and denote it as (A), then draw a horizontal line from A.
2） Locate the figure 5 in the top row and denote it as (B), then draw a vertical line down from B.
3） Denote the point where two lines intersect as (C). This point (C) shows the resultant numerical
value. So, 55 mm = 2.165 in.
2. Conversion of 550mm into inch
As the figure 550 does not occur in the table, it is required to inquire the value corresponding to
55mm, and then multiply this value by 10.
- 1-25
1-26 -
- 1-27
1-28 -
- 1-29
1-30 -
- 1-31
1-32 -
- 1-33
1-34 -
- 1-35
1-36 -
- 1-37
Temperature
• To convert from Fahrenheit to Celsius, consider the center column as the Fahrenheit scale and
read the corresponding Celsius temperature in the left column.
• To convert from Celsius to Fahrenheit, consider the center column as Celsius temperatures and
read the corresponding Fahrenheit temperature in the right column.
1-38 -
- 1-39
1-40 -
SY365H(BH)-10 Hydraulic Excavator Safety
Safety
2 Safety.....................................................................................................................................2-1
2.1 Instructions for safety signs .................................................................................................2-5
2.2 General precautions .............................................................................................................2-6
2.2.1 summarize....................................................................................................................2-6
2.2.2 Safety rules ..................................................................................................................2-6
2.2.3 Keep working area tidy...............................................................................................2-7
2.2.4 Liquid storage ..............................................................................................................2-7
2.2.5 Part washing ................................................................................................................2-8
2.2.6 Machine cleaning ........................................................................................................2-8
2.2.7 Decent clothing............................................................................................................2-9
2.2.8 Personal protective equipment (PPE)......................................................................2-9
2.2.9 Correct use of tools.................................................................................................. 2-10
2.2.10 Fire extinguisher and emergency exit................................................................. 2-10
2.3 Preparations before maintenance ....................................................................................2-11
2.3.1 Preparations before working ...................................................................................2-11
2.3.2 WARNING decals .................................................................................................... 2-12
2.3.3 Self-preparation........................................................................................................ 2-13
2.4 Precautions for maintenance............................................................................................ 2-14
2.4.1 Work during engine running ................................................................................... 2-14
2.4.2 Dismantling accessories of machine..................................................................... 2-15
2.4.3 Working under machine .......................................................................................... 2-15
2.4.4 Adding or changing fluid.......................................................................................... 2-16
2.4.5 Parts alignment......................................................................................................... 2-16
2.4.6 When a hammer is used ......................................................................................... 2-17
2.4.7 When compressed air is used ................................................................................ 2-17
2.4.8 Welding...................................................................................................................... 2-17
2.4.9 Tension spring........................................................................................................... 2-18
2.4.10 Safe operation for high pressure hoses.............................................................. 2-18
2.4.11 Be careful when you work with high-pressure fluid ........................................... 2-19
- 2-1
Safety SY365H(BH)-10 Hydraulic Excavator
2.4.12 Be careful when you work with hot coolant ........................................................ 2-20
2.4.13 A/C system.............................................................................................................. 2-20
2.4.14 Electrical safety ...................................................................................................... 2-21
2.4.15 Switching power off................................................................................................ 2-21
2.4.16 Battery operation.................................................................................................... 2-22
2.4.17 Accumulator............................................................................................................ 2-22
2.4.18 Reducing fire and explosion risks........................................................................ 2-23
2.4.19 Proper disposal for waste ..................................................................................... 2-24
2.5 Miscellaneous..................................................................................................................... 2-24
2.5.1 Miscellaneous........................................................................................................... 2-24
2.5.2 Precautions for using mobile crane ....................................................................... 2-27
2.5.3 Precautions for using bridge crane........................................................................ 2-27
2.5.4 Selection of wire ropes ............................................................................................ 2-28
2-2 -
2-3 -
WARNING
2-4 -
2.Safety
2.1 Instructions for safety signs
Most accidents are usually caused by failure to follow basic process and safety rules for mainte-
nance during operation. To ensure safe maintenance and repair of the machine, please familiarize
yourself with and understand the maintenance and repair skills in this manual. Some of them re-
quire special tools designed by Sany Heavy Machinery Co., Ltd. for special purpose.
Safety signs
The following signs are used to inform you of potential hazardous situations that may cause per-
sonal injuries or damage.
In this manual and on the machine label plate, the following signs are used to indicate levels of po-
tential danger.
Indicates a critical hazardous situation that, if not avoided, will result in death
or severe injuries.
Indicates a potential hazardous situation that, if not avoided, may result in
death or severe injuries.
Indicates a potential hazardous situation that, if not avoided, may result in
minor or medium damage, and may also be used to alert against, for example,
unsafe operations that may result in personal injuries, machine and
environmental damage.
CAUTION
• Incorrect maintenance operations are very dangerous and may result in severe injuries or
death.
• Always read through and understand this manual before maintaining the machine.
• In no case can applications and operations prohibited in this manual be carried out. If the opera-
tion to be carried out is not explicitly prohibited in this manual, guarantee the safety of yourself
and others.
• If fuel amount, particulate size or latitude exceeds the upper limit specified for the model and
application, injuries may be caused and damages arising from this are not covered in the
warranty.
• Machines provided by Sany Heavy Machinery Co., Ltd. to purchasers of various countries meet
all applicable regulations and standards. Excavator purchased from another country or a per-
son of another country may not suit certain safety devices and technical requirements required
for use in your country. If you have any questions about machine’s compliance with national
standards and regulations for use, contact dealers authorized by Sany Heavy Machinery Co.,
Ltd. before using it.
- 2-5
2.2 General precautions

2.2.1 summarize
It is very important to develop appropriate safety rules and post or hang them in conspicuous pla-
ces for all persons visiting or using the workshop. If possible, provide the workshop staff with safety
rules in written form and discuss with them or answer related questions from them. Following
safety rules for workshop can ensure the safety of staff and create the most suitable environment
for working and learning.
Always remember that putting safety first. And you should not keep it in mind before you starting
work and forget about it when you complete the work. Most accidents are caused by negligence,
operations in haste or disregard for safety rules. Keep it in mind that if you work carefully and
strictly abide by the rules in this manual, maintenance will become safe and enjoyable.
CAUTION
• Improper operation can be quite dangerous. Before operation, please read through the section
Safety in the Operation and Maintenance Manual.
2.2.2 Safety rules
• Before any lubrication or repair, please read

all safety decals on the machine. Refer to
the safety manual for location of safety dec-
als and detailed precautions.
• Learn the safety rules related to the work
process and apply the learning to work.
Please ask for help instead of taking risk
when there is any problem.
• Only authorized workers are allowed to
carry out work that requires a license or a
qualification certificate. Fig.2-1
• Figure out the work you need to do. Main-
tain the hydraulic excavator without any in-
structions may result in major errors. If you
are not sure about the specific procedure
during maintenance, refer to the Service
Manual. If you have any question about the
content and method of work, please ask for
help from other people.
• Rough-and-tumble play is strictly prohibited
in the workshop. Distraction and small talk
2-6 -
during maintenance increases the risk of

injuries.
• If you want to smoke, please smoke in the
area designated for smokers. Smoking is
strictly prohibited in the working area.
2.2.3 Keep working area tidy
Liquids such as the oil, lubricating oil, fuel and

antifreeze splashed on the ground may cause
slipping, thus they should be cleared up im-
mediately if found. No matter who is responsi-
ble for clearing up, everyone in the workshop
should be obliged to clean up spilled liquid on
the ground.
Keep the workshop clean. Waste and used

parts should be cleaned up in time; it is forbid-
den to leave waste and used parts on the
work platform or the ground of workshop.
Fig.2-2
All equipment and tools must be put back in
place every time you use them. Please keep
the workshop clean and tidy in order to avoid
accidents.
Keep in mind that good workshop hygiene is

critical to creating a safe and comfortable
working environment.
2.2.4 Liquid storage
Liquids such as the fuel, lubricating oil, cool-

ant and detergent should be stored properly in
a place away from the working area. Keep the
storage area well ventilated.
It is forbidden to place containers with liquids

at will without a cover, otherwise spillage of
liquid may cause fires. Carefully read the in-
formation about liquid storage and handling
on each container label.
Please properly store and dispose liquids in

accordance with labels on containers. It is for-
Fig.2-3
bidden to pour a liquid into the container for
- 2-7
storing another liquid. Disorganized storage of

liquids may result in equipment damage, fire
or explosion.
Do not smoke or use open fire around liquids,

otherwise there is a risk for fire or explosion.
Wear personal protective equipment when

you handle liquids. Work with all the fluids
carefully.
2.2.5 Part washing
1. It is forbidden to use gasoline, diesel or oth-

er flammable fluids to wash parts. Please use
specified flame-retardant solvent to wash
parts, otherwise there is a risk of fire and
explosion.
Fig.2-4
2.2.6 Machine cleaning
Use high-pressure hot water, mild and non-

flammable degreasing soap or detergent
when you clean the components of machine.
Do not use any flammable or corrosive
detergent.
It is forbidden to use high-pressure steam to

clean the machine. Cleaning the machine with
steam may damage the paint, rubber pipes,
and electrical system of the machine.
Do not wash or rinse the inside of cab with

high pressure equipment. Otherwise, the in-
Fig.2-5
ternal electrical elements may be damaged.
2-8 -
2.2.7 Decent clothing
Indecent clothing, loose clothing, casual cloth-

ing, wearing jewelry, unsuitable shoes and
long hair may result in personal injuries.
Make a list of dressing codes that specifying

prohibited clothing in workshop; check each
worker individually against the list before
working.
Fig.2-6
2.2.8 Personal protective equipment (PPE)
If there are specific provisions for personal

protective equipment used in workshop, PPE
must be worn in the workshop or in other
areas where it is required.
Personnel who do not properly wear the PPE

are not allowed to stay in the workshop.
Always ensure the PPE is intact. Replace it if

necessary.
Fig.2-7
- 2-9
2.2.9 Correct use of tools
Before working, thoroughly check the tools,

machines, forklift, crane and maintenance ve-
hicle required for work.
Choose right tools for a certain work. Use of

unauthorized, wrong, defective or broken
tools may result in severe personal injuries.
Make sure all the tools are intact and properly

used.
Keep the tools clean. When the work has

been completed, sort and count the tools and Fig.2-8
store them properly to ensure that no tool is
left in the machine.
2.2.10 Fire extinguisher and emergency exit
Before working, take some time wandering

about the workshop and knowing where the
emergency exits and fire extinguishers are. If
maintenance is performed on site, fire extin-
guishers should be provided nearby.
If you have no idea how to use the fire extin-

guisher, refer to the instructions on it.
Fig.2-9
2-10 -
2.3 Preparations before maintenance

2.3.1 Preparations before working
Preparations before working
Please park the machine on some flat stable

ground. Lower the work equipment to the
ground and place it safely and stably.
Place cushion blocks under the track to pre-

vent the machine from moving.
Turn the throttle control knob to 1st position to

run the engine at a low speed with no load for
5 minutes, and then turn the key switch to
OFF to shut down the engine. Fig.2-10
Turn the key switch to ON, and then move the

control lever forwards and backwards, left-
wards and rightwards for 2 to 3 times to re-
lieve the system pressure.
Remove the key from the key switch and pull

the safety lock control lever to the locking
position.
Make sure that there is no other people or

equipment in the working area; make sure
that other workers can see you (especially Fig.2-11
when maintenance is being performed on
site).
Fig.2-12
- 2-11
2.3.2 WARNING decals
If two or more workers are to carry out the

same work at the same time, they should
agree on the workflow and communication
signals. Be sure to inform your colleagues be-
fore any step begins.
Hang up ―No Operation‖ decal or similar

warning decal on the key switch or direction
control device before maintenance to warn
others that the machine is under
maintenance.
Fig.2-13
Provide additional WARNING decals around
the machine when necessary.
If someone starts the engine, touches and op-

erates the control lever or pedal during main-
tenance, it will lead to severe accident.
Fig.2-14
2-12 -
2.3.3 Self-preparation
Only personnel certified by Sany Heavy Ma-

chinery Co., Ltd. can maintain or repair the
machine. An observer may be assigned if
necessary.
Wear protection suit and safety shoes re-

quired by the work.
Please wear rubber apron and rubber gloves

when contacting corrosive materials. Wear a
pair of protective gloves when you work with
the wood, wire ropes or sharp metal.
Fig.2-15
Wear a protective mask when you remove
springs and elastic components or top up the
batteries. When you conduct welding or cut-
ting operation, please wear a helmet and
goggles.
Don’t conduct grinding, flame cutting or weld-

ing if breather or ventilation equipment is not
available. If welding must be conducted on
this machine, please read pages 1~12 Pre-
cautions for arc welding to know the correct
operational process. Fig.2-16
- 2-13
2.4 Precautions for maintenance

2.4.1 Work during engine running
Work during engine running
It is forbidden to start the machine during

maintenance unless specified otherwise in the
Service Manual. If the machine must be
started during work, observe the following
rules:
1） Operation near the fan, fan belt or other

rotary components will cause the danger of
being rolled by the components. Please pay
greater attention to it.
Fig.2-17
2） Do not drop or insert tools or other objects
in fan or fan belt, which may cause the part to
break or fly out, resulting in personal injuries.
3） Turn the safety lock control lever to

"LOCK" position to prevent the work equip-
ment from moving unexpectedly.
4） If you perform maintenance when the en-

gine is running, make sure that a worker sits
on the cab seat and is always ready to shut
down the engine. All personnel must keep in
Fig.2-18
touch with each other.
5） It is forbidden for the worker in cab to

touch any control lever. If a control lever must
be operated, make sure that you can always
see other workers and warn them to move
swift to a safe place before operation.
6） When the machine is in operation, the

surface of most parts will become hot, and the
surface temperature on some parts will be-
come very high. If necessary, always wear the
PPE when you work around high-temperature Fig.2-19
parts to avoid burns.
7） When the machine is in operation, the hy-

draulic system, cooling system and fuel sys-
tem may under high temperature and high
2-14 -
pressure. Thus, be careful when you work

around these systems.
2.4.2 Dismantling accessories of machine
When it is necessary to dismantle large ac-

cessories from the machine, be sure to use
correct hoisting equipment and ensure that
the weight of load does not exceed the rated
hoisting capacity of equipment.
Dismantled accessories or components

should be properly placed to prevent them
from falling or moving. Make sure accessories
or components are stably placed on a flat sur-
face and they should not obstruct the pedes-
trian traffic or any fire fighting access.
Fig.2-20
2.4.3 Working under machine
Lower the work equipment onto the ground

before maintaining the machine. Never main-
tain the machine without supporting it
securely.
If it has to lift the machine or work equipment

for maintenance, support the work equipment
or machine with the cushion blocks or brack-
ets that strong enough to firmly support them.
Do not support the machine with slag bricks,
hollow tires or shelves, because they will col-
lapse under continuous load. And do not sup- Fig.2-21
port the machine with a single jack.
Working under the machine can be very dan-

gerous when the track shoe is away from the
ground and the machine is only supported by
the work equipment because once the hy-
draulics pipeline is damaged or the control
lever is accidentally hit, the work equipment or
machine will suddenly fall, resulting in casu-
alty accidents. Therefore, don’t work under
- 2-15
the machine if it is not firmly supported with

cushion blocks or brackets.
2.4.4 Adding or changing fluid
When adding or changing fluids for system,

remember that these systems may be under
high temperature and high pressure.
The machine should be switched off before

operation. The filler cap can only be un-
screwed when the system is cooled down,
otherwise it may cause severe burns or fluid
splash.
Slowly unscrew the filler cap, drain plug, or

pressure relief plug to prevent fluid from
ejection.
Fig.2-22
2.4.5 Parts alignment
Be very careful when you install or align parts.
Do not use hands or fingers to align holes or

bonding surfaces with each other in order to
prevent hands or fingers from being crushed
or pinched.
Use proper tools to align the parts with each

other to prevent injury to your hands or
fingers.
Fig.2-23
2-16 -
2.4.6 When a hammer is used
When knocking hard metal part with a ham-

mer, such as pin, bucket teeth, cutting edge or
bearing, parts and metal fragments flying off
will lead to injury. Therefore please wear gog-
gles and gloves and ensure no person is in
the surrounding area.
Try to avoid installing parts or pins with a met-

allic hammer for fear of part damage. Try to
use soft or non-iron hammer whenever
possible.
Fig.2-24
2.4.7 When compressed air is used
When you do cleaning with the compressed

air, particles may fly off and result in personal
injuries. Thus, it is important to wear PPE
such as eye protection, dust masks and pro-
tective gloves.
2.4.8 Welding
There is a risk of fire or electric shock during

welding, therefore, welding must be carried
out by qualified welders with appropriate
equipment. Unqualified personnel are not al-
lowed for welding.
Fig.2-25
- 2-17
2.4.9 Tension spring
Be very careful during track maintenance be-

cause track tension springs may pose a dan-
ger. Track tension springs are always under
high pressure. Improper operation during dis-
mantling may cause the springs to fly out,
which may result in severe personal injuries.
Don’t knock the track tension springs, as they

may bear huge pressure and break suddenly,
leading to injury.
Be very careful when you remove and refit the

Fig.2-26
tracks. When the main chain link of track is
dismantled, the track assembly may suddenly
break and cause personal injuries. When you
detach the main chain link of track, keep away
from the traveling path of track.
2.4.10 Safe operation for high pressure hoses
If leakage is found in the high-pressure hose,

it may cause an operational failure and even
lead to a fire. If bolts on the hose come loose,
stop working and tighten the bolts to specified
torque. Stop working immediately and replace
the hoses if hoses are damaged as follows:
1） Hydraulic tube connectors are damaged

or leak.
2） The covering is worn or broken, or steel

wire of the reinforcement layer is exposed.
3） Some parts of the covering swell. Fig.2-27
4）There are impurities inside the covering.
5） Removable parts are twisty or squashed.
2-18 -
2.4.11 Be careful when you work with high-pressure fluid
Pressure always exists in the hydraulic sys-

tem. When you check or replace the pipes, al-
ways check if pressure in the hydraulic circuit
has been relieved. If there is remaining pres-
sure in the hydraulic circuit, serious accidents
will occur. Therefore, it is important to observe
following rules:
1） Press the relief button of breather valve to

relieve system pressure before maintenance
of hydraulic system.
2） Keep the hydraulic system off any open

flame, and eliminate splashing hydraulic oil, if
any, at once.
3） Diesel or hydraulic fluid under pressure

can penetrate skin or eyes, leading to severe
injury, blindness or death. It is difficult to visu-
ally check if the pressurized hydraulic oil
leaks. You need to find leakage with a piece
of cardboard or wood chip. Do not touch
leaked oil directly, and be sure to wear a face
Fig.2-28
mask or protective goggles to protect your
eyes. If oil penetrates your skin, rinse it with
water and seek medical attention as soon as
possible.
4） When the engine is running, high pres-

sure will arise inside the fuel pipeline. If the
fuel pipeline system is to be checked or main-
tained, wait until the engine is shut down for at
least 30 s and the internal pressure
decreases.
- 2-19
2.4.12 Be careful when you work with hot coolant
As temperature of engine increases, pressure

in cooling system builds up. Stop the engine
to allow the system to cool down before re-
moval of radiator cap. You should not remove
it until the coolant cools down.
Fig.2-29
2.4.13 A/C system
• Keep away from fire during maintenance of

A/C system;
• When topping refrigerant up, always select
a correct refrigerant, which should be refrig-
erant R134a. Any other refrigerants are not
allowed because they will damage the A/C
system;
• If the A/C refrigerant enters the eye, it may
lead to blindness; and if it splashes to the
skin, it may lead to frostbite;
• It is strictly forbidden to discharge the refrig- Fig.2-30
erant directly into the atmosphere, instead,
a refrigerant circulation system should be
used.
WARNING
• R134a refrigerant is a non-toxic gas at
room temperature, but it turns into a highly
toxic gas when it exposes to fire.
2-20 -
2.4.14 Electrical safety
Before testing the machine’s electric circuits,

always get to know the elements to be tested
in the system. High voltage and strong current
both can cause equipment damage, electric
sparks, explosion and even fire.
Before maintaining or testing the electrical

system, always get to know the system volt-
age. Be sure to check the electric circuits and
make sure the circuits are disconnected be-
fore maintenance.
Fig.2-31
For work around flammable liquids or explo-
sive systems, only the specified explosion-
proof lamps can be used. Using unapproved
lighting equipment may cause an explosion or
fire.
2.4.15 Switching power off
Before any maintenance, be sure to discon-

nect the battery lead or switch off the master
power switch (e.g. for the equipment).
When the battery is to be disconnected, dis-

connect the negative (-) connector before dis-
connecting the positive (+) connector.
When the battery is to be connected, ensure

that all the switches of electrical system are
set to OFF, and then connect the positive (+)
connector before connecting the negative (-)
connector.
Fig.2-32
- 2-21
2.4.16 Battery operation
Working around the batteries can be danger-

ous, especially when the batteries are used
for a long time. Here are some precautions
you should know when you maintain the bat-
teries or work around the batteries:
1） Always wear the PPE when you work

around the batteries.
2）Gas can be easily explosive when it is re-

leased from the battery. When the battery box
has been opened, wait enough time until gas
Fig.2-33
in the box diffuses, and then perform
maintenance.
3） Be sure to choose a well-ventilated place

for handling the batteries.
4） If the batteries are corroded, rinse them

with a mixture of sodium bicarbonate and
warm water.
5） In case of skin or eye contact with battery

electrolyte, rinse the skin or eye immediately
with plenty of clean water and see a doctor as
Fig.2-34
soon as possible.
2.4.17 Accumulator
As accumulator is filled with high pressure ni-

trogen, improper operation may lead to explo-
sion and severe accident. Therefore please
comply with the following precautions:
1） Don’t disassemble the accumulator;
2） Keep the accumulator away off fire sour-

ces or do not expose it to fire;
3） Don’t punch, weld or gas-cut the

accumulator;
Fig.2-35
4） Don’t collide with or roll the accumulator,
or make it suffer any impact;
2-22 -
5） Gas shall be discharged before handling

of the accumulator. Please contact dealers
authorized by Sany Heavy Machinery Co.,
Ltd. to conduct this operation.
2.4.18 Reducing fire and explosion risks
Please shut down the engine and turn off the

electrical equipment when refueling the tank.
Be extremely cautious when refueling the hot
engine. Avoid any spark around the grounded
fuel nozzle.
Please handle all solvents and dry chemicals

according to the steps described on the con-
tainers in a well-ventilated place.
Clean away dust and residues on the ma-

chine, and don’t place greasy cleaning cloth
Fig.2-36
or other inflammable materials on it.
Please clean parts with non-inflammable sol-

vent rather than gasoline, diesel or other in-
flammable liquid.
Store inflammable liquids and materials in

proper containers according to safety
regulations.
Check and maintain fire extinguishers regu-

larly to ensure that they are always ready for
use.
- 2-23
2.4.19 Proper disposal for waste
Improper waste disposal may lead to environ-

mental and ecological perils. Consult your lo-
cal recycling center or the dealers authorized
by Sany Heavy Machinery Co., Ltd. about re-
cycling or disposal methods.
1） Potential harmful waste from the equip-

ment of Sany Heavy Machinery Co., Ltd in-
cludes hydraulic fluid, fuel, coolant,
refrigerant, filter, battery, etc.
2） Please store the drained liquid with a

Fig.2-37
leak-proof container instead of a food or drink
container, as the latter may cause mistaken
drinking.
3） Do not pour waste fluid on the ground, in

the sewer or any source of water;
4） Leakage of refrigerant will damage the

earth atmosphere. Please recover or recycle
the A/C refrigerant according to relevant laws
and regulations.
Fig.2-38
2.5 Miscellaneous
2.5.1 Miscellaneous
Precautions for hoisting and signaling
2-24 -
1) Only one designated worker can signal and

co-workers must frequently communicate with
each other. The designated signaler must dis-
tinctly signal as specified where the driver and
other signaler(s) can see the operating condi-
tions clearly. The signaler must stand in front
of the load and safely guide the driver.
• Do not stand beneath the load.

• Do not step on the load.
2) Before hoisting, check the wire rope slings.

Fig.2-39
3) Wear gloves all the way during hoisting.
(Wear a pair of leather gloves, if available.)
4) Visually measure the weight of load and

check its center of gravity.
5) Use suitable slings according to the load

weight and hoisting method. If the wire ropes
used to hoist load are too thick, the load may
slip or fall off.
6) Do not hoist the load with a single wire

rope. Otherwise, the load will rotate and may
slip out of the wire rope. Use two or more wire
ropes symmetrically.
7) In general, the angle for hoisting does not

exceed 60°. Do not hoist heavy loads at a
large angle for hoisting. When the load is
hoisted with two or more wire ropes, force ex-
erted on each wire rope increases with the an-
gle for hoisting. The right figure shows the
permissible load change in kN at various an-
gles for hoisting when 2 wire ropes are used
for hoisting and the permissible vertical hoist-
ing limit of each wire rope is 9.8kN{1,000kg}.
When 2 wire ropes are used to hoist a load
vertically, the permissible total hoisted weight
is 19.6kN{2,000kg}, and when the 2 steel wire
ropes are at a hoisting angle of 120°, the
weight is reduced to 9.8kN{1,000kg}. If a load
of 19.6kN {2,000kg} is hoisted with 2 wire
ropes when the angle for hoisting is 150°, the
- 2-25
force exerted on each wire rope is 39.2kN

{4,000kg}.
8) When the wire ropes are installed to an an-

gular load, use a pad to protect them. If the
load is smooth, use suitable material to pre-
vent the wire ropes from slipping.
9) Secure the wire ropes and sling chains to

the load with, e. g., specified eyebolts and U-
shaped rings with pins.
10) Install wire ropes at the center part of the

hooks.
• If the wire rope slings are too close to the

top of hooks during hoisting, the wire ropes Fig.2-40
may slip off the hooks. The hooks have the
maximum strength at the center part of the
hooks.
11) Do not use twisted or kinked wire ropes.
12) Observe the following rules when a load is

hoisted:
• Lift the load slowly until the wire ropes are

tensioned. Do not grasp the wire ropes
when you handle them with hands, other-
wise your fingers may easily be pinched.
Fig.2-41
• When the wire ropes are released, stop the
crane and check status of hoisted load, wire
ropes and pads.
• If the load is unsteady or the wire ropes or
sling chains are twisted, lower the load and
hoist it again.
• Do not hoist the load in tilted state.
13) Observe the following rules when a load is

lowered:
• When a load is lowered, steady it at 30 cm

above the ground and slowly lower it.
• Check if the load is steady before removing
the wire rope slings.
2-26 -
• Eliminate the kinks and sludge from wire

ropes and sling chains for hoisting, and put
the wire ropes and sling chains in the desig-
nated place.
2.5.2 Precautions for using mobile crane
WARNING
• Read the operation and maintenance manual for crane in advance and operate the crane
safely.
2.5.3 Precautions for using bridge crane
1） Before working, check the wire ropes, brake, clutch, controller, rail, overhoist protection de-
vice, earth leakage circuit breaker, anti-collision device for crane and alarm lamp for power appli-
cation, and check the safety.
2） React to the hoisting signal.
3） Operate the crane at a safe place.
4） Be sure to check the direction of the indicator board (east, west, south and north) and the di-
rection of control buttons.
5） Do not lift the load in tilted state. Do not move the crane when the hoisted load rotates.
6） Do not lift or lower the load while the crane is moving sideways, or forward/backward.
7） Do not drag wire rope slings.
8） Before lifting a load up, check the safety when the load gets off the ground.
9） Arrange the path for traveling in advance, and then lift the load to a safe height.
10） Position the control switch at a place where it does not obstruct working or any passage.
11） Do not turn the control switch after crane operation.
12） Remember the position of main power switch so that power can be switched off immediately
in any emergency.
13）If the crane stops due to a power failure, set the power switch to OFF. When a switch, which
has been turned off via the earth leakage circuit breaker, is turned on, check whether devices re-
lated to the switch are in operation.
14） If any obstacle is found around the crane, stop operation.
- 2-27
15） After work, stop the crane at the specified place and lift the hooks to at least 2 m above the
ground. Do not leave wire rope slings on the hooks.
2.5.4 Selection of wire ropes
According to the weight of parts to be hoisted, select the appropriate wire rope (see the table
below).
Wire rope
("Z” (right regular lay) or "S" (left regular lay) wire rope, not galvanized)
Nominal diameter of wire Permissible load
rope
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
CAUTION
• Note: Permissible load is within 1/6 of breaking force of wire rope. (Safety factor: 6)
2-28 -
SY365H(BH)-10 Hydraulic Excavator Technical Specifications
Technical Specifications
3 Technical Specifications.............................................................................................3-1
3.1 Specified dimension..............................................................................................................3-3
3.1.1 Dimension ....................................................................................................................3-3
3.1.2 Working range .............................................................................................................3-4
3.2 Technical specifications .......................................................................................................3-5
3.3 Weight table ...........................................................................................................................3-7
3.4 Oil, fuel and coolant ..............................................................................................................3-8
3.5 Engine curve ..........................................................................................................................3-9
- 3-1
Technical Specifications SY365H(BH)-10 Hydraulic Excavator
WARNING
3-2 -
3.Technical Specifications
3.1 Specified dimension

3.1.1 Dimension
Fig.3-1
Name Unit SY365H(BH)-10
Overall length (for

A mm 11320
transportation)
B Overall width mm 3190
Overall height (for
C mm 3550
transportation)
D Width of superstructure mm 3150
E Overall height (top of the cab) mm 3320
F Standard track shoe width mm 600
G Track gauge mm 2590
H Min.ground clearance mm 550
I Tail swing radius mm 3560
J Ground contact length of track mm 4140
K Track length mm 5065
Ground clearance of
L mm 1250
superstructure
- 3-3
3.1.2 Working range
Fig.3-2
3-4 -
Name Unit SY365H-10 SY365BH

a Max. digging height mm 9692 9720
b Max. dumping height mm 6867 6720
c Max. digging depth mm 7056 6810
d Max. vertical wall digging depth mm 3969 4020
e Max. digging reach mm 10773 10570
f Min. swing radius mm 4490 4490
g Max. height at min. swing radius mm 8611 8611
3.2 Technical specifications
- 3-5
3-6 -
3.3 Weight table
Note：This table is only used as the reference for operating components or transportation.
- 3-7
3.4 Oil, fuel and coolant
• Recommended engine oil: API CI-4 or above.

• Recommended gear oil: GL-5.
• Please buy genuine SANY oil from Sany Heavy Machinery Co., Ltd or dealers authorized by
Sany Heavy Machinery Co., Ltd to ensure oil quality.
3-8 -
3.5 Engine curve
• GH-6HK1XKSC-01
• Test conditions:
• Temperature: 298K, at standard atmospheric pressure;
Fig.3-3
- 3-9
3-10 -
SY365H(BH)-10 Hydraulic Excavator Structure and Function
Structure and Function
4 Structure and Function................................................................................................4-1

4.1 Engine and cooling system..................................................................................................4-5
4.1.1 Engine-related parts ...................................................................................................4-5
4.1.2 Radiator and intercooler.............................................................................................4-6
4.2 Powertrain ..............................................................................................................................4-7
4.2.1 Powertrain ....................................................................................................................4-7
4.2.2 Travel reducer assembly............................................................................................4-8
4.2.3 Swing reducer mechanism ..................................................................................... 4-10
4.2.4 Swing bearing ........................................................................................................... 4-12
4.3 Lower structure................................................................................................................... 4-13
4.3.1 Track frame and tension mechanism .................................................................... 4-13
4.3.2 Idler ............................................................................................................................ 4-15
4.3.3 Carrier roller .............................................................................................................. 4-16
4.3.4 Track roller ................................................................................................................ 4-17
4.3.5 Crawler ...................................................................................................................... 4-19
4.3.6 Three-teeth track shoe ............................................................................................ 4-21
4.4.1 Layout of hydraulic parts ......................................................................................... 4-22
4.4.2 Hydraulic tank and filler ........................................................................................... 4-24
4.4.3 Hydraulic pump......................................................................................................... 4-25
4.4.4 Regulator................................................................................................................... 4-32
4.4.5 Adjustment of the regulator..................................................................................... 4-36
4.5.1 Main control valve .................................................................................................... 4-46
4.6.1 Swing motor .............................................................................................................. 4-78
4.6.2 Swing retention brake.............................................................................................. 4-82
4.6.3 Central swivel joint ................................................................................................... 4-88
4.6.4 Travel motor (Nabtesco) ......................................................................................... 4-89
- 4-1
Structure and Function SY365H(BH)-10 Hydraulic Excavator
4.7 Control system.................................................................................................................... 4-99

4.7.1 summarize................................................................................................................. 4-99
4.7.2 Manual pilot valve .................................................................................................. 4-100
4.7.3 Travel pilot valve..................................................................................................... 4-106
4.7.4 Solenoid valve .........................................................................................................4-110
4.7.5 PPC accumulator ....................................................................................................4-111
4.7.6 Pilot oil filter..............................................................................................................4-112
4.7.7 Hydraulic cylinder....................................................................................................4-113
4.8 Work equipment ................................................................................................................4-115
4.8.1 Part size....................................................................................................................4-115
4.8.2 Arm size....................................................................................................................4-117
4.8.3 Bucket size...............................................................................................................4-119
4.9 A/C system........................................................................................................................ 4-121
4.9.1 summarize............................................................................................................... 4-121
4.9.2 Layout of A/C elements ......................................................................................... 4-122
4.9.3 A/C control panel.................................................................................................... 4-123
4.9.4 Schematic circuit diagram..................................................................................... 4-124
4.9.5 A/C cooling principle .............................................................................................. 4-125
4.9.6 Compressor ............................................................................................................ 4-127
4.9.7 Clutch....................................................................................................................... 4-129
4.9.8 Condenser............................................................................................................... 4-129
4.9.9 Expansion valve ..................................................................................................... 4-130
4.9.10 Evaporator ............................................................................................................ 4-130
4.9.11 Dryer ...................................................................................................................... 4-131
4.9.12 Pressure switch.................................................................................................... 4-132
4.9.13 Fresh air sensor ................................................................................................... 4-133
4.9.14 Refrigerant ............................................................................................................ 4-133
4.10 Engine control................................................................................................................. 4-150
4.10.1 summarize ............................................................................................................ 4-150
4.10.2 System operation ................................................................................................. 4-151
4.10.3 System components............................................................................................ 4-151
4.10.4 Controller............................................................................................................... 4-153
4.11 Electrical control system ............................................................................................... 4-156
4.11.1 Control functions .................................................................................................. 4-156
4.11.2 Machine control system diagram ....................................................................... 4-157
4.11.3 Engine - pump combination control function .................................................... 4-159
4.11.4 Pump control function.......................................................................................... 4-164
4.11.5 Valve control function........................................................................................... 4-168
4.11.6 High/low speed travel control ............................................................................. 4-170
4.11.7 Engine warm-up/overheating alarm .................................................................. 4-172
4.11.8 Excessively low oil pressure alarm.................................................................... 4-173
4-2 -
4.11.9 Automatic idling/acceleration control ................................................................ 4-174

4.11.10 System parts....................................................................................................... 4-175
4.12 Display system ............................................................................................................... 4-179
4.12.1 summarize ............................................................................................................ 4-179
4.12.2 Display................................................................................................................... 4-180
4.12.3 Display panel ........................................................................................................ 4-182
4.12.4 Operation of display interfaces .......................................................................... 4-184
- 4-3
WARNING
4-4 -
4.Structure and Function
4.1 Engine and cooling system

4.1.1 Engine-related parts
Fig.4-1
1. Air cleaner Technical Specifications

2. Silencer assembly Oil capacity: 35 L
3. Air cleaner
4. Rubber mount
5. Flywheel
6. Coupling
7. Piston pump
- 4-5
4.1.2 Radiator and intercooler
Fig.4-2
1. Air intercooler Technical Specifications

2. Radiator outlet hose Radiator assembly:
3. Radiator inlet hose ZH1250×385×1380-S125Y110Z25
4. Fuel cooler Aluminum tube-and-fin radiator
5. Water radiator Radiator capacity: 12.1 L
6. Oil radiator
7. A/C condenser
4-6 -
4.2 Powertrain
4.2.1 Powertrain
Fig.4-3
1．Swing motor(M5×180CHB-10A-3NA/265) 6．Accumulator

2．Swing reducer(RG20D25G2-140) 7．Multi-way valve(KMX32NA/P45203)
3．Swing bearing 8．Reducer assembly(M3V270/160D-
RG7.5D)
4．Guide wheel 9．Piston pump(K5V160DTH1×4R-9T06-V)
5．Swing joint 10．Engine(GH-6HK1XKSC-01)
- 4-7
4.2.2 Travel reducer assembly
Fig.4-4
4-8 -
1. Gear hub 7. 2# planetary carrier pin

2. 1# planetary gear 8. 2# sun gear
3. 1# planetary carrier pin 9. 2# planetary carrier
4. 1# sun gear 10. Motor
5. 1# planetary carrier 11. Check port
6. 2# planetary gear 12. Oil filler and oil drain port
Reduction ratio: 40.467
S/N Inspection Item Standard Measures

Clearance between 2# planetary 0.100～ 1.10
13
gear and gear hub 0.356
Clearance between 1# planetary 0.133 ～ 1.00
14
gear and gear hub 0.386
Replacement
Clearance between 1# sun gear and 0.05 ～ 0.286 1.10
15
1# planetary gear
Clearance between 2# sun gear and 0.076 ～ 1.00
16
2# planetary gear 0.304
- 4-9
4.2.3 Swing reducer mechanism
Fig.4-5
4-10 -
1. Plug 11. 2# planetary gear subassembly

2. Oil seal 12. 2# planetary gear (number of teeth: 23)
3. Self-alignment bearing 13. Spring pin
4. Ring gear (number of teeth: 66) 14. Swing reducer plug
5. 2# planetary carrier 15. Grease fitting
6. 1# planetary carrier 16. Self-alignment bearing
7. 2# sun gear (number of teeth: 18) 17. Bearing seal
8. 1# sun gear (number of teeth: 15) 18. Swing pinion
9. Swing motor 19. Oil dipstick
10. 1# planetary gear (number of teeth: 25) 20. Filler pipe
Reduction ratio: 25.2
S/N Inspection Item Standard Measures

Clearance between Standard Clearance limit
21 swing motor shaft clearance Replacement
and 1# sun gear 0.18～ 0.28 —
Clearance between 0.16～ 0.50 1.00
22 1# sun gear and 1#
planetary gear
23 1# planetary gear
and ring gear
24 1# planetary carrier
and 2# sun gear
25 2# sun gear and 2# Replacement
planetary gear
26 2# planetary gear
and ring gear
Clearance between 0.07～ 0.23 —
27 2# planetary carrier
and swing pinion
28 swing pinion and
swing bearing
- 4-11
4.2.4 Swing bearing
Fig.4-6
1. Swing bearing cone (number of teeth: 78) Technical Specifications

2. Steel ball Reduction ratio: 78/11=7
3. Swing bearing outer ring Grease filling quantity: 27±1 kg
a. “S” part in the soft area of the cone
b. ‘S” part in the soft area of the cup
4-12 -
Unit: mm
Inspection Item Standard Measures
Standard Clearance
Axial clearance of bearing
clearance limit Replacement
(mounted on the chassis)
0.5 ～ 1.6 3.2
4.3 Lower structure

4.3.1 Track frame and tension mechanism
Fig.4-7
- 4-13
1. Idler • The track rollers have different sizes and numbers

2. Track frame depending on the model, but the same basic structure.
3. Carrier roller • Number of track rollers (on one side): 9

4. Sprocket
5. Track roller
6. Track
7. Long guard board
8. Short guard board
9. Guide seat
Standard track shoe
4-14 -
4.3.2 Idler
Fig.4-8
- 4-15
4.3.3 Carrier roller
Fig.4-9
4-16 -
4.3.4 Track roller
Fig.4-10
- 4-17
4-18 -
4.3.5 Crawler
Fig.4-11
- 4-19
4-20 -
4.3.6 Three-teeth track shoe
Fig.4-12
- 4-21
4.4 Hydraulic system, part 1

4.4.1 Layout of hydraulic parts
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic oil filter
6. Multi-way valve
7. Piston pump
8. Radiator
9. Left travel motor
10. Right travel motor
11. Swing motor
12. Safety lock rod
13. Left pilot valve
14. Central swivel joint
15. Right pilot valve
16. Travel pilot valve Fig.4-13
17. Accumulator
18. Solenoid valve group
18A. High speed travel solenoid valve
18B. Service valve
18C. Service valve
18D. Bucket converging solenoid valve
18E. Service valve
18F. Pilot pressure solenoid valve
4-22 -
Fig.4-14
- 4-23
4.4.2 Hydraulic tank and filler
Fig.4-15
1. Hydraulic tank Technical Specifications

2. Liquid level meter Oil tank capacity: 340L
3. Drain filter element assembly
4. Oil filler cap Breather valve
5. Breather valve Filter precision: 10μm
6. Oil suction filter element Ambient temperature: -20℃～100℃
7. Oil return filter element Pressure setting: Intake side→0.005MPa
Exhaust side → 0.05 MPa
4-24 -
4.4.3 Hydraulic pump
Model: K5V160DTH1SXR-9T46-BV
Fig.4-16
Overview
• The pump consists of 2 variable swashplate type piston pumps, 2 regulators and 1 pilot gear
pump.
- 4-25
a1：Front pump main pres- Psv2：Rear pump regulator 3：Pilot gear pump
sure check port control port
a2：Rear pump main pres- Dr1：Front pump oil drain port 4：Front pump regulator
sure check port
a3：Front pump regulator Dr2：Bleed plug 5：Rear pump regulator
pressure check port
a4：Rear pump regulator con- Dr3：Rear pump oil drain port
trol pressure check port
a5：Pilot gear pump output Dr4：Bleed plug
pressure check port
PH1： Front pump pressure B1：Pump oil suction port
sensor mounting port
PH2： Rear pump pressure B3：Pilot gear pump oil suc-
sensor mounting port tion port
A1：Front pump oil inlet
A2：Rear pump oil inlet
A3：Pilot gear pump oil outlet 1：Front pump
Psv1：Front pump regulator 2：Rear pump
control port
Fig.4-17
4-26 -
1. Front shaft 9. End cover

2. Minimum displacement adjusting screw 10. Rear shaft
3. Front case 11. Rear case
4. Swashplate 12. Gear pump
5. Slipper 13. Piston
6. Piston 14. Maximum displacement adjusting screw
7. Cylinder 15. Gear pump shaft
8. Port plate 16. Drive pin
Fig.4-18
- 4-27
Function • The swashplate (4) has a plane (A), and the

slipper (5) always presses against this plane
• The engine torque is transferred to the shaft when it makes a circular motion.
(1) to drive the cylinder (7) to rotate, and the • The swashplate (4) guides the high-pressure
9 pistons (6) slide along the surface of the oil to the surface (B) and forms a static pres-
port plate (8). The piston (6) reciprocates sure bearing when it slides.
within the cylinder (7) to alternately suck the • The piston (6) makes an axial relative move-
low-pressure oil and discharge the high- ment inside each cavity of the cylinder (7).
pressure oil. • The cylinder (7) seals the pressurized oil to
• The displacement is changed through the port plate (8) and makes a relative
change of the inclination angle of the rotation.
swashplate. • This surface is so designed that the oil pres-
Structure sure balance is maintained at a suitable level.
• The oil inside each cavity of the cylinder (7) is
• The cylinder (7) is supported on the shaft sucked and discharged through the port plate
(1) by the spline (17). (8).
• The shaft (1) is supported by the front and
rear bearings (18).
• The piston (6) top is made into a concave
sphere which is filled with the slipper (5) to
form a device.
• The piston (6) and slipper (5) form a spheri-
cal bearing.
Working process
• The cylinder (7) rotates with the shaft (1),
and the slipper (5) slides on the plane (A).
• In this case, the swashplate (4) moves
along the cylindrical surface (B). Therefore,
the angle (a) between the center line (X) of
the swashplate (4) and the axial direction of
the cylinder (7) may change.
• (a) is the inclination angle of the
Fig.4-19
swashplate.
4-28 -
• When the centerline (X) of the swashplate

(4) is at an inclination angle of the swash-
plate relative to the axial direction of the cyl-
inder (7), the plane (A) will act as a cam
relative to the slipper (5).
• In this way, the piston (6) will slide inside
the cylinder (7), so the difference between
capacities (E) and (F) will be generated in-
side the cylinder (7). Fig.4-20
• The oil suction/discharge quantity of a pis-
ton is equal to (F) - (E).
• When the cylinder (7) rotates and the ca-
pacity of the cavity (E) becomes smaller,
the pressurized oil will be discharged.
• On the other hand, the capacity of the cavity
(F) becomes larger during which the oil is
sucked.
• When the centerline (X) of the swashplate

(4) coincides with the axial direction of the
cylinder (7) (the inclination angle (a) of the
swashplate = 0), the difference between ca-
pacities (E) and (F) inside the cylinder (7)
will become 0.
• In this state, the suction and discharge of
pressurized oil won’t be performed, i. e.
there will be no oil pumping action. (How- Fig.4-21
ever, the inclination angle of the swashplate
angle isn’t set to 0 actually.)
- 4-29
Oil delivery control

• If the inclination angle (a) of the swashplate
becomes larger, the difference between ca-
pacities (E) and (F) becomes larger and the
pump oil delivery quantity (Q) increases.
• The piston (13) is used to change the incli-
nation angle (a) of the swashplate.
• The piston (13) makes a reciprocating mo-
tion in a straight line under the control of the
regulator.
• The straight motion is transferred to the
swashplate (4) via the drive pin (16) to drive Fig.4-22
the swashplate to slide and change the in-
clination angle of the swashplate, thus
changing the displacement of the main
pump.
Pilot pump
Fig.4-23
4-30 -
307：Valve stem 361：Body

308：Valve seat 433：Screw
309：Retaining ring 434：Screw
310：Spring pin 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 element 850：Washer
Function
• The engine drives the drive shafts of the main pump and pilot pump via the transmission and
then drives the pilot pump through gear engagement.
- 4-31
4.4.4 Regulator
Fig.4-24
4-32 -
- 4-33
4-34 -
Functional principles
• The regulator controls the flow of the main
pump based on the command signal pres-
sure so that the pump driving power doesn’t
exceed the engine power.
• Pumps 1 and 2 are equipped with a regula-
tor respectively. The main parts of the regu-
lator include the solenoid proportional
reducing valve (1), electro-hydraulic
changeover valve (2), variable power regu-
lator (3), positive flow regulator (4), servo
piston (5) and servo reversing valve (6).
The regulator opens or closes the oil circuit
Fig.4-25
of the servo piston (5), changes the inclina-
tion angle of the swashplate, and controls
the pump flow based on the various com-
mand signal pressure.
1. Control mechanism composition
Current control: in normal case

• Through change of the command current I
flowing into the solenoid proportional reduc-
ing valve, the inclination angle (output flow)
of the pump can be controlled. The regula-
tor is adopted with a positive flow control (or
positive control) mode in which the output
flow Q increases with the increase of the
command current I. This mechanism can
ensure that the current at a required flow
corresponding to the operation is input, so
that the pump only outputs the required
flow, therefore, the useless power won’t be
wasted.
Power control (+ power switching): in case of

an emergency (with the rod withdrawn)
• In the case of an emergency, the power
switching command pressure Pf is used to
switch the power setting value. The power
switching command pressure (the secon-
dary pressure of the solenoid proportional
- 4-35
reducing valve: P2) is introduced into the

power control unit of each pump regulator
through the pump internal passage, and is
switched to the same power setting value.
• When the power is switched, the inclination
angle (output flow) of the pump is automati-
cally reduced according to the rise of the
pump output pressure Pd1, thereby limiting
the input torque to a certain value or less.
(The input power becomes constant power
at constant rotational speed.)
• In the power control state, the regulators of
the respective pumps are controlled to have
the same inclination angle (output flow). For
this reason, the overload of the prime motor
can be automatically prevented regardless
of the load of the 2 pumps in the power con-
trol state. And since the power switching
pressure in the normal case is 0 MPa, the
power control is in a non-operating state.
• The best power performance can be ob-
tained in the engaged working state through
this mechanism.
Although the regulator has the above two con-

trol mechanisms, in case of their combined
actions, the small inclination angle (small flow)
command can be prioritized by the mechani-
cal calculation described later.
4.4.5 Adjustment of the regulator
• The minimum and maximum flow rates can be adjusted with the adjusting screws (953, 954) on
the pump body side, and the power control characteristics cab be adjusted with the adjusting
screw (C) (628) and adjusting wheel (C) (627) of the regulator, and the flow control characteris-
tics can be adjusted with the hexagon socket head setscrew (924).
4-36 -
Fig.4-26
531：Tilting pin 808：Fixing nut

532：Servo piston 953：Minimum flow adjusting screw
548：Feedback pin 954：Maximum flow adjusting screw
806：Fixing nut
Adjustment of the maximum flow (on the

pump body side)
• Loosen the hexagon nut (808) and tighten

(or loosen) the hexagon socket head set-
screw (954). The control characteristics ex-
cept the maximum flow are not changed.
Fig.4-27
- 4-37
Adjustment of the minimum flow (on the

pump body side)
• Loosen the hexagon nut (806) and tighten

(or loosen) the hexagon socket head set-
screw (953). Although the case in which
other control characteristics aren’t changed
is the same as that of adjustment of the
maximum flow, it shall be noted that the re-
quired power may increase under the maxi-
mum output pressure (overflow) condition if
excessive tightening occurs.
Fig.4-28
Input power
1）Adjustment of outer spring
• Loosen the hexagon nut (630), and then

tighten (or loosen) the adjusting screw (C)
(628). When the adjusting screw (C) (628)
is tightened, the control line graph will move
to the right as shown in the right figure, and
the input power increases. In addition, if the
adjusting screw (C) (628) is rotated for N
turns, the inner spring (626) will also be ro-
tated and then the setting value will be
changed accordingly, so the adjusting Fig.4-29
wheel (C) (627) shall be rotated in the oppo-
site direction for N×A turns. Please refer to
the attached table for the value of the A.
4-38 -
2）Adjustment of inner spring

tighten (or loosen) the adjusting wheel (C)
(627). When the adjusting wheel (C) (627)
is tightened, the flow rate increases as
shown in the right figure, and the input
power increases.
Fig.4-30
Adjustment of the flow control

characteristic

tighten (or loosen) the hexagon socket head
setscrew (924). When the hexagon socket
head setscrew (924) is tightened, the con-
trol line graph will move to the right as
shown in the right figure.
Fig.4-31
Action description
Flow control
• The output flow of the pump can be con-

trolled steplessly through the command cur-
rent I (when the pump is at a constant
speed) as shown in the right figure.
Fig.4-32
- 4-39
1）Flow increase action
• When the command current I increases, the

secondary pressure of the solenoid propor-
tional reducing valve (P2 ) rises, so the pilot
piston (643) moves in the direction of A and
then stops until P2 is balanced with the
spring force of the pilot spring (646). The
movement of the pilot piston drives the lev-
er (2) (613) by means of the pin (875) to ro-
tate in the arrow direction at the B fulcrum.
Then the rotation of the lever (2) drives the
feedback rod (611) by means of the pin
Fig.4-33
(897) to rotate in the same arrow direction
of B at the C fulcrum. Then the valve spool
(652) connected to the feedback rod moves
in the D direction, during which the C1 port
is connected to the tank port, so the pres-
sure in the large-diameter chamber of the
servo piston is released, and the servo pis-
ton (532) moves toward the E direction
through the output pressure Pd1 of the
small-diameter chamber, thus increasing
the flow. As the feedback rod is connected
with the servo piston and the valve spool,
when the servo piston moves toward the E
direction, the feedback rod rotates at the F
fulcrum, thus moving the spool to the origi-
nal position. Through such movement, the Fig.4-34
opening between the spool valve and the
valve body will be slowly closed, and the
servo piston will stop until the opening is
fully closed.
4-40 -
2）Flow decrease action
• When the command current I decreases,

the secondary pressure of the solenoid pro-
portional reducing valve (P2 ) decreases,
so the pilot piston (643) moves in the direc-
tion of G and then stops until P2 is balanced
with the spring force of the pilot spring
(646). The movement of the pilot piston
drives the feedback rod (611) by means of
the pin (897) to rotate in the same arrow di-
rection of H at the I fulcrum. Then the valve
spool (652) connected to the feedback rod
Fig.4-35
moves in the J direction, during which the
output pressure Pd1 is introduced into the
large-diameter chamber of the servo piston
via the spool and the C1 port. On the other
hand, the output pressure Pd1 is introduced
into the small-diameter chamber of the ser-
vo piston, whereby the piston moves in the
direction of K by means of the difference in
area, so that the inclination angle is re-
duced and then the flow rate is also re-
duced. As the feedback rod is connected
with the servo piston and the valve spool,
when the servo piston moves toward the E
direction, the feedback rod rotates at the L
nal position. Through such movement, the Fig.4-36
opening between the valve spool and the
fully closed.
- 4-41
Power control (in case of an emergency)
• As shown in the right figure, the overload of

the prime motor can be prevented when the
load pressure increases and the inclination
angle of the pump is reduced.
• The operation of the power control is the
same as that of the flow control, so the fol-
lowings are brief.
Fig.4-37
4-42 -
Overload prevention action
• When the pump output pressure Pd1 rises,

since it acts on the step unit of the compen-
sation piston (621), the compensation rod
(623) moves in the direction of M and stops
until the output pressure Pd1 is balanced
with the elastic force of the outer spring
(625) and the inner spring (626). The move-
ment of the compensation rod drives the
lever (1) (612) by means of the pin (875) to
rotate in the arrow direction at the N ful-
crum. Then the rotation of the lever (1)
Fig.4-38
drives the feedback rod (611) by means of
the pin (897) to rotate in the opposite arrow
direction of N at the O fulcrum. Then the
valve spool (652) connected to the feed-
back rod moves in the P direction, during
which the output pressure Pd1 is introduced
into the large-diameter chamber of the ser-
vo piston via the spool and the C1 port. And
the output pressure Pd1 is introduced into
the small-diameter chamber of the servo
piston, whereby the piston moves in the di-
rection of Q by means of the difference in
area, so that the inclination angle is re-
duced and then the flow rate is also re-
duced. As the feedback rod is connected
with the servo piston and the valve spool, Fig.4-39
when the servo piston moves toward the Q
direction, the feedback rod rotates at the R
nal position. Through such movement, the
opening between the valve spool and the
fully closed.
- 4-43
Flow recovery action
• When the pump output pressure Pd1 de-

creases, the compensation rod (623)
moves in the direction of S by the elastic
force of the outer spring (625) and the inner
spring (626) and stops until the output pres-
sure Pd1 is balanced with the elastic force.
The movement of the compensation rod
(623) drives the lever (1) (612) by means of
the pin (875) to rotate in the arrow direction
at the T fulcrum. Then the rotation of the
lever (1) drives the feedback rod (611) by
Fig.4-40
means of the pin (897) to rotate in the oppo-
site arrow direction of T at the U fulcrum.
Then the valve spool (652) connected to
the feedback rod moves in the V direction,
during which the C1 port is connected to
the tank port, so the pressure in the large-
diameter chamber of the servo piston is re-
leased, and the servo piston (532) moves
toward the W direction through the output
pressure Pd1 of the small-diameter cham-
ber, thus increasing the flow. As the feed-
back rod is connected with the servo piston
and the valve spool, when the servo piston
moves toward the W direction, the feedback
rod rotates at the X fulcrum, thus moving
the spool to the original position. Through Fig.4-41
such movement, the opening between the
valve spool and the valve body will be
slowly closed, and the servo piston will stop
until the opening is fully closed.
Priority mechanism for small inclination

angle (small flow) command
• As described above, the tilt command of the

flow control is transmitted by the lever (2)
(613), and the tilt command of the power
control is transmitted to the feedback rod
(611) and the spool (652) by the large hole
4-44 -
of the lever (1) (612). However, the pin (φ5)

on the large hole (φ9) is a protruding struc-
ture and is only in contact with the rod and
the pin on the side of the smaller inclination,
and the φ9 hole and the pin (897) of the rod
on the side of the larger inclination are not
in contact with each other and in a free
state. Therefore, the flow control and power
control commands on the pin tilt side can
be prioritized by this mechanical selection
method.
Power switching control (power reduction

control)
• As shown in the right figure, the power set-

ting value of the pump can be controlled by
the power switching pressure Pf.
• When the power switching pressure Pf in-
creases, the compensation rod (623) is
pushed to the right by the pin (898) and the
compensation piston (621), so that the incli-
nation angle and then the power setting val-
ue of the pump can be reduced as
described in the overload prevention action Fig.4-42
of the power control. On the contrary, when
the power switching pressure Pf decreases,
the power setting value can be increased.
• The power switching pressure Pf is 0 MPa
in the normal pump case, and is 4.9 MPa in
case of an emergency.
- 4-45

4.5.1 Main control valve
Main valve appearance
4-46 -
Fig.4-43
- 4-47
Main valve structure
4-48 -
Fig.4-44
- 4-49
Fig.4-45
4-50 -
Fig.4-46
- 4-51
Fig.4-47
4-52 -
Fig.4-48
- 4-53
Hydraulic circuit diagram
4-54 -
Fig.4-49
Working principles
(1) Valve spool in the neutral position
- 4-55
(Main circuit)
• When all valve spools are in the neutral position, the hydraulic oil from the hydraulic pump (front)
will flow to the pump port P1 and then to the main passage (1), then pass through the neutral by-
pass (2) (M-shaped spool valve function) of straight travel (308), left travel (301), boom 1 (303),
bucket (304) and arm 2 (306) valve spools, and then return to the hydraulic tank via the oil return
ports R1 and R3.
• The hydraulic oil from the hydraulic pump (rear) will flow to the pump port P2 and then to the
main passage (3), then pass through the neutral bypass (4) (M-shaped spool valve function) of
right travel (301), swing (305), boom 2 (307) ), service (309) and arm 1 (302) valve spools, and
then return to the hydraulic tank via the oil return ports R1 and R3.
4-56 -
Fig.4-50
- 4-57
(2) Travel
(Pilot circuit)
• When the left or right travel valve spool is switched, the side bypass will be closed, and thus the
pressure at the port Py (signal port for travel) will increase.
• When the pilot port XBtL for the left travel valve spool (301) is pressurized, the neutral bypass
(2) on the boom 1 side will be closed, and the hydraulic oil from the hydraulic pump (front) will
flow into the left travel motor via the port BtL.
• Similarly, when the pilot port XBtr for the right travel valve spool (301) is pressurized, the neutral
bypass (2) on the arm 1 side will be closed, and the hydraulic oil from the hydraulic pump (rear)
will flow into the right travel motor via the port Btr.
• On the other hand, the oil returned from the left or right travel motor will pass through the left
(right) travel valve spool via the port AtL (Atr), and then will return to the hydraulic tank via the oil
return ports R1 and R3.
• When the travel motor on the opposite side is operated (i.e. when the pilot ports XAtr and XAtL
are pressurized), the above procedures will be followed.
Fig.4-51
(3) Arm
Arm operated for extension
(Pilot circuit)
• When the arm 1 valve spool (302) is switched, the side bypass will be closed, thus the pressure
at the port Px (signal port for work equipment) will increase.
4-58 -
• When the arm is extended, the pilot pressure oil will be supplied into the ports XAa1 and XAa2.
When the pilot pressure oil is applied on both sides of the ports XAa1 and XAa2, the arm 1 and
arm 2 valve spools will be switched to the left side as shown in Fig. 4-51. Thus, the hydraulic oil
flowing from P2 will be introduced into the neutral bypass (4) through the main passage (3). The
neutral bypass will be disconnected through switching of the arm 1 valve spool (302). For this
purpose, the hydraulic oil flowing into the parallel passage will push away the cone valve (253)
of the logic valve and flow into the arm 1 valve spool (302) from the U-shaped passage. Then,
the hydraulic oil from the arm 1 valve spool (302) will be supplied to the arm cylinder piston rod
cavity (R).
• On the other hand, the hydraulic oil flowing from the port P1 will be introduced into the neutral
bypass (2) through the main passage (1). The neutral bypass will be disconnected through
switching of the arm 2 valve spool (306). For this purpose, the hydraulic oil flowing from the par-
allel passage will push away the cone valve (514) of the check valve, and the hydraulic oil flow-
ing from the neutral bypass will push away the cone valve (511) of the check valve and flow into
the arm 2 valve spool (306) from the U-shaped passage. Then, the hydraulic oil from the pas-
sage of the arm 2 valve spool (306) will be converged at the port Aa and then supplied to the
arm cylinder piston rod cavity (R).
• The oil returned from the arm cylinder piston head cavity (H) will flow into the tank passages of
the arm 1 and arm 2 via the port Ba, and return to the hydraulic tank via the tank ports R1 and
R3.
- 4-59
Fig.4-52
Arm operated for retraction
(Pilot circuit)
• When the arm 1 valve spool (302) is switched, the side bypass will be closed, thus the pressure
at the port Px (signal port for work equipment) will increase. At the same time, the pressure oil
4-60 -
will be supplied into the port PaL, and the release signal will be sent to locking valve selector as-
sembly (252).
(Main circuit)
• When the arm is retracted, the pilot pressure oil will be supplied into the ports XBa1 and XBa2.
When the pilot pressure oil is applied on both sides of the ports XBal and XBa2, the arm 1 and
arm 2 valve spools will be switched to the right side as shown in Fig. 4-52. Thus, the hydraulic
oil flowing from P2 will be introduced into the neutral bypass (4) through the main passage (3).
The neutral bypass will be disconnected through switching of the arm 1 valve spool (302). For
this purpose, the hydraulic oil flowing into the parallel passage will push away the cone valve
(253) of the logic valve and flow into the arm 1 valve spool (302) from the U-shaped passage.
Then, the hydraulic oil will flow to the periphery of the arm 1 valve spool (302), and will be sup-
plied to the arm cylinder piston head cavity (H) via the port Ba1.
• On the other hand, the hydraulic oil flowing from the port P1 will be introduced into the neutral
bypass (2) through the main passage (1). The neutral bypass will be disconnected through
switching of the arm 2 valve spool (306). For this purpose, the hydraulic oil flowing from the par-
allel passage will push away the cone valve (514) of the arm 2 check valve, and the hydraulic oil
flowing from the neutral bypass will push away the cone valve (511) of the check valve and flow
into the arm 2 valve spool (306) from the U-shaped passage. Then, the hydraulic oil from the in-
ternal passage of the arm 2 valve spool (306) will be converged at the port Bal and then supplied
to the arm cylinder piston rod cavity (H).
• On the other hand, the oil returned from the arm cylinder piston rod cavity (R) will be pressurized
by means of the dead weight of arm, etc. to return to the port Aa. The hydraulic oil returned to
the port Aa will flow into the valve spool via the hole (a) on the periphery of the arm 1 valve spool
(302), and push away the cone valve (302-317) inside the valve spool only when a low load is
applied, and will be converged at the port Bal via the hole (b) on the periphery, which is called
the arm regeneration function.
• If the pressure in the arm cylinder piston head cavity and the U-shaped passage rises, the arm
regeneration cutoff valve spool (257-103) will be switched to the left side as shown in Fig. 4-53
and closed by means of the back pressure of the cone valve (302-317) inside it. By this means,
the arm regeneration function will be released, and the oil returned from the arm cylinder piston
rod cavity (R) will flow into the valve spool from the hole (a) on the periphery of the arm 1 valve
spool (302) and then into the arm regeneration cutoff valve (257) from the hole (c) on the periph-
ery of the arm 1 valve spool (302), and return to the hydraulic tank via the tank ports Rl and R3.
• At low load
- 4-61
Fig.4-53
• Pressure rise of arm cylinder piston head cavity (H)
4-62 -
Fig.4-54
Boom operated for lifting
(Pilot circuit)
(Main circuit)
• When the boom 2 valve spool (307) is switched, the side bypass will be closed, thus the pres-
sure at the port Px (signal port for work equipment) will increase.
• When the boom is lifted, the pilot pressure oil will be supplied to the port XAb1, and the boom 1
valve spool (303) will move to the left side as shown in Fig. 4-54. Thus, the hydraulic oil flowing
from P1 will be introduced into the neutral bypass (2) through the main passage (1). The neutral
- 4-63
bypass will be disconnected through switching of the boom 1 valve spool (303). For this pur-
pose, the hydraulic oil flowing into the parallel passage will push away the cone valve (511) of
the check valve and flow into the boom 1 valve spool (303) from the U-shaped passage. Then,
the hydraulic oil will flow to the periphery of the boom 1 valve spool (303), and will be supplied to
the boom cylinder piston head cavity (H) from the port Ab.
• At the same time, the pilot pressure oil will also be supplied to the port XAb2, and the boom 2
valve spool (307) will move to the left side as shown in Fig. 4-54. The hydraulic oil flowing from
the port P2 is cut off by switching the neutral bypass of the boom 2 valve spool (307), so that the
hydraulic oil flowing to the parallel passage flows into the boom 2 valve spool (307) via the U-
shaped passage. Then, it will push away the cone valve (511) of the check valve, and will be
converged with the port Ab and supplied to the boom cylinder piston head cavity (H), (which is
called the boom converging function)
• On the other hand, the oil returned from the boom cylinder piston rod cavity (R) will flow to the
periphery of the boom 1 valve spool (303) from the port Bb, and return to the hydraulic tank via
the tank ports R1 and R3.
4-64 -
Fig.4-55
Boom operated for lowering
(Pilot circuit)
- 4-65
• When the boom 2 valve spool (307) is switched, the side bypass will be closed, thus the pres-
sure at the port Px (signal port for work equipment) will increase. At the same time, the pressure
oil will be supplied into the port PbL, and the release signal will be sent to locking valve selector
assembly (252).
(Main circuit)
• When the boom is lowered, the pilot pressure oil will be supplied to the port XBb1, and the boom
1 valve spool (303) will move to the right side as shown in Fig. 4-55. Thus, the hydraulic oil flow-
ing from the port P1 will be introduced into the neutral bypass (2) via the main passage (1). The
neutral bypass will be disconnected through switching of the boom 1 valve spool (303). For this
purpose, the hydraulic oil flowing into the parallel passage will push away the cone valve (511)
of the check valve and flow into the boom 1 valve spool (303) from the U-shaped passage. Then,
the hydraulic oil will flow to the periphery of the boom 1 valve spool (303), and will be supplied to
the boom cylinder piston rod cavity (R) from the port Bb.
• On the other hand, the oil returned from the boom cylinder piston head cavity (H) will passes
through the hole (a) and periphery of the boom 1 valve spool (303).
• The returned oil will raise the pressure through the dead weight of the boom. To maintain suffi-
cient pressure, and the cone valve (303-317) inside the valve spool will be pushed to the right
side as shown in Fig. 4-55 via the internal passage of the valve spool so that the oil will flow out
of the valve spool. This pressure oil will be resupplied to the boom cylinder piston rod cavity (R)
as the hydraulic oil for boom lowering (which is called the boom regeneration function). A part of
the returned oil flowing from the hole (a) to the internal passage of the valve spool will return to
the hydraulic tank via the hole (b).
4-66 -
Fig.4-56
(5) Bucket
Bucket operated for digging
(Pilot circuit)
• When the bucket valve spool (304) is switched, the side bypass will be closed, thus the pressure
at the port Px (signal port for work equipment) will increase. Meanwhile, the pressure oil will also
be supplied to the port XBp2.
(Main circuit)
• When the bucket is operated for digging, the pilot pressure oil will be supplied to the port XBc,
and the bucket valve spool (304) will move to the left side as shown in Fig. 4-56. Thus, the hy-
draulic oil flowing from the port P1 will be introduced into the neutral bypass (2) via the main pas-
sage (1). The neutral bypass will be disconnected through switching of the bucket valve spool
(304). For this purpose, the hydraulic oil flowing into the parallel passage will push away the
cone valve (511) of the check valve and flow into the bucket valve spool (304) from the U-
shaped passage. Then, the hydraulic oil will flow to the periphery of the bucket valve spool
(304), and will be supplied to the bucket cylinder piston head cavity (H) from the port Bc.
- 4-67
• On the other hand, the oil returned from the bucket cylinder piston rod cavity (R) via the port Ac
will flow to the tank ports R1 and R3 from the periphery of the valve spool and return to the hy-
draulic tank.
• When the boom is lifted and the bucket is operated for digging at the same time, the pilot pres-
sure oil will be supplied to the port PAcs, thus the stroke of the bucket valve spool will not only
be limited to the full stroke position but can be limited to a halfway position. By this means, the
passage of the bucket cylinder will be throttled, and the hydraulic oil will also flow into the boom
1 valve spool (303) from the bucket valve spool (304), thus the boom lifting will be preformed
preferentially.
Fig.4-57
Bucket operated for unloading
(Pilot circuit)
• When the bucket valve spool (304) is switched, the side bypass will be closed, thus the pressure
at the port Px (signal port for work equipment) will increase. Meanwhile, the pilot pressure oil will
also be supplied to the port XBp2.
(Main circuit)
• When the bucket is operated for unloading, the pilot pressure oil will be supplied to the port XAc,
and the bucket valve spool (304) will move to the right side as shown in Fig. 4-57. Thus, the hy-
draulic oil flowing from the port P1 will be introduced into the neutral bypass (2) via the main pas-
sage (1). The neutral bypass will be disconnected through switching of the bucket valve spool
4-68 -
(304). For this purpose, the hydraulic oil flowing into the parallel passage will push away the
cone valve (511) of the check valve and flow into the bucket valve spool (304) from the U-
shaped passage. Then, the hydraulic oil will flow to the periphery of the bucket valve spool
(304), and will be supplied to the bucket cylinder piston rod cavity (R) from the port Ac.
• On the other hand, the oil returned from the bucket cylinder piston head cavity (H) via the port
Bc will flow to the tank ports R1 and R2 from the periphery of the valve spool and return to the
hydraulic tank.
Fig.4-58
Bucket converging
• When the bucket is operated for digging or unloading, the pilot pressure oil will be supplied to
the port XBp2, and the bypass cutoff valve spool (310) will be switched. Thus, the hydraulic oil
flowing from the port P2 will be introduced into the neutral bypass (4) via the main passage (3).
The neutral bypass will be disconnected through switching of the bypass valve spool (310). For
this purpose, the hydraulic oil will push away the check valve (515), and will be converged with
the bucket valve spool (304) via the internal passage and U-shaped passage.
(6) Swing
Individual swing operation
(Pilot circuit)
- 4-69
• When the swing valve spool (305) is switched, the side bypass will be closed, thus the pressure
(Main circuit)
• When the individual swing operation is performed, the pilot pressure oil will be supplied to the
port XAs (or XBs), and the swing valve spool (305) will be switched. Thus, the hydraulic oil flow-
ing from the port P2 will be introduced into the neutral bypass (4) via the main passage (3). The
neutral bypass will be disconnected through switching of the swing valve spool (305). For this
purpose, the hydraulic oil flowing into the parallel passage will push away the logic cone valve
(254-101) of the swing logic valve assembly and flow into the swing valve spool (305) from the
U-shaped passage. Then, the hydraulic oil will flow to the periphery of the swing valve spool
(305), and will be supplied to the swing motor from the port As (or Bs).
• On the other hand, the oil returned from the swing motor via the port Bs (or As) will flow to the
tank ports R1 and R2 from the periphery of the valve spool and return to the hydraulic tank.
Fig.4-59
(7) Priority function
• In case of the combined operation of the arm retraction and the swing, etc., the hydraulic oil from
the port P sufficiently flows into the work equipment at a high load, so that the operability is
improved.
4-70 -
• The following is a case where the swing operation is prioritized with respect to the arm
retraction.
(Main circuit)
• When the pressure oil is applied to the port Pna1 of the logic control valve (255), the piston
(255-356) and the spool (253-107) move upward, and the lifting amount of the cone valve (253-
101) is limited. By this means, the oil from the parallel passage to the U-shaped passage is throt-
tled, then the oil from the arm 1 valve spool preferentially flows to the swing valve spool, so that
the swing operation is prioritized.
• Similarly, when the pressure oil is applied to the port Pns of the logic control valve (255), the lift-
ing amount of the cone valve (254-101) is limited, so that the boom lifting operation is prioritized
with respect to the swing operation.
Fig.4-60
(8) Service valve
The service valve spool is used for control of hydraulic shear and other additional devices.
Service valve operation
(Pilot circuit)
• When the service valve spool (309) is switched, the side bypass will be closed, thus the pressure
(Main circuit)
• When the service valve is performed, the pilot pressure oil will be supplied to the port XAo (or
XBo), and the service valve spool (309) will be switched. Thus, the hydraulic oil flowing from the
port P2 will be introduced into the neutral bypass (4) via the main passage (3). The neutral
- 4-71
bypass will be disconnected through switching of the service valve spool (309). For this purpose,
the hydraulic oil flowing into the parallel passage will push away the cone valve (511) of the
check valve and flow into the service valve spool (309) from the U-shaped passage.
• Then, the hydraulic oil will flow to the periphery of the service valve spool (309), and will be sup-
plied to the additional device from the port Ao (or Bo).
• On the other hand, the oil returned from the additional device via the port Bo (or Ao) will flow to
the tank ports R1 and R2 from the periphery of the valve spool and return to the hydraulic tank.
Fig.4-61
Service valve converging
For the purpose of service valve converging, the pilot pressure oil will be supplied to the port
XBp1, and the bypass cutoff valve spool (310) will be switched. Thus, the hydraulic oil flowing from
the port P1 will be introduced into the neutral bypass (2) via the main passage (1). The neutral by-
pass will be disconnected through switching of the bypass cutoff valve spool (310). For this pur-
pose, the hydraulic oil will push away the cone valve (515) of the check valve, and will be
converged with the service valve spool (309) via the internal passage and the U-shaped passage.
(9) Straight travel
When the travel valve spool (301) is operated simultaneously with other valve spools.
The case where the travel valve spool (301) is operated simultaneously with the swing valve spool
(305) is considered hereinafter.
4-72 -
(When the ports XAtL, XAtr and XAs are supplied with the pilot pressure oil.)
(Pilot circuit)
• When the side bypass of the right/left travel valve spool (301) and the side bypass of the swing
valve spool on the downstream side are closed, the pilot pressure oil will be supplied from the
port PG to the port PTa for switching the straight travel valve spool (308).
(Main circuit)
• When the straight travel valve spool (308) is switched, the port P2 will be preferentially con-
nected to the right/left travel valve spool (301), and the port P1 will be preferentially connected
to the parallel passage of swing · boom 2 · service· arm 1 passage/boom 1 · bucket · arm 2 pas-
sage. For this purpose, the hydraulic oil from the port P2 will mainly flow into the ports Atl and
Atr, and will be uniformly supplied to the two travel motors.
• On the other hand, the hydraulic oil from the port P1 will be supplied to the swing motor via the
port As.
• When the pressure at the port P2 is less than that at the port P1, a part of the hydraulic oil from
the port P1 will be delivered to the P2 side. By this means, a rapid drop in the travel speed can
be prevented.
Fig.4-62
(10) Function of the locking valve
• The locking valve selector assembly (252) is mounted between the arm cylinder piston rod cav-
ity (R) and the arm 1 valve spool (302)/arm 2 valve spool (306) to reduce the internal leakage of
the valve spool due to the cylinder pressure.
• Similarly, the locking valve selector assembly (252) is also installed between the boom cylinder
piston head cavity (H) and the boom 1 valve spool (303)/boom 2 valve spool (307) to reduce the
internal leakage of the valve spool due to the cylinder pressure.
- 4-73
• The following shows the case where the boom cylinder piston head cavity (H) is supplied with
oil. (This also applies to the case where the arm cylinder piston rod cavity (R) is supplied with
oil.)
Valve spool in the neutral position

• When the boom 1 valve spool (303) and the boom 2 valve spool (307) are in the neutral position,
the valve spool (252-511) inside the locking valve selector assembly will be pressed against the
valve body (252-101) seat of the locking valve selector assembly by the preload of the spring
(252-512) as shown in Fig. 4-62.
• In this position, the hydraulic oil on the boom cylinder piston head cavity (H) will flow via the hole
(a) to pass through the periphery of the valve spool (252-511) of the locking valve selector as-
sembly, and will be pressed on the valve body seat by means of the cone valve (513) in the hole
(b). By this means, the internal leakage will be reduced.
Fig.4-63
Boom operated for lowering
• When the boom is lowered, the port PbL, XBb1 and XBb2 will be supplied with the pilot pressure
oil. Because of the pilot pressure oil, the valve spool (252-511) inside the locking valve selector
4-74 -
assembly will move to the top as shown in Fig. 4-63. With the movement of the valve spool (252-
511) inside the locking valve selector assembly, the hole (a) will be cut off, and the hydraulic oil
on the boom cylinder piston head cavity (H) won’t flow into the spring chamber (RH). In addition,
the oil in the spring chamber (RH) cavity will flow into the leaked oil circuit via the hole (b). It can
be seen that, the cone valve (513) will be jacked by the pressure of the boom cylinder piston
head cavity (H), and the function of the locking valve selector assembly (252) will be released.
Fig.4-64
Boom operated for lifting

• When the boom is lifted, the ports XAb1 and XAb2 will be supplied with the pilot pressure oil.
The cone valve (513) will be opened by the oil flowing from the boom 1 valve spool (303) and
the boom 2 valve spool (307), thus the hydraulic oil will flow into the port Ab.
(11) Function of the main relief valve
The main relief valve is mounted on the valve body A (101). Its functions are shown below.
• The hydraulic oil is filled in the cavity (a) through the holes of valve rod housing (601-101) and
valve rod (601-511) via the passage (P) to press the valve rod (601-511) against the valve rod
housing (601-101) so as to form a reliable seal.
- 4-75
• When the pressure in the passage (P) exceeds the set preload of the spring (601-521), the cone
valve (601-401) will be opened and the hydraulic oil will pass through the gap between the valve
rod housing (601-101) and the valve sleeve (601-102) from the periphery of the cone valve
(601-401) and flow to the low-pressure passage (R).
• The pressure in the cavity (a) will drop due to the opening of the cone valve (601-401), and the
valve rod (601-511) will be opened. By this means, the hydraulic oil in the passage (P) will di-
rectly flow into the low-pressure passage (R).
• When the pressure oil above 3 Mpa is supplied to the port Pz, it will push the piston (601-302) to
move leftwards and increase the set preload of the spring (601-512) so that the charge air pres-
sure state will be achieved.
Fig.4-65
(12) Function of the port relief valve
The port relief valve is installed between the cylinder port and the low-pressure passage. Beside
the functions of an relief valve, it also has the functions of an anti-cavitation oil supplement check
valve. Its functions are shown below.
Functions as an relief valve

• The hydraulic oil is filled in the cavity (B) through the hole (A) of the piston (301) to press the
valve rod (511) against the valve seat (541) and the valve seat (541) is pressed against the valve
body seat so as to form a reliable seal.
4-76 -
Fig.4-66
• When the pressure in the passage (P) exceeds the preload of the spring (621), the cone valve
(611) will be opened and the hydraulic oil will flow to the low-pressure passage (R) via the hole
(C) from the periphery of the cone valve (611).
Fig.4-67
• The pressure in the cavity (B) will drop due to the opening of the cone valve (611), and the valve
rod (511) will be opened. By this means, the hydraulic oil in the passage (P) will directly flow into
the low-pressure passage (R).
- 4-77
Fig.4-68
• Functions as an anti-cavitation oil supplement check valve
When negative pressure occurs in the passage (P), the hydraulic oil will be supplied from the pas-
sage (R). When the pressure in the passage (R) is higher than that in the passage (P), the valve
seat (541) will move to the right. Then, the hydraulic oil will flow into the passage (P) from the pas-
sage (R) through the periphery of the valve seat (541) so as to prevent cavitation.
Fig.4-69

4.6.1 Swing motor
Model: M5X180CHB-10A-3NA/265
4-78 -
Fig.4-70
Table 4–1 Technical Specifications
M5X180CHB-10A-
Model
3NA/265
Theoretical
180.1 cm3/rev
displacement
Set pressure of relief
26.0 MPa
valve
Max. swing speed 1470 rpm
Brake release
2.7-4.9 MPa
pressure
- 4-79
A：Main oil port 1. Relief valve

B：Main oil port 2. Damping valve
M：Oil supplement port
PA：Pressure check port
PB：Pressure check port
DR：Lubricating oil port
PG：Brake release port
SH：Brake command port
LAR：Breather port
IP：Gear oil supply port
4-80 -
- 4-81
1. Spacer bushing 6. Check valve spring 11. Plate

2. Shell 7. Check valve 12. Piston
3. Disc 8. Port plate 13. Driving shaft
4. Brake spring 9. Cylinder barrel
5. Casing 10. Brake piston
4.6.2 Swing retention brake
• The PG port is directly connected to the pilot gear pump under the pressure of 3.9 MPa;
Fig.4-71
• The port SH is connected with the port PX of the main valve, therefore, if the movements except
traveling are performed on the main valve, a pressure will be created at the port PX to connect
PG with the oil cavity a under the piston 7, and the hydraulic oil will push the brake piston up-
ward, compress the brake spring 1 and separate the disk 5 from the plate 6, thus the brake will
be released.
4-82 -
Fig.4-72
• Otherwise, no pressure will be generated at the port PX, therefore, PG will be disconnected from
the oil cavity a under the piston 7, the brake spring 1 will push the brake piston, and the disc 5
and the plate 6 will be pushed together, thus the brake will be applied.
Relief valve part
Structure
• The relief valve part includes relief valves (1) and (2) and check valves (3) and (4).
Function
• When the machine is in the swing retention mode, the control valve (5) will close the motor outlet
oil circuit, but the motor will continue to rotate due to the inertial force, so the motor output will
abnormally increase, which will cause motor damage.。
• To prevent motor damage, the relief valve will overflow the pressure oil at an abnormally high
pressure to the oil port (M) from the motor outlet side (high-pressure side).
- 4-83
Operation
1. In case of start of swing (assuming the

oil port A is filled with high-pressure oil)
• When the swing control lever is operated to
the right swing position, the pressure oil
from the pump will be supplied to the port
(A) through the control valve (5).
• When the starting torque is generated in-
side it due to the increase of pressure at the
oil port (A), the motor will start to rotate
• The pressure oil from the motor outlet will
return from the oil port (B) to the tank via
the control valve (5).
Fig.4-73
1. 2. In case of stop of swing

• When the swing control lever returns to the
neutral position, the supply of pressure oil
from the pump to the oil port (A) will be
interrupted.
• The pressure oil from the motor outlet will
not return to the tank because the oil circuit
between the control valve (5) and the tank
is closed, thus leading to increase in the
pressure at the port (B).
• When the swing resistance is generated on
the motor, the brake will start to work.
• When the pressure at the port (B) increases
to the set value of the relief valve (2), relief
will occur.
• The motor with a large brake torque applied
Fig.4-74
on it will stop running.
• When the relief valve (2) starts to work, the
overflown pressure oil and the pressure oil
from the oil port (M) will be supplied to the
oil port (B) via the check valve (4).
• The oil port (B) is protected against cavita-
tion under the above conditions.
4-84 -
Damping valve
Working diagram
1. Valve body
2. Spool valve (on side A)
3. Spring (on side A)
4. Plug
5. Spool valve (on side B)
6. Spring (on side B)
7. Plug
- 4-85
Effect illustration diagram
Fig.4-75
Overview
• The machine may shake during rotation

due to the inertia of swing body, recoil force
and rigidity of mechanical system, compres-
sibility of hydraulic oil, etc. The anti-swing
valve can effectively mitigate this effect. It
can be effectively used to prevent the over-
flow of the load in the bucket and reduce
the cycle time when rotation stops (the
good positioning performance ensures rap-
id movement for the next operation.)
Fig.4-76
4-86 -
Operation
1. In case of generation of the brake pressure

at the oil port (B)
• The pressure MB is generated in the oil
cavity d through the notch, and the valve
spool pushes the spring (6) leftwards by the
area difference of D1>D2. Then B is con-
nected to e. In this case, the pressure A is
less than the set pressure of the spring (3),
therefore, the spool valve (2) will not move
and then will obstruct the hydraulic oil, thus
ensuring the braking.
Fig.4-77
2. After stop of the motor

• The closing pressure is generated through
the oil port B, leading to motor reversing
(the first reversing). In this case, reversing
pressure will be generated at the oil port A.
Pressure A is generated in the oil cavity a,
such that the spool valve (2) pushes the
spring (3) rightwards, thus connecting A to
B. In this case, b is connected to f through
the orifice on the valve spool (5). Therefore
the reversing pressure of the oil port A will
be bypassed to the port T to prevent the
second reversing. Fig.4-78
- 4-87
4.6.3 Central swivel joint
Fig.4-79
1. Bolt 9. O-ring
2. O-ring 10. Skeleton dust ring
3. Cover 11. Swing shaft
4. O-ring 12. Tapered plug
5. Washer 13. Hexagon socket head bolt
6. Retaining ring 14. Plain washer
7. Swing seal ring (CSI) 15. Dust ring
8. Swing body
4-88 -
4.6.4 Travel motor (Nabtesco)
Model: GM70VA
Fig.4-80
A：Main oil port
B：Main oil port
Am：Pressure check port
Bm：Pressure check port
Pi：2-speed pilot pipe port
Dr：Oil drain port
- 4-89
Structure
The motor consists of the following main components:

• Drive train that produces swing force.
• Anti-slip parking brake.
• Variable mechanism for switching the motor capacity.
• Relief valve assembled in the motor control valve.
• Brake valve components (balance valve) that mainly control the hydraulic oil circuit.
4-90 -
Fig.4-81
Action description
Working principle of motor

• The high-pressure hydraulic oil from the hydraulic pump enters via the oil ports (VA, VB) and
flows into the cylinder block (3) through the brake valve assembly, motor cover (2) and port plate
(8).
- 4-91
The high-pressure oil acts on the right pistons within the range of 180° of the Y-Y line from TDC to
BDC as shown in the figure below.
F1=P×A (P: pressure, A: piston area)
The F1 force is divided into a component force F2 perpendicular to the slope and the radial compo-
nent forces F31~F34 (or F35) according to the inclination angle of the swashplate.
These radial component forces act as the swing forces on the Y-Y axis, resulting in the torque of
T=r1•F31+r2•F32+r3•F33+r4•F34.
(Additional F35 when 5 pistons are used for high pressure)
This torque is transmitted to the spline of the spindle (9) through the cylinder block (3) and finally
transmitted to the spindle (9).
Fig.4-82
Principle of parking brake
• The parking brake is released when the high-pressure oil from the balancing valve assembly di-
rectly assembled in the motor cover (2) acts on the piston brake (6). The brake torque always
exists when there is no pressure. This braking torque is generated by the friction between the
meshing plate (7) inserted into the housing (1) and the friction plate (5), and is transmitted to the
cylinder block (3) through the spline of the cylinder block. When no pressure acts on the piston
brake (6), the piston brake (6) will be held by the brake spring (30) and will push the meshing
plate (7) and the friction plate (5) toward the housing (1). And the generated friction force will
push the rotating cylinder block (3) to drive the spindle (9) to generate the braking torque.
4-92 -
Fig.4-83
High/low speed switching process
• The high speed travel command PA acts on the end face of the spool (41-2) to generate a thrust
to the right. If the thrust overcomes the leftward pressure of the spring (41-7), the spring will be
compressed and the spool (41-2) will move to the right to connect P and C. The highest pressure
is introduced from the motor ports MA and MB through the check valve (17) to the 2-speed pis-
ton (21). Therefore, the swashplate (11) is turned over along the L line formed by the two spheri-
cal hinges (12) until the swashplate hits the stopper (1-1). At this time, the displacement of the
- 4-93
piston (14) is reduced to become a small-capacity motor. So it can run at high speed without re-
fueling the oil pump. The capacity ratio of this model is 1.53.
On the contrary, if there is no pressure on the high speed travel command PA, the spool (41-2) will
return to the left by the spring (41-7) force. Then the oil introduced into the 2-speed spool (41-2)
will return to the tank through the throttle valve (41-12). Then the thrust of the 2-speed piston (21)
will disappear. The nine pistons (14) are evenly distributed on the swashplate (11) and pressed
against the swashplate (11). The force formed is almost at the center of the swashplate (11) as
shown in the figure. The spherical hinge (12) is at a position offset from the center S. The rotational
force generated by the thrust of the S and the piston causes the swashplate to return to its original
position and the switching to the low speed travel.
If the specified pressure is exceeded, the reaction force of the pin (41-6) will return the spool (41-
2) to the left. The oil pressing against the 2-speed piston (21) will return to the tank. Then the
swashplate will be tilted to become a large-capacity motor and the low speed travel will be
switched. And once this pressure is lower than the specified value, the spool (41-2) will return to
the right and the high speed travel will be switched.
Fig.4-84
Working principle of relief valve
Two relief valves are configured to serve the following functions:
• When the hydraulic motor is stopped, the brake pressure generated on the motor discharge side
is kept below a certain value in order to prevent the load inertia.
4-94 -
• When the hydraulic motor is started, it is driven by the set pressure to maintain rapid accelera-
tion, and when it is to be stopped, it is slowed down by the brake and the pressure is reduced for
a short time. Then the meshing of the reducer, the track and carrier roller assembly and other
components are smoother, and the circuit pressure is maintained within the set pressure to buf-
fer the charge air pressure.
When the hydraulic motor is running, if the pressure of the relief valve port A rises, this pressure
acts on the effective diameter of the valve seat (40-3) of the valve (40-2) and passes through the
small hole of the valve (40-2) to act on the connecting piston (40-4) inside the valve and rise to the
port A pressure, and the valve (40-2) overcomes the adjusting spring (40-9) by the difference in
the area between the effective diameter of the valve seat and the hole diameter of the connecting
piston so as to reach the specified set pressure.
When the hydraulic motor is braked, the rear piston (40-7) will be on the left side due to the drive
pressure. If the pressure at the port A rises, it will pass through the small holes of the valve and the
connecting piston (40-2) to act on the piston (40-7), and the piston will move to the right until it hits
the housing. During this time, the valve (40-2) will maintain a relatively low pressure at the port A
to overcome the adjusting spring (40-9) and drain the oil via the port B. When the piston hits the
housing, it works in the same way when the motor is started.
Fig.4-85
- 4-95
Motor parts maintenance criteria
4-96 -
- 4-97
4-98 -
4.7 Control system

4.7.1 summarize
Fig.4-86 Position of travel lever
1. Travel pilot valve 7. Transitional block 1. Holding 8. Arm ”extension“

2. Left travel lever 8. Hydraulic pump 2. Boom “lifting” 9. Swing - rightward
3. Right travel lever 9. Main control valve 3. Boom “lowering” 10. Swing - leftward
4. Right PPC valve 10. Solenoid valve 4. Bucket ‘unloading“ 11. Neutral
5. Right joystick 11. Left joystick 5. Bucket ‘digging” 12. Travel “reverse”
6. Accumulator 12. Left PPC valve 6. Holding 13. Travel ”forward“
7. Arm “retraction”
- 4-99
4.7.2 Manual pilot valve
Fig.4-87
4-100 -
P ：From the pilot pump relief valve

P1 ：Left pilot valve: arm extension/right pilot valve: boom lowering
P2 ：Left pilot valve: arm retraction/ right pilot valve: boom lifting
P3 ：Left pilot valve: leftward swing/right pilot valve: bucket digging
P4 ：Left pilot valve: rightward swing/right pilot valve: bucket unloading
T ：To the tank
Fig.4-88
- 4-101
1. Valve rod 6. Nut (for control lever connection)

2. Adjusting spring 7. Connector
3. Central spring 8. Plate
4. Piston 9. Positioner
5. Disc 10. Valve body
Operation
1. In the neutral position

• The oil ports (A) and (B) of the control valve
and the oil ports (P1) and (P2) of the PPC
valve will be connected to the discharge
cavity (D) through the flow groove (f) of the
valve rod (1).
Fig.4-89
4-102 -
2. Fine control (neutral → fine control)

• When the piston (4) is pushed by the disc
(5), the positioner (9) will be pushed, and
the valve rod (1) will also be pushed to
move downward by the adjusting spring (2).
• When the flow groove (f) is disconnected
from the discharge cavity (D), it will be inter-
connected with the pump pressure cavity
(PP) almost at the same time. The pilot
pressure of the control pump will be guided
from the oil port (P1) to the oil port (A) via
the flow groove (f). When the pressure at
the oil port (P1) becomes higher, the valve
rod (1) will be pushed back, and the flow
groove (f) will be disconnected from the
pump pressure cavity (PP) and connected
with the discharge cavity (D) almost at the
same time to release the pressure at the oil
port (P1). As a result, the valve rod (1) will
Fig.4-90
move upward and downward until the force
of the adjusting spring (2) is balanced with
the pressure at the oil port (P1).
• The valve rod (1) and valve body (10) flow
groove (f) will be in the middle of the dis-
charge cavity (D) and the pump pressure
cavity (PP), which will remain unchanged
before the positioner (9) contacts with the
valve rod (1). The adjusting spring (2) will
contract in direct proportion to the stroke of
the control lever. The pressure at the oil port
(P1) will also increase in direct proportion to
the stroke of the control lever. In this way,
the control valve rod will move to the bal-
ance position of the cavity (A) pressure (the
same as the pressure at the oil port (P1))
and the return spring force.
- 4-103
3. Fine control (when the control lever returns)

• When the disc (5) starts to return, the valve
rod (1) will be pushed upward by the force
of the central spring (3) and the pressure at
the oil port (P1) .
• Therefore, the flow groove (f) will be con-
nected with the discharge cavity (D) to dis-
charge the pressure oil at the oil port (P1).
• If the pressure at the oil port (P1) drops ex-
cessively, the valve rod (1) will be pushed
downward by the adjusting spring (2).
• The flow groove (f) will be disconnected
from the discharge cavity (D) and intercon-
nected with the pump pressure cavity (PP)
almost at the same time. A pressure will be
provided before the pressure at the oil port
(P1) returns to a level corresponding to the
position of the control lever.
• When the control valve rod returns, the oil Fig.4-91
in the discharge cavity (D) will flow in from
the flow groove (f) in the valve on the non-
operating side. The oil will pass through the
oil port (P2) and flow into the cavity (B) to
replenish the cavity with pressure oil.
4-104 -
4. Full stroke
• The disc (5) will push the piston (4) down-
ward, and the positioner (9) will push the
valve rod (1) downward.
• The flow groove (f) will be disconnected
nected with the pump pressure cavity (PP).
• Therefore, the pressure oil from the reduc-
ing valve will pass through the flow groove
(f) and flow to the cavity (A) from the oil port
(P1) so as to push the control valve rod.
• The oil returned from the cavity (B) will flow
to the discharge cavity (D) from the oil port
(P2) through the flow groove (f).
Fig.4-92
- 4-105
4.7.3 Travel pilot valve
Fig.4-93
P： From the pilot pump P4：Right travel forward

P1：Left travel backward P5：Travel signal
P2：Left travel forward P6：Travel signal
P3：Right travel backward T： To the tank
4-106 -
Fig.4-94
1. Retaining plate 5. Central spring

2. Valve body 6. Adjusting spring
3. Piston 7. Valve
4. Grommet
Working process
Operation
- 4-107
1. In the neutral position

• The oil ports (A) and (B) of the control valve
and the oil ports (P1) and (P2) of the PPC
valve will be connected to the discharge
cavity (D) through the fine control hole (f) of
the valve rod (1).
Fig.4-95
2. Fine control (neutral → fine control)

• When the piston (4) is pushed by the disc
(5), the positioner (9) will be pushed, and
the valve rod (1) will also be pushed to
move downward by the adjusting spring (2).
• When the fine control hole (f) is discon-
nected from the discharge cavity (D), it will
be interconnected with the pump pressure
cavity (PP) almost at the same time.
• The pilot pressure of the control pump will
be guided from the oil port (P1) to the oil
port (A) via the fine control hole (f).
• When the pressure at the oil port (P1) be-
comes higher, the valve rod (1) will be
pushed back, and the fine control hole (f)
Fig.4-96
will be disconnected from the pump pres-
sure cavity (PP) and connected with the dis-
charge cavity (D) almost at the same time
to release the pressure at the oil port (P1).
• As a result, the valve rod (1) will move up-
ward and downward until the force of the
adjusting valve rod (2) is balanced with the
pressure at the oil port (P1).
• The position of valve rod (1) and valve body
(10) [the fine control hole (f) in the middle of
the discharge cavity (D) and the pump
4-108 -
pressure cavity (PP)] will remain un-

changed before the positioner (9) contacts
with the valve rod (1).
• The adjusting spring (2) will contract in di-
rect proportion to the stroke of the control
lever.
• The pressure at the oil port (P1) will also in-
crease in direct proportion to the stroke of
the control lever.
• In this way, the control valve rod will move
to the balance position of the cavity (A)
pressure (the same as the pressure at the
oil port (P1) and the return spring force.
3. Fine control (when the control lever returns)

• When the disc (5) starts to return, the valve
rod (1) will be pushed upward by the force
of the central spring (3) and the pressure at
the oil port (P1).
• Therefore, the fine control hole (f) will be
connected with the discharge cavity (D) to
release the pressure oil at the oil port (P1).
• If the pressure at the oil port (P1) drops ex-
cessively, the valve rod (1) will be pushed
downward by the adjusting spring (2).
• The fine control hole (f) will be disconnected
nected with the pump pressure cavity (PP)
almost at the same time.
• A pressure will be provided before the pres-
sure at the oil port (P1) returns to a level Fig.4-97
corresponding to the position of the control
lever.
• When the control valve rod returns, the oil
in the discharge cavity (D) will flow in from
the fine control hole (f) in the valve on the
non-operating side. The oil will pass
through the oil port (P2) and flow into the
cavity (B) to replenish the cavity with pres-
sure oil.
- 4-109
4. Full stroke
• The disc (5) will push the piston (4) down-
ward, and the positioner (9) will push the
valve rod (1) downward.
• The fine control hole (f) will be disconnected
nected with the pump pressure cavity (PP).
• Therefore, the pressure oil from the reduc-
ing valve will pass through the fine control
hole (f) and flow to the cavity (A) from the oil
port (P1) so as to push the control valve
rod.
• The oil returned from the cavity (B) will flow
to the discharge cavity (D) from the oil port
(P2) through the fine control hole (f). Fig.4-98
4.7.4 Solenoid valve
Fig.4-99
4-110 -
1. Solenoid valve group P1: To pilot filter

2. Accumulator P2: To main valve port PG
3. High speed travel solenoid valve T: To tank
4. Service valve A1: To swing joint port X
5. Service valve A2: To pilot lines block P
6. Bucket converging solenoid valve
7. Spare
8. Pilot pressure solenoid valve
4.7.5 PPC accumulator
Fig.4-100
1. Air plug
2. Hosing
- 4-111
3. Seat valve spool
4. Retainer
5. Bag
6. Oil port
Gas quantity: 300 cc (for PPC)
4.7.6 Pilot oil filter
Fig.4-101
4-112 -
1. Nameplate Technical Specifications

2. Top cap Maximum flow: 40 L/min
3. O-ring Filtering precision: 10 um
4. Seal ring Operating pressure: 20 Mpa
5. Filter Maximum operating pressure: 40 Mpa
6. Hosing Pressure loss: 0.05 Mpa
Maximum allowable differential pressure: 1
Mpa
Oil inlet/outlet O-ring specification: 30×3.1
4.7.7 Hydraulic cylinder
Boom cylinder
Fig.4-102
Arm cylinder
Fig.4-103
Bucket cylinder
- 4-113
Fig.4-104
4-114 -
4.8 Work equipment

4.8.1 Part size
Fig.4-105
- 4-115
Fig.4-106
Lubrication
4-116 -
4.8.2 Arm size
Fig.4-107
- 4-117
4-118 -
4.8.3 Bucket size
Fig.4-108
- 4-119
4-120 -
4.9 A/C system

4.9.1 summarize
Fig.4-109
- 4-121
1. A/C unit A: Fresh air

2. Hot water pumping pipe B: Recirculation air
3. A/C compressor C: Warm/cold air
4. Refrigerant pipe
5. Condenser
6. Hot water return pipe
7. Duct
4.9.2 Layout of A/C elements
Fig.4-110
1. Sunlight sensor 5. Compressor

2. Control panel 6. Fresh air sensor
3. A/C unit 7. Recirculation air sensor
4. Condenser
4-122 -
4.9.3 A/C control panel
Fig.4-111
1. OFF switch 5. Automatic mode setting switch

2. Fan speed setting switch 6. Recirculation/fresh air selector switch
3. Temperature setting switch 7. LCD display zone
4. Vent mode setting switch 8. A/C switch
- 4-123
4.9.4 Schematic circuit diagram
Fig.4-112
4-124 -
4.9.5 A/C cooling principle
Schematic diagram of refrigeration cycle
- 4-125
Fig.4-113
Schematic diagram of heating cycle
Fig.4-114
4-126 -
4.9.6 Compressor
Fig.4-115
1. Stator 9. Slipper
2. Front radial bearing 10. Front cylinder block
3. Thrust bearing 11. Piston
4. Rear radial bearing 12. Front cylinder head
5. Rear cylinder head 13. Shaft seal
6. Relief valve 14. Spindle
7. Rear cylinder block 15. Hub
8. Swashplate 16. Rotor
Working principles
The 10S15C compressor is used. 5 pistons are totally provided for the compressor, one piston is
installed before and behind each piston respectively, thus 10 pistons are equipped in total (5 are
arranged before and behind the piston respectively). The rotation of the swashplate causes the
- 4-127
piston to reciprocate to change the low-temperature and low-pressure gaseous refrigerant sucked
from the evaporator into a high-temperature and high-pressure one.
Fig.4-116
4-128 -
4.9.7 Clutch
1. Clutch rotor
2. Stator coil (14.4 Ohm)
3. Snap ring
4. Ball bearing
5. Clutch stator
6. Central plate
Fig.4-117
• The electromagnetic clutch is used to transfer torque. When the engine is running, the compres-
sor may not work. The electromagnetic clutch will control the compressor to work only when the
A/C is in the refrigeration mode.
• Working principle
When the A/C switch is turned on, the clutch coil with electromagnet will be charged to generate a
magnetic field to stick the iron plate so that the clutch stator and rotor will be combined together to
drive the compressor spindle to rotate.
4.9.8 Condenser
Fig.4-118
- 4-129
1. Condenser core Function

2. Condenser bracket • It converts the high-temperature and high-
3. Bolt with washer pressure gaseous refrigerant (16 kg/cm2,
4. Refrigerant inlet about 80°C) to a high-temperature and high-
5. Refrigerant outlet pressure liquid refrigerant (16 kg/cm2, about
60°C or below).
4.9.9 Expansion valve
1. Spring
2. Membrane
3. Temperature sensing rod
4. Needle valve
Principle
• The refrigerant from the reservoir is injected

from the orifice and rapidly expands, thus it
becomes a low-temperature and low-pres-
sure liquid (mist) and flows into the
evaporator.
Fig.4-119
4.9.10 Evaporator
1. Expansion valve
2. Evaporator
Principle
• The evaporator and condenser with a simi-

lar structure are a heat exchanger. The hot
air in the cab is sent to the evaporator by
the blower motor, and exchanges heat with
the evaporator surface. The heat absorbed
becomes cold air, and is sent back to the
cab through each air duct. The evaporator
surface absorbs heat → the refrigerant in
Fig.4-120
the evaporator absorbs heat → the
4-130 -
refrigerant evaporates. The evaporated re-

frigerant (gas) is sucked away by the
compressor.
4.9.11 Dryer
1. Inlet
2. Outlet
3. Receiver/Dryer
4. Drying agent
Function
• Temporarily store the refrigerant

• Remove water from the refrigerant
• Filter dust in the refrigerant
• Check the refrigerant quantity
Fig.4-121
- 4-131
4.9.12 Pressure switch
1. O-ring
2. Movable contact
3. Cover
4. Plug and fixing contact
5. Spring
6. Cavity
7. Diaphragm
Purposes:
• The pressure switch is a combination switch

(high- and low-voltage combination switch)
installed between the reservoir and the ex-
pansion valve (high-pressure pipe).
Fig.4-122
• When the pressure is too high, the com-
pressor will stop.
• When the pressure is too low, the low tem-
perature environment will terminate.
Action features:
Characteristic
High-pressure action value
Low-pressure action value
Medium pressure action

value
4-132 -
4.9.13 Fresh air sensor
The ambient temperature sensor is installed

beside the condenser or at the fresh air inlet
to measure the ambient temperature and is
composed of a thermistor.
Technical parameters
Description Specification
Operating voltage 4.4~5.6 V
range
Operating tempera- -30~60 ℃
ture range
Storage temperature -40~90 ℃
range
Fig.4-123
Resistance value 1700±85Ω
value 1700±85Ω 3900±195 K
Allowable operating 1.6 mA （MAX）
current
4.9.14 Refrigerant
1. General characteristics of refrigerant
• Strong heat absorptivity, easy to be liquefied

• Incombustible and non-explosive
• Stable chemical composition, non-deteriorated
• Non-toxic
• Non-corrosive
• No damage to clothing
2. Refrigerant circulation
• After evaporating in the evaporator, the refrigerant is changed from gas to liquid by the compres-
sor and condenser, thus it is circulated.
- 4-133
Fig.4-124
4-134 -
3. Refrigerant filling
• Refrigerant filling method and quantity:

（1）Refrigerant: HFC-134a;
（2） Refrigerant filling quantity: 900 ±50 g
(for reference only);
（3） Refrigerant filling method: Do not fill
the liquid refrigerant from the low-pressure
side. If re-operation is required due to fail-
ure, the filled refrigerant must be dis-
charged and then refilled.
Fig.4-125
• Check the flow state of the refrigerant in the

A/C circulation system through the sight
glass:
（1） Appropriate filling: Almost no bubbles

are seen when the refrigerant flows. When the
engine is gradually accelerated from idle to
1,500 rpm, the bubbles disappear and the re-
frigerant is transparent;
（2） Excessive filling: No bubbles are seen

when the refrigerant flows;
（3） Insufficient filling: Bubbles are usually

seen when the refrigerant flows.
Fig.4-126
4. Vacuumization
• Causes of vacuumization
The most important thing when installing the

A/C unit is that there shall be no water inside
the unit. The refrigerant (R134a) used is
easily soluble in water. If a small amount of
water remains in the unit, it will freeze in the
small hole of expansion valve, the compressor
valve will be rusted, etc., so it is necessary to
remove the moisture from the cooling system
as much as possible before filling the refriger-
ant. To minimize residual water in the cooling
system, the best way is to remove water in the
- 4-135
unit by gasifying it through boiling by means

of vacuumization.
• Steps of vacuumization
（1） Connection of the manifold pressure
gauge;
i) Close the high-pressure valve (HI) and
low-pressure valve (LO) of the manifold
pressure gauge.
ii) Connect the charging hose (red, blue) to
the compressor auxiliary valve.
Red hose - High-pressure side (mark D)
Blue hose - Low-pressure side (mark S)
★ Press the compressor auxiliary valve on
the side with a L-shaped bend at the front
end of the compressor. If the auxiliary valve
on the opposite side is pressed, the internal Fig.4-127
valve of the compressor won’t be opened.
In addition, be careful not to reverse the
high-pressure and low-pressure parts.
iii) Connect the charging hose (green) in the
middle of the manifold pressure gauge to
the vacuum pump.
（2） Vacuumization
i) Open the high-pressure valve (HI) and
low-pressure valve (LO) of the manifold
pressure gauge;
ii) Turn on the vacuum pump switch and
perform vacuumization (for about 15 min);
iii) When the negative pressure scale (i. e.
vacuum level) on the pressure gauge
reaches above 750 mmHg, disconnect the
vacuum pump switch, and close the high-
pressure valve and low-pressure valve of
the manifold pressure gauge .
4-136 -
（3） Airtightness inspection
i) Place the closed high- and low-pressure

valves of the manifold pressure gauge for
more than 5 min, and confirm that the pres-
sure reading doesn’t return to zero;
ii) When the pointer of the pressure gauge re-

turns near 0, it means there is leakage. There-
fore, the pipe joint must be further corrected
and tightened, and then vacuumization shall Fig.4-128
be performed again until there is no leakage.
（4） Air leakage inspection
i） Connect the charging hose (green) origi-

nally connected to the vacuum pump to the
fluorine tank;
ii） Connect the charging hose (green) to the

manifold pressure gauge, open the fluorine
tank valve, press the bleed valve of the pres-
sure gauge (be careful not to press it directly
by hand so as to prevent freezing injury
caused by refrigerant injection), and dis-
charge the air in the charging hose by means
of the refrigerant pressure (release the bleed
valve when hearing sizzle);
Fig.4-129
iii） When the high-pressure valve of the

manifold pressure gauge is opened, add the
refrigerant until the low pressure gauge read-
ing reaches 1 kgf/cm2, and close the high-
pressure valve after filling;
iv） For the sake of caution, check the cooling

system for air leakage with a leak detector;
v） If there is leakage, repair the leaky part

(tighten it).
Fig.4-130
5. Refrigerant filling
- 4-137
• After vacuumization is completed, it is necessary to add the refrigerant into the cooling system
as per the following essentials:
Filling from the high-pressure side:
（1） Remove the charging hose (green) of

the manifold pressure gauge from the vacuum
pump and connect it to the fluorine tank;
（2） Open the fluorine tank valve, press

down the bleed valve on the side of the mani-
fold pressure gauge, and discharge the air in
the charging hose by means of the refrigerant
pressure;
Release the bleed valve when sizzle is

heard after the refrigerant is discharged. Do
not press the bleed valve directly by hand so
as to prevent freezing injury. Fig.4-131
（3） When the engine isn’t in operation,

open the high-pressure valve of the manifold
pressure gauge and the fluorine tank valve,
and add one and a half tank of refrigerant
(about 600 g).
In this case, do not run the compressor.

Once it is in operation, the fluorine tank and
hose may be damaged due to the return of
the refrigerant, which will lead to dangers.
Do not run the compressor when there isn't

refrigerant, otherwise, the compressor will be
burnt.
Fig.4-132
Do not open the low-pressure valve of the
manifold pressure gauge (the compressor
4-138 -
may be damaged if liquid compression

occurs).
（4） Close the high-pressure valve of the

manifold pressure gauge and the fluorine tank
valve.
• Filling from the low-pressure side (supple-

mentary filling):
（1） First, confirm that the high-pressure

valve of the manifold pressure gauge is
closed;
（2）Start the engine and open all the doors;
（3）Turn on the A/C switch; set the tempera-

ture control at "MIN"; Fig.4-133
（4） Set the engine speed to 1,300~1,500

rpm;
（5） During refrigerant filling, open the low-

pressure valve of the manifold pressure
gauge and the fluorine tank valve, and add
the refrigerant until no bubbles are seen in the
reservoir;
Note:
Manifold pressure gauge reading (for refer-

ence only): High pressure 13~17 kg/cm2 (at
ambient temperature of 30° C); low pressure
1.5~2 kg/cm2 (at ambient temperature of 30°
C).
（6） Close the low-pressure valve of the

manifold pressure gauge and the fluorine tank
valve after refrigerant filling.
（7） Carefully check whether there is leak-

age with a leak detector.
Do not open the high-pressure valve (HI) of

Fig.4-134
the manifold pressure gauge. If the high-pres-
sure valve is opened, the high-pressure gas
will flow reversely, and the fluorine tank and
charging hose will crack, which may lead to a
danger (or cause major injury);
- 4-139
Do not put the fluorine tank upside down.

(The refrigerant is added when the engine is
started). If the fluorine tank is put upside
down, the liquid refrigerant will be directly
sucked into the compressor so that liquid
compression will occur, which will damage the
compressor valve and bushing. It is required
that the fluorine tank should be placed verti-
cally and the refrigerant in the gaseous state
should be added.
（8）At a low ambient temperature
If refrigerant filling can’t be performed at a low

ambient temperature, it is necessary to put
the fluorine tank in warm water below 40°C to
increase the pressure of the refrigerant in the
fluorine tank.
（9）At a high ambient temperature
On the contrary, if the fan is used to cool the

compressor at a high ambient air temperature,
the filling operation can be performed
smoothly.
Fig.4-135
4-140 -
• Replacement of the fluorine tank:
If the refrigerant in the fluorine tank is used up

during filling, the fluorine tank can be replaced
as per the following essentials.
（1） Close the high-pressure valve and low-

pressure valve of the manifold pressure
gauge;
（2） Raise the pin and circular plate of the

fluorine tank valve, and remove the empty
tank;
（3） Install a new fluorine tank on the fluo-

rine tank valve; Fig.4-136
（4） Remove the air inside the charging

hose as per the following methods:
i) Tighten the fluorine tank valve, and then

loosen it slightly;
ii) Open the low-pressure valve of the mani-

fold pressure gauge slightly;
iii) Press the bleed valve while discharging the

refrigerant, and immediately close the fluorine
tank valve and the low-pressure valve of the
manifold pressure gauge.
★ Do not press the bleed valve directly by

hand so as to prevent freezing injury. Fig.4-137
（5） Do not press the bleed valve directly by

hand so as to prevent freezing injury.
6. Fault detection with the manifold pressure gauge
After engine warm-up, it is necessary to read the pressure value of the manifold pressure gauge
under the following specific conditions.
1） The temperature at the air inlet is 30~35°C.
2） The engine speed is 1,500 rpm.
3） The fan speed is high.
4） The temperature control is set at MIN.
5）The "Repeated Circulation‖ is set.

- 4-141
• Readings of the cooling system meter in normal state:
Readings of the meter:
Low-pressure end: 0.15~0.25 MPa (1.5~2.5 kg·f/cm2)
High-pressure end: 1.37~1.57 MPa (14~16 kg·f/cm2)
Fig.4-138
• Water in the refrigeration system
Condition: Intermittent refrigeration, finally no refrigeration
Fig.4-139
4-142 -
Symptom of Troubleshooting
Possible cause Diagnosis
refrigeration system method
• When the system is • Water in the refrig- • The dryer is in a • Replace the re-
running, vacuum or eration system supersaturation ceiver/dryer.
normal pressure ex- freezes at the ex- state. • Remove water from
ists at the low-pres- pansion valve, • Water in the refrig- the system by
sure end. which causes tem- eration system means of continu-
porary stop of the freezes at the ex- ous pumping.
circulation. How- pansion valve, • Add a proper
ever, when the ice which hinders the amount of new
melts, the system circulation of the re- refrigerant.
returns to the nor- frigeration system.
mal state.
• Insufficient refrigeration
Condition: Insufficient refrigeration
Fig.4-140
- 4-143
• The pressures at • Gas leakage occurs • There isn’t enough • Check whether
the highand low- in a certain part of refrigerant in the there is gas leakage
pressure ends are the refrigeration system. with a leak detector,
relatively low. system. • Refrigerant leakage and repair the leaky
• Bubbles are contin- occurs. part if necessary.
uously seen • Add a proper
through the sight amount of
glass. refrigerant.
• Insufficient • If the pressure val-
refrigeration. ue approximates to
0 when the meter is
connected, set the
system in vacuum
state after inspec-
tion and repair.
•Poor refrigerant circulation

Fig.4-141
4-144 -
• The pressures at • Dirt in the reservoir • The reservoir is • Replace the

the high- and low- hinders the refriger- blocked. reservoir
pressure ends are ant flow.
relatively low.
• Frost is formed on
the pipes from the
parts to the
reservoir.
• No refrigerant circulation
Symptom: No refrigeration (intermittent refrigeration in some cases)
Fig.4-142
- 4-145
• Vacuum appears at • Moisture and dirt in • The refrigerant • Check the expan-
the low-pressure the refrigerant hin- does not circulate. sion valve and
end and the pres- der the refrigerant EPR.
sure at the high- flow. • Remove dirt in the
pressure end is ex- • Gas leakage in the expansion valve by
tremely low. expansion valve blowing. If this does
• Frost or dew is thermo-sensitive not work, replace
formed on the pipes pipe hinders the re- the expansion
before and behind frigerant flow. valve.
the expansion valve • Replace the
or receiver/dryer. receiver.
• Remove air by
pumping and add a
proper amount of
refrigerant. If the
thermo-sensitive
pipe leaks gas, re-
place the expansion
valve.
•Excessive refrigerant filling or inadequate refrigeration of the condenser

Condition: Inadequate refrigeration
Fig.4-143
4-146 -
• The pressures at • The excessive re- • Excessive refriger- • Clean the

the high- and low- frigerant in the sys- ant in the system → condenser.
pressure ends are tem can’t bring a excessive refriger- • Check the fan mo-
excessively high. proper refrigeration ant filling. tor operation.
• Bubbles are not effect. • Inadequate refriger- • If the above two
seen through the • The condenser fails ation of the con- conditions are nor-
sight glass even to provide adequate denser → blockage mal, check the re-
when the engine refrigeration. of the condenser ra- frigerant quantity.
speed drops. diating fin or failure Add a proper
of the fan motor. amount of
refrigerant.
• Air in the refrigeration system

Symptom: Poor refrigeration
If the refrigerant is added without vacuumization after the refrigeration system is started, the me-
ter reading will be as follows.
Fig.4-144
- 4-147
• The pressures at • Air enters the refrig- • Air enters the refrig- • Check whether the
the highand low- eration system. eration system; compressor oil is
pressure ends are • Vacuumization is unclean or
excessively high. not sufficient. inadequate;
• The low-pressure • Pump out the air
pipe is hot by hand and add new
touch; refrigerant.
• Bubbles can be
seen through the
sight glass.
• Improper installation of the expansion valve/defective thermo-sensitive pipe (excessively wide

opening)
Fig.4-145
• The pressures at • The expansion • There is excessive • Check the installa-

the high- and low- valve is faulty or the refrigerant in the tion of the thermo-
pressure ends are thermo-sensitive low-pressure pipe; sensitive tube;
excessively high; pipe is installed • The expansion • If the above condi-
• Frost or a large improperly. valve opening is too tion is normal,
amount of dew is wide. check the expan-
formed on the low- sion valve and re-
pressure pipe. place it if it is
defective.
• Compressor failure
4-148 -
Condition: No refrigeration
Fig.4-146
• The pressure at the • There is leakage in- • The compression • Repair or replace
low-pressure end is side the failure occurs; the compressor.
excessively high; compressor. • The valve is leaky
• the pressure at the or damaged, and
high-pressure end the parts slip off.
is excessively low.
Compressor oil
A certain amount of oil shall be injected into the A/C system for lubrication. The compressor oil is
dissolved in the refrigerant and circulated throughout the system. When the A/C system is shut
down, the compressor oil will remain in the parts of the system. If the system is not supplemented
with a proper amount of oil when the main parts are replaced, insufficient lubrication will be
caused. The amount of oil that shall be added when the main parts are replaced is shown in the fol-
lowing table:
- 4-149
4.10 Engine control

4.10.1 summarize
Fig.4-147
1. Battery relay 6. Controller

2. Battery 7. Fuel injection pump
3. Key switch 8. ECM
4. Fuel control knob
5. Starter motor
Overview
• The engine is started and stopped by the key switch (3).
• The controller (6) receives the signal from the fuel control knob (4), and transmits the target
speed signal to the ECM via CAN bus to control the fuel injection pump (7) and control the en-
gine speed.
• If the key switch (3) is turned to OFF, the ECM (8) will de-energize the fuel supply solenoid valve,
the fuel injection port of the fuel injection pump will stop the engine oil supply, and the engine will
be shut down.
4-150 -
4.10.2 System operation
Start the engine
• When the key switch is turned to START

position, the start signal will be transmitted
to the starter motor and then the motor will
be driven to start the engine.
• At this time, the controller will detect the sig-
nal voltage from the fuel control knob and
set the engine speed to the value set by the
fuel control knob. Fig.4-148
Engine speed control
• The fuel control knob sends a signal voltage

corresponding to the angle of rotation to the
controller.
• Then the controller sends a speed signal to
the ECM based on the signal voltage to
control the fuel injection pump and ulti-
mately control the engine speed.
Fig.4-149
Stop the engine
• When the key switch is turned to STOP po-

sition, a shutdown signal will be sent to the
ECM to control the fuel pump to stop
working.
Fig.4-150
4.10.3 System components
Fuel control knob
- 4-151
Fig.4-151
1．Knob
2．Dial
3．Spring
4．Ball
5．Potentiometer
6．Plug
4-152 -
Function
• When the throttle knob is turned, the resist-

ance of the sliding rheostat inside the knob
will be changed so that the voltage signal
collected by the controller will also be
changed. The controller will perform calcu-
lation according to the collected value, send
the speed signal to the ECM, and control
the injection quantity of the injection pump
so that the engine can reach the set control Fig.4-152
speed.
• When the throttle voltage is outside the
zone, the controller will give an alarm code
and the engine will run at low idle speed.
The area composed of oblique lines in the
right figure is the abnormality inspection
area.
Note: The leftmost limit position indicates 0%,

and the rightmost limit position indicates
100%.
4.10.4 Controller
SEHC-283B (Huaxing)
- 4-153
Fig.4-153
Controller signal distribution
4-154 -
- 4-155
4.11 Electrical control system

4.11.1 Control functions
4-156 -
4.11.2 Machine control system diagram
Fig.4-154
- 4-157
Fig.4-155
Note: The above figure is the electrical control diagram. For specific details of the hydraulic circuit,
see the hydraulic knowledge section.
4-158 -
4.11.3 Engine - pump combination control function
Fig.4-156
- 4-159
Function
• This function allows the operator to select
the system working mode to change the en-
gine power output according to different
work of the machine. There are four work-
ing modes: P, H, S and I. The working
modes are set according to the working
gear positions as follows: Mode I: 1st~3rd
gears; Mode S: 4th~9th gears; Mode H:
10th gear; Mode P: 11th.
• The master controller controls the pump so
that it can absorb all torques at the engine Fig.4-157
output point. These torques depend on the
pump absorption torque specification, fuel
control knob setting and actual engine
speed in each mode.
4-160 -
Technical parameters
Mode P
Speed (rpm) 1850～1950
Power (KW) 200
Mode H
Speed (rpm) 1750～1850
Power (KW) 183
Mode S
Fig.4-158
Speed 1300～ 1400～ 1600～
(rpm) 1400 1600 1750
Power 75 126 177
(KW)
Mode I
Speed (rpm) 1000～1200
Power (KW) 60
Fig.4-159
- 4-161
Control method for each mode

• Mode P
• Matching point of Mode P (rated speed):
200kW/1950rpm
• If the pump load increases and the pressure
rises, the engine speed will decrease. If so,
the engine speed will increase near the
matching point, thus allowing the pump con-
troller to reduce the pump output. Con-
versely, if the pump load decreases and the
pressure drops, the pump controller will
continue to increase the pump output until Fig.4-160
the engine speed reaches near the match-
ing point.
Fig.4-161
Fig.4-162
4-162 -
• Corresponding power output percentage of

each mode
•
Mode P H S I
Power 85% 85% 83% 80%
output
ratio
• In this case, the controller keeps the pump

oil absorption torque along the stable horse-
power curve and controls the engine speed
through joint control of the engine and the Fig.4-163
pump.
Fig.4-164
Fig.4-165
- 4-163
4.11.4 Pump control function
Fig.4-166
4-164 -
Fig.4-167
- 4-165
Fig.4-168
Function
• It directly uses the handle pilot pressure signal as the hydraulic pump displacement control sig-
nal. The pilot pressure acts on the valve stem on one hand and is collected by the controller on
the other hand. The controller maintains the hydraulic pump displacement at the determined val-
ue under the corresponding pilot pressure based on the function of the given hydraulic pump dis-
placement and the pilot pressure. When a combination action is performed, the given
displacement of each action shall be increased.
Operation
4-166 -
• When the work equipment acts, the controller will collect the pilot pressure sensor signal and
give the control displacement of pumps 1 and 2 according to the pilot pressure signal.
Constant power control
Function
• It mainly calculates theoretical maximum
displacement of the pump. The system
adopts constant power control. The two reg-
ulators are hydraulically linked so that the
two actuators having the same specifica-
tions and acting at the same time can be
synchronized. The pump flow change is
mainly determined by the sum Pε of work-
Fig.4-169
ing pressures of the two hydraulic pumps.
As long as 2P0≤Pε≤2Pmax, the sum of
power of the two hydraulic pumps will al-
ways remain constant and will not exceed
the diesel engine power.
Operation
• When the work equipment acts, the controller will collect the main pressure sensor signal of
pumps 1 and 2 and realize constant pump power control according to the main pressure signal.
ESS control
Function
• It controls the pump power based on the engine speed variation due to the load change, thus
the engine output is used more effectively. (Engine stalling can be avoided when the machine
operates under plateau and other harsh conditions).
Operation
The target operating speed of the engine is controlled by the throttle control knob.
• The controller collects the actual engine speed signal and performs closed loop control of the
target speed. Then, the controller involves the output under closed loop control in the solenoid
valve control signal calculation and sends the final regulating current signal to the pump propor-
tional solenoid valve.
• The solenoid valve supplies pilot pressure oil to the pump regulator to control the pump flow
based on the signal from the controller.
- 4-167
4.11.5 Valve control function
Fig.4-170
Valve control function

• Bucket flow control
• Swing priority control
4-168 -
1）Bucket flow control
Function
• It controls the pump swashplate angle ac-
cording to the bucket handle opening.
Operation
• When the bucket handle acts, the controller
will collect the signals of the bucket unload-
ing pressure sensor and bucket digging
pressure sensor to control the bucket con-
verging proportional valve. Fig.4-171
Fig.4-172
2）Swing priority control
Function
• The pressure oil of pump 1 passes over the
arm 1 valve spool and flows to the swing
motor valve spool for priority swing
operation.
Operation
• The controller will activate the solenoid
valve when the signals from the pump 1 oil
delivery pressure sensor, arm pressure
sensor and swing pressure sensor are
under the following conditions. The solenoid
valve delivers the pilot pressure oil to the
arm flow controller so that the parallel oil cir-
cuit of the arm 1 valve spool is limited. The
swing valve spool guarantees the swing
- 4-169
motor power preferentially to avoid the im-

pact of the upper swing platform rotation at
the time of arm retraction on the positioning
precision.
Operational conditions
• Swing pressure sensor: With the output
signal;
• Arm pressure sensor: With the output
signal.
4.11.6 High/low speed travel control
Fig.4-173
Function
4-170 -
• It controls the travel mode.
Operation
• When the low travel speed mode is set, the maximum travel motor swashplate angle will be
achieved, and the machine will travel at a low speed.
• When receiving the signal sent by the travel pressure sensor under the following conditions, the
controller will activate the solenoid valve. Then, the solenoid valve will deliver the pilot pressure
oil to the travel motor swashplate angle control valve to minimize the swashplate angle so as to
increase the travel speed.
• The high travel speed function on the display is enabled.
Note: When the track on one side is lifted above the ground and rotated with the work
equipment, the pressure of the pump on one side will increase to achieve fast rotation of
the lifted track. When the machine travels in the fast traveling mode, this traveling mode will
be kept unchanged even if the work equipment is operated (the work equipment pressure
sensor is turned to ON).
- 4-171
4.11.7 Engine warm-up/overheating alarm
Fig.4-174
1）Engine warm-up
Function
• This helps to assist the engine startup at the low temperature and reduce white smoke and noise
generated after the engine is started. When the ignition switch is turned to ON position, the ECM
will detect the engine coolant temperature based on a signal from the engine coolant
4-172 -
temperature sensor, thereby changing the warm-up time. The resistance between the glow plug
terminal and the ground wire is 6 Ω at room temperature.
Operation
• The excavator automatically warms up when the power is turned on and the engine is started.
• The excavator automatically warms up when the low-temperature switch is turned off, the power
is turned on and the engine is started.
2）Engine overheating alarm
Function
• If the coolant temperature is too high (above 101°C) during the operation, the display will show
an alarm.
Operation
• The controller receives the coolant temperature value from the ECM. If the coolant temperature
is too high, an alarm message will be generated and sent to the display. Upon receipt of the
alarm message, the display will activate the alarm indicator to turn on.
• Power-on
• Coolant temperature >°C
4.11.8 Excessively low oil pressure alarm
Function
• The oil pressure signal is sent from the ECM to the controller via the CAN. If the engine runs for
more than 25 s, the engine speed is greater than 600 rpm and the oil pressure is below 98 kPa,
an alarm message will be generated and sent to the display and then the display will receive it.
- 4-173
4.11.9 Automatic idling/acceleration control
Fig.4-175
Function
• It decreases the engine speed to reduce
the fuel consumption and noise when all
travel levers are put in the neutral position.
• If any control lever is operated, the engine
speed will immediately return to the value
set by the fuel control knob.
Operation
• When the control lever lever is returned to
the neutral position for 0.2 s, the diesel en- Fig.4-176
gine will immediately decelerate to the first
gear speed which is 100 rpm lower than the
set speed. If the engine automatically en-
ters the low speed (1200 rpm) after 3 s, the
hydraulic system air flow loss and diesel en-
gine wear can be reduced, thus achieving
energy conservation and noise reduction.
When the travel lever is operated again, the
4-174 -
diesel engine will automatically return to its

original speed.
• If any control lever is operated when the en-
gine decelerates, the engine speed will im-
mediately rise to the level set by the fuel
control knob.
4.11.10 System parts
1）Pump pressure sensor
Fig.4-177
- 4-175
Operation
• The relationship between the pressure ap-
plied to the sensor and the output voltage is
shown in the right figure.
Fig.4-178
2）Pilot pressure sensor
Fig.4-179
4-176 -
Operation
• The relationship between the pressure ap-
plied to the sensor and the output voltage is
shown in the figure below.
Fig.4-180
1. 3）Fuel level sensor
Fig.4-181
1. Float 3. Hosing
2. Lever 4. Connector
Function
• After the signal from the sensor is collected
by the controller, the relevant information
will be displayed on the display. For exam-
ple, for the resistance output type sensor
related to the hydraulic oil temperature, fuel
level, coolant temperature and others, the
controller collects the processed voltage
signal, performs the calculation, and then
displays the relevant information on the
display.
Electrical parameters:
- 4-177
• Total resistance 100Ω

• Total resistance tolerance: ±5%
• Upper resistance limit: Ru≤9.6Ω
• Lower resistance limit: Rd≥86Ω
• Resistance change: non-linear
Mechanical parameters:
• Swing angle of swing shaft: 105°
• Vertical distance between upper and lower
limits of the float (measurable liquid level):
500 mm.
4-178 -
4.12 Display system

4.12.1 summarize
Fig.4-182
• The machine condition is monitored by sensors installed on various parts of the machine and
processed by the controller, and the obtained information is immediately shown on the display
panel to inform the operator of the machine condition.
• The display panel also has various mode selection switches and function keys to operate the
machine control output.
• The content on the display panel is generally divided into the following two parts.
1. Alarm information when a fault occurs on the machine.
2. Machine condition (coolant temperature, hydraulic oil temperature, fuel level, etc.).
- 4-179
4.12.2 Display
SECD_7I0F_02
Fig.4-183
Overview
• The display has the function of displaying • When the LCD display panel has less than 10
monitoring information and selecting the dark dots (dots not lighted) or bright dots (dots
working mode. always lighted), it conforms to the technical
• The display is configured with a CPU (cen- standard.
tral processing unit) for information proc- • When the display works continuously, blue
essing, display and output. bright dots may be displayed on the interface
• The display is a LCD (liquid crystal) display. on a black background, which is normal.
• When the display starts, there will be flashing
Input and output signals of connector stripes, which is normal.
4-180 -
Pin No. Signal name Input/output

1 CAN low
2 CAN high
3 CAM-
7 Display reset
9 Camera power
supply (12V)
12 CAM+
17 Display power
supply
24 GND
25 GPS power
supply
29 Display tamper- Input
proof
33 GND
34 GPS power
supply
- 4-181
4.12.3 Display panel
CAUTION
• When the alarm indicator lamp comes on,
stop the operation immediately and check
and repair relevant parts.
• The display can’t display the whole work-
ing status of the machine.
• Do not rely on the display completely in
case of maintenance and inspection of the
machine.
The display panel has the functions of moni-

toring display, video selection and switching of
electric components.
Display appearance
This display mainly consists of 3 parts:
A：SANY LOG display area

Fig.4-184
B： Main image display areaMain image dis-
play area
C：Key area
SANY LOG display area
For displaying SANY LOG
When the excavator key switch is turned to

"ON", the display will be powered and started
by the battery to enter the initial interface.
Fig.4-185
4-182 -
Main image display area
Skip to the main interface 3 s after entering

the LOG interface after power on. The full
screen display of the main interface of the dis-
play during the working status is as shown in
the Figure. Where:
【1】 System time
【2】 Working mode (depending on gears)
【3】 GPS signal
【4】 Gear (according to the throttle knob

position)
【5】 Total working time

Fig.4-186
【6】 Fuel level gauge
【7】 Locking mark (locking countdown

reminder)
【8】 Maintenance mark and maintenance

time
【9】 Instantaneous fuel flow
【10】 Single working time
【11】 Coolant thermometer
【12】 Display area of fault alarm mark and

important fault icon
【13】 Enter the ―Video Interface‖
【14】 Automatic idling status
【15】 High/low speed travel status
【16】Icon of entering the ―Fault Information

Query‖
【17】 Icon of entering the ―Information

Query‖
Key area
The key area includes 5 function keys.
Function key
- 4-183
Function keys are F1, F2, F3, F4, and F5 (as shown in the figure) with their purposes correspond-
ing to the function icons displayed on the main image display area above them.
• When different function icons are displayed, each key will have a different purpose.
• When no corresponding function icon is displayed in the main image display area, this function
button will be invalid.
The corresponding relationship between common function display icons and keys is shown in the
table below.
4.12.4 Operation of display interfaces
Home page
The home page is the operation interface when the excavator works normally.
4-184 -
Operation methods
1. Enter the video interface
When the camera is installed for the machine,

press down the key F1 to enter the video
interface.
2. Automatic idling selection
Use F2 to cancel and start the automatic idling

function.
When F2 displays the symbol , pressing this

AUTO
n/min
key can cancel the automatic idling function,

and when displays the symbol , pressing
n/min
Fig.4-187
this key can enable the automatic idling
function.
Note: The default mode of the automatic idling

is the ―Start‖ mode when the machine is
powered on each time.
• By default, the automatic idling switch is

turned on. When all travel levers are put in
the neutral position for 0.2 s, the engine will
decelerate by 100 rpm immediately and
then enter the idle state automatically after
3 s (the controller will automatically adjust
the speed to the idle speed) to save fuel
and reduce noise.
• If the controller detects an action or position
change in the idle state, the engine will au-
tomatically return to the speed correspond-
ing to the position.
3. High/low travel speed selection
Use F3 to realize switching between ”High

Travel Speed” and “Low Travel Speed”. When
F3 displays the symbol , pressing this key
can select the high travel speed, and when
displays the symbol , pressing this key can
select the low travel speed.
- 4-185
Note: The default travel speed is the low

speed when the machine is powered on each
time.
4. Fault information query
When the alarm indicator light lights up on the

display, a DTC will appear at the bottom of the
display. At this time, the red symbol √ will ap-
pear on F4.
Press down this key to enter the fault informa-

tion query interface.
5. System information query
Press F5 to enter the system information

query interface.
Note: Enter the password before entering the

system information interface, so please con-
tact dealers authorized by Sany Heavy Machi-
nery Co., Ltd.
Information list password interface
Select the “Running Information” in the “Infor-

mation List” interface, and press down F3 to
enter the information list password entry inter-
face (enter the password only for the first time
entry after power on each time). The running
information can be queried only after the
password passes verification.
Key operation
• F1 Enter and delete the password

• F2 Select the input bit
• F3 Confirm the password
• F4 Enter the [System Unlocking Interface]
• F5 Back to [Home Page].
Fig.4-188
4-186 -
Information list interface
Press F5 on the Home Page to enter the infor-

mation list interface, and select the informa-
tion to be queried on the information list
interface.
Key operation
• F1 Select functions
• F2 -
• F3 Confirm to enter
• F4 Enter the [System Setting Interface]
Fig.4-189
Engine and throttle signal
Select the [Running Information] in the [Infor-

mation List] interface to enter the running in-
formation query, and the first entry is the
[Engine and Throttle Signal].
Key operation
• F1 Enter the [Input/Output Signal Query]

• F2 Enter the [Pilot Pressure Signal]
Fig.4-190
- 4-187
Pilot pressure signal
Press F2 on the ―Engine and Throttle Signal‖

interface, or press F1 on the [Main Pump and
Cooling Pump Signal] interface to enter the
[Pilot Pressure Signal] interface.
Key operation
• F1 Enter the [Engine and Throttle Signal]

• F2 Enter the [Main Pump and Cooling Pump
Signal]
Fig.4-191
Main pump and cooling pump signal
Press F2 on the [Pilot Pressure Signal] inter-

face or press F1 on the [Input/Output Signal
Query] interface to enter the [Main Pump and
Cooling Pump Signal] interface.
Key operation
• F1 Enter the [Pilot Pressure Signal]

• F2 Enter the [Input/Output Signal Query]
Fig.4-192
4-188 -
Input/output switch signal query
Press F2 on the [Main Pump and Cooling

Pump Signal] interface or press F1 on the [En-
gine and Throttle Signal] interface to enter the
[Input/Output Signal Query] interface.
Key operation
• F1 Enter the [Main Pump and Cooling Pump

Signal]
• F2 Enter the [Engine and Throttle Signal]
Fig.4-193
Fault information
Select the [Fault Information] in the [Informa-

tion List] interface to query the fault code and
fault information.
Key operation
• F1 Return to the previous page

• F2 —
• F3 —
• F4 —
• F5 Return to the [Information List] interface
Fig.4-194
- 4-189
GPS Monitoring Information
Select the [GPS Monitoring] in the [Informa-

tion List] interface to query the GPS monitor-
ing information.
Key operation
• F1 —
• F2 —
• F3 —
• F4 —
Fig.4-195
System Language Selection
Select the [System Language] in the [Informa-

tion List] interface to enter the system lan-
guage selection interface, and Chinese and
English are available currently.
Key operation
• F1 —
• F2 Chinese
• F3 English
• F4 —
Fig.4-196
4-190 -
System Clock Calibration
Select the [System Clock] in the [Information

List] interface to enter the [System Clock Cali-
bration] interface.
Key operation
• F1 Enter and delete the calibration value

• F2 Select the calibration bit
• F3 Confirm the calibration
• F4 —
Fig.4-197
- 4-191
Maintenance information
Select the [Maintenance Information] in the

[Information List] interface to enter the mainte-
nance information query interface. The main-
tenance information includes maintenance
items for every 50 h, 250 h, 500 h, 1,000 h
and 2,000 h. Note: It can be accessed only
when there is a maintenance reminder.
Key operation
• F1 —
• F2 —
• F3 Enter the maintenance password
confirmation
• F4 Pause and start cycleplay of the mainte-
nance item
• F5 Return to the [Information List] interface Fig.4-198
Fig.4-199
4-192 -
System setting list
Press F4 on the [Information List] interface to

enter the [System Setting] interface. Enter the
system setting interface to enter the [System
Setting] interface, and the password entry
mode is the same as the [Information List
Password Interface].
Key operation
• F1 Select items
• F2 —
• F3 Confirm
• F4 —
Fig.4-200
Machine configuration
Select the [Machine Configuration] in the

[System Setting] interface to query the ma-
chine configuration information.
Key operation
• F1 —
• F2 —
• F3 —
• F4 —
• F5 Return to the [System Setting] interface
Fig.4-201
- 4-193
Working time calibration
Select the [Working Time] in the [System Set-

ting] interface to calibrate the working time of
the machine. Enter the working time calibra-
tion password to enter the [Working Time Cali-
bration] interface, and the password entry
mode is the same as the [Information List
Password Interface].
Note: The working time can be modified twice,

and it is unable to enter the subinterface to
calibrate when the countdown number is 0.
Key operation
• F1 Enter and delete the calibration value

• F2 Select the calibration bit
• F3 Confirm
• F4 —
• F5 Return to the [System Setting]
Fig.4-202
Machine configuration calibration
Select the [Configuration Calibration] in the

[System Setting] interface to calibrate the ma-
chine configuration information. Enter the con-
figuration calibration password to enter the
[Configuration Calibration] interface, and the
password entry mode is the same as the [In-
formation List Password Interface].
Key operation
• F1 Enter the [Machine Number Calibration]

• F2 Calibrate the engine
• F3 Confirm calibration and return to the set-
ting interface
• F4 Calibrate the hydraulic model
• F5 Calibrate the controller model
Fig.4-203
4-194 -
Alarm content setting
Select the [Alarm Content] in the [System Set-

ting] interface to enter the [Alarm Content Set-
ting] interface.
Key operation
• F1 Select setting items

• F2 －
• F3 Confirm the selected setting items
• F4 －
Fig.4-204
Display brightness adjustment
Select the [Brightness of the Display Screen]

in the [System Setting] interface to enter the
[Adjustment of Brightness of the Display
Screen] interface.
Key operation
• F1 Increase the brightness

• F2 Reduce the brightness
• F3 Confirm the adjusted brightness
• F4 －
• F5 Return to the [Information List]
Fig.4-205
- 4-195
Travel off-tracking setting
The system will set the level II password for

entry.
Key operation
• F1 Select setting items

• F2 Enter the digit
• F3 Delete the digit
• F4 Confirm
Fig.4-206
Engine information
Display the historical fault and total running

time of the engine.
Key operation
• F1 Display the historical fault and total run-

ning time selection
• F2 Enter the engine fault query interface
• F3 Confirm to send request
• F4 Enter the engine other information
interface
• F5 Return to the setting selection interface
Fig.4-207
4-196 -
Engine fault information
Display the engine fault information
Key operation
• F1 Enter the next page

• F2 —
• F3 —
• F4 —
• F5 Return to the engine information
interface
Fig.4-208
Daily maintenance information
It will be popped up automatically upon the

first start every day.
Key operation
• F1 —
• F2 —
• F3 —
• F4 —
Fig.4-209
- 4-197
Locking information
When the locking signal is received, enter the

locking information interface, and the locking
signal can be divided into the grade I locking
signal and the grade II locking signal.
Key operation
• F1 —
• F2 —
• F3 —
• F4 —
• F5 Enter the password unlocking interface
Fig.4-210
System unlocking interface
The appearance of this interface on the dis-

play indicates that the excavator is set in the
system unlocking state.
Key operation
• F1 Select the up/down bit

• F2 Select the left/right bit
• F3 Confirm the password
• F4 —
• F5 Return to the [System Setting]
Fig.4-211
4-198 -
SY365H(BH)-10 Hydraulic Excavator Standard values of components
Standard values of components
5 Standard values of components ............................................................................5-1

5.1 Table of Standard Values of Engine Related Components.............................................5-3
5.2 Table of Standard Values of Body Related Components ................................................5-4
- 5-1
Standard values of components SY365H(BH)-10 Hydraulic Excavator
WARNING
5-2 -
5.Standard values of components

5.1 Table of Standard Values of Engine Related Components
- 5-3
5.2 Table of Standard Values of Body Related Components
5-4 -
- 5-5
5-6 -
- 5-7
5-8 -
- 5-9
5-10 -
- 5-11
5-12 -
SY365H(BH)-10 Hydraulic Excavator Test and adjustment
Test and adjustment
6 Test and adjustment ......................................................................................................6-1

6.1 Exhaust smoke color measurement...................................................................................6-3
6.2 Valve clearance adjustment.................................................................................................6-4
6.3 Inspection and adjustment of A/C compressor belt tensioner ........................................6-7
6.4 Measurement of swing bearing clearance.........................................................................6-8
6.5 Inspection and adjustment of track tensioner ...................................................................6-9
6.6 Inspection and adjustment of hydraulic oil in the work equipment, swing and travel
hydraulic lines............................................................................................................ 6-10
6.7 Inspection and adjustment of oil pressure in control oil line ........................................ 6-15
6.8 Measuring the output pressure of solenoid valve.......................................................... 6-16
6.9 Measuring the output pressure of pilot valve ................................................................. 6-18
6.10 Adjustment of work equipment and swing pilot valve ................................................. 6-20
6.11 Inspection of the drift of hydraulic cylinder for work equipment................................. 6-20
6.12 Release of residual pressure from hydraulic lines ...................................................... 6-23
6.13 Leakage measurement ................................................................................................... 6-24
6.14 Bleeding air from each system....................................................................................... 6-28
- 6-1
Test and adjustment SY365H(BH)-10 Hydraulic Excavator
WARNING
6-2 -
6.Test and adjustment

6.1 Exhaust smoke color measurement
Measurement apparatus for exhaust smoke
Logo Part name

Filter type
1
smokemeter
2 Opacity smokemeter
DO NOT touch any hot part when instal-

ling or removing the measuring tool.
1. Measurement with a filter type smokemeter
1）Install a filter paper into the smokemeter.
2） Insert the inlet pipe of the smokemeter in-

to the exhaust pipe.
3） Start the engine and run it continuously till

the engine coolant temperature is within the
operating range
4） When the engine accelerates suddenly or

is at high idle speed, operate the smokemeter
to allow the exhaust flow to pass through the
Fig.6-1
filter paper.
Remove the filter, and obtain the measuring

value by using a support apparatus.
5） Remove the filter, and obtain the measur-

ing value by using a support apparatus.
6） Remove the measuring tool from the ma-

chine after measurement, and ensure that the
machine is back to normal.
- 6-3
2. Measurement with a opacity smokemeter
1） Mount the opacity smokemeter on the ex-

haust pipe, and clamp it at the outlet.
Fig.6-2
2） Switch on the opacity smokemeter and

warm up for about 15 min.
3） Start the engine and run it continuously

until the engine water temperature rises within
the operation range.
4） When the engine accelerates suddenly or

is at high idle speed, use the opacity smoke-
meter to measure the smoke.
5） Remove the measuring tool from the ma-

machine is back to normal. Fig.6-3
6.2 Valve clearance adjustment

Repair standard (in mm)
Standard Calibration
Position Item Limit value
value method
Valve clearance (when the
— 0.4 — Adjustment
engine is in cold state)
The valve clearance shall be checked and adjusted in the cold state as follows:
6-4 -
nspection
1. Remove the rocker arm cover.
2. Turn the No. 1 or No. 6 piston to the top

dead center position of the compression
stroke as follows.
• Rotate the engine until the top dead center
line on the crank pulley is aligned with the
timing pointer.
• Turn the No. 1 or No. 6 piston to the top
dead center position of the compression
stroke.
Note: Fig.6-4
When the rocker arms on both the intake and

exhaust sides cannot be rotated by hand, it
can be judged that the pistons have been
turned to the top dead center position of the
compression stroke. Rotate the engine for an-
other round on this basis, and the compres-
sion top dead center positions of the No. 1
and No. 6 pistons are reversed.
3. When the No. 1 piston is at top dead center,

adjust the valve clearance in the order of the
black dots (●) listed in the table below.
Cy
linde 1 2 3 4 5 6
r No.
Ex
haus
● ○ ● ○ ● ○
t
valve
In
take ● ● ○ ● ○ ○
valve
- 6-5
1） When a thickness gauge is used for

measuring, some resistance shall be felt when
moving the gauge in the clearance.
2） If the thickness gauge can move easily in

the clearance, accurate measurement values
cannot be obtained.
4. If the measured values are outside the

specified range, adjust it as follows.
Fig.6-5
Adjustment
1. When adjusting the valve clearance, loosen

the lock nut first and then rotate the adjusting
screw till the thickness gauge for the standard
clearance can be pulled out with slight
resistance.
After adjustment, stop the adjustment screw

with a screwdriver and tighten the lock nut for
fixing.
Torque for lock nut: 21-30 N. m

{2.1- 3.1kgf.m} Fig.6-6
3. Proceed to the next step until all valve
clearances marked with (●) are adjusted.
4. Check the valve clearance again with the

thickness gauge, and adjust again if it devi-
ates from the standard value.
5. It is easier to operate if the adjusting screw

is rotated with when the engine is in the
vehicle.
6-6 -
6.3 Inspection and adjustment of A/C compressor belt tensioner

Inspection
Apply a force of about 58.8N (6kgf) with your

fingers to the midpoint of the belt between the
drive pulley and the compressor pulley, and
check the deflection (A), which shall be within
5~8mm (0.20 in.~0.31 in.).
Fig.6-7
Adjustment
If the deflection is not appropriate, follow the

steps below to make an adjustment.
1. Loosen the bolts (1) and (2).
2. Move the compressor (3) and the bracket

(4) together to adjust the belt tension.
3. Position the compressor (3). Tighten the

bolts (1) and (2).
4. Check the belt tensioner again after

adjustment.
Fig.6-8
Note:
• Check whether each pulley is damaged,

and whether the V grooves and V belts are
worn. In particular, ensure that the V belt
does not contact the bottom of the V
groove.
• In any of the following cases, please con-
tact the dealer authorized by Sany Heavy
Machinery Co., Ltd. in your region to re-
place your belt.
• The fan belt is already extended, with little
margin for adjustment.
• Any cutting or crack is found on the belt.
• Abnormal slipping occurs or a squeaking
sound is heard.
- 6-7
• After installing a new belt, be sure to read-

just it after one hour of operation.
6.4 Measurement of swing bearing clearance

Measurement tool for swing bearing
clearance
Symbol Part Number Part Name
H 60033930 Dial gauge
• Measure the clearance of the swing bearing

mounted on the machine as follows.
Park the machine on level ground, and

lower the work equipment to the ground.
Fig.6-9
Do not put your hand or foot under the
carrier.
1. Fix the dial gauge H to the track frame, with

the indicator pointing the lower end surface of
the outer ring.
2. Extend the work equipment to give maxi-

mum reach, with the bucket tip and the bottom
of the superstructure on the same level.
• At this moment, the front of the superstruc-

ture lowers while the rear rises.
Fig.6-10
6-8 -
3. Reset the dial gauge (H) to zero.
4. Make the arm almost perpendicular to the

ground and lower the boom until the front
track shoe tilts.
• At this moment, the front of the superstruc-

ture rises while the rear lowers.
5. Read the value indicated by the dial gauge

(H).
• The value of the dial gauge H represents

the bearing clearance. Fig.6-11
• For details of the standard values, see
“Swing Oil Line” of the section Structure
and Function.
6. Operate the machine to the condition of

Step 2, and check if the pointer of the dial
gauge is back to zero.
• If not, repeat Step 3 through Step 5.
6.5 Inspection and adjustment of track tensioner

Inspection
1. Drive the machine forward for a distance

which is equal to the length of the track con-
tacting the ground, allow the engine to run at
low idle speed, and slowly stop the machine.
2. Place a rod on the track over the idler (1)

and the first carrier roller (2).
• An angle bar is recommended as it is resist-

ant to bending. Or a L-shaped beam, which
has similar property.
Fig.6-12
3. Measure the maximum Clearance a be-
tween the upper surface of the track and the
bottom of the rod.
• Standard maximum clearance (a): 10~30
mm (0.4~1.2 in)
- 6-9
Adjustment
If the track tension is inappropriate, follow the

steps below to make an adjustment.
1. To decrease tension
1） Loosen the valve (1), drain the grease
and tighten the valve.
DO NOT loosen the valve for more than

one turn. If the valve is too loose, grease
under high pressure inside the valve may
eject the valve out. Fig.6-13
2） After adjustment, check the track tension
again with the method described above.
2. To increase tension
1） Fill grease through the grease fitting (2)
with a grease gun.
2） After adjustment, check the track tension
again with the method described above.
• Fill grease till the distance between the idler

plate and the track frame end equals 0 mm.
If the tension is still low, it indicates that the
pin and bushing are excessively worn. The
pin and bushing are needed to be replaced,
or a piece of track shoe removed.
Fig.6-14
6.6 Inspection and adjustment of hydraulic oil in the work equipment,

swing and travel hydraulic lines
Tools required for inspection and adjustment
Symbol Part No. Part name

Hydraulic
— 60038932 pressure
tester
6-10 -
B210770000 Test
084 couplings
• The hydraulic oil pressure in the hydraulic

oil lines of the work equipment as well as
swing and travel mechanisms (output pres-
sure of hydraulic pump) could also be moni-
tored through the display screen.
Measurement
1. Preparation
Lower the work equipment to the ground

and shut down the engine. After the engine
stops, operate the control lever several times
to release the residual pressure in the pipe-
lines; loosen the butterfly nut on the breather
valve, and press down the release button to
release pressure from the hydraulic tank.
1） Remove the pressure measuring plug (1) Fig.6-15

and (2).
• Plug (1): for the oil lines of front hydraulic

pump.
• Plug (2): for the oil lines of rear hydraulic
pump.
2） Install test couplings to the main oil line

and connect them to the hydraulic pressure
tester.
• Use an oil pressure gauge with a capacity

of 40 MPa {408 kgf/cm2}.
3） Start and run the engine until the hydraul-

ic oil pressure rises within the operation
range.
2. Unloading pressure measurement
1） Start the engine
2） Measure the hydraulic oil pressure with

the engine at high idle speed and all control
levers being placed in the middle.
- 6-11
• Indicate the hydraulic oil pressure when the

unloading valve works.
3. Measurement of work equipment relief

pressure
1） Start the engine and operate the control

lever related to the measured cylinder to the
full stroke.

the engine at high idle speed and the cylinder
in overflow state.

main relief valve opens.
4. Measurement of swing relief pressure
1） Start the engine, and extend the work

equipment forward as much as possible with
the bucket supporting against the ground to
limit swing.

the engine at high idle speed and the swing oil
line in relief pressure.

swing motor relief valve opens.
• The swing motor relief pressure is lower
than the main relief pressure.
6-12 -
5. Measurement of travel relief pressure
1） Start the engine and lock the travel

mechanism.

the engine at high idle speed and the travel oil
line in relief pressure.
• The main relief valve displays the hydraulic

oil pressure at the relief status. The pres-
sure is always the high relief pressure when
the travel oil line is in relief pressure.
Fig.6-16
Adjustment
Unloading and relief valves for booms shall

not be adjusted
1. Adjustment of main relief pressure (high

pressure setting)
• When the high relief pressure in the work

equipment and travel oil lines is abnormal,
adjust the high relief pressure setting of the
main relief valve (3) in the procedures
below. Fig.6-17
1） Disconnect the pilot hose.
2） Loosen the nut (4), and turn the adjusting

bolt (5) to adjust the pressure.
• To increase pressure, turn the retainer

clockwise. To decrease pressure, turn the
retainer counterclockwise.
• Each turn of the adjusting bolt varies the

pressure by:
About 12.5 MPa {About 128 kg/cm2}
Lock nut: Fig.6-18
- 6-13
53.5±4.9 N·m{5.5±0.5 kgf·m}
3） Recheck the pressure after adjustment

with the same procedures used for
measurement.
• Before measuring pressure, connect the pi-

lot hose first.
• If the high pressure setting is adjusted, the
low pressure setting shall also be adjusted.
2. Adjustment of swing relief pressure
• If the measured swing relief pressure is ab-

normal, adjust the swing motor relief valve
(6) in the procedures below.
Fig.6-19
1） Loosen the lock nut (7), and turn the ad-

justing screw (8) to adjust the pressure.
• To increase pressure, turn the retainer

clockwise. ● To decrease pressure, turn the
retainer counterclockwise.
• Each turn of the adjusting screw varies the
pressure by:
About 6.71 MPa {About 68.4 kg/cm2}
Lock nut:
78-103 Nm {8.0-10.5 kgm} Fig.6-20
2） Recheck the pressure after adjustment

with the same procedures used for
measurement.
6-14 -
6.7 Inspection and adjustment of oil pressure in control oil line

Tools required for inspection and adjustment

Hydraulic
21008760 pressure
— tester
B210770000 Test
084 couplings
Measurement

1. Remove the pressure measuring plug (1).
2. Install a test coupling and connect it to the

hydraulic pressure tester.

of 6 MPa {61 kgf/cm2}.
3. Start the engine and allow it to run until the

temperature of the hydraulic oil rises within
the operation range.
4. Measure the oil pressure with the engine at

high idle speed and all control levers in neutral
position.
Fig.6-21
Adjustment
- 6-15
1. If the pressure measured is lower than

3.5MPa {36kgf/cm2}, loosen the lock nut (2),
screw in the adjusting stud (3) till the pressure
indicated by the pressure gauge increases to
the specified range, and then tighten the lock
nut (2).
2. Remove all measuring tools from the ma-

6.8 Measuring the output pressure of solenoid valve

Measuring tool

Hydraulic
21008760 pressure
— tester
B210770000 Test
084 couplings
• Measure the output pressure of the sole-

noid valve when making sure the initial
pressure of the control oil line is normal.

6-16 -
1. Disconnect the hose from the solenoid

valve and measure the pressure at the outlet.
Solenoid valves to be
No.
measured
High speed traveling solenoid
1
valve
2 Backup proportional valve
3 Backup proportional valve
Bucket converging solenoid
4
valve
Standby Fig.6-22
5
6 Pilot pressure solenoid valve
2. Install a tee at the position of the solenoid

valve where the hose is to be connected, and
connect the hose.
3. Install a test coupling to the tee, and con-

nect the coupling to the hydraulic pressure
tester.

of 6 MPa {61 kg/cm2} .
4. Start and run the engine until the tempera-

ture of hydraulic oil rises within the operation
range.
5. Run the engine at full throttle, operate the

control levers to open or close each solenoid
vale, and measure the pressure.
• The function of each solenoid valve can be

monitored by the monitor panel. (Special
function of the machine monitor).

Status and Function Table - Pilot lock solenoid

valve
- 6-17
6.9 Measuring the output pressure of pilot valve

Measuring tool

Hydraulic
21008760 pressure
— tester
B210770000 Test
084 couplings
• Measure the output pressure of the pilot

valve when making sure the initial pressure
of the control oil line is normal.
6-18 -
1. Remove the pilot oil pressure switch or

plug.
No. Oil line to No. Oil line to

be be
meas meas
ured ured
1 Right 7 Right
traveling swing
2 Left 8 Arm
traveling dumping
3 Bucket 9 Arm
dumping digging
4 Boom 10 Left
lowering swing Fig.6-23
5 Boom
lifting
6 Bucket
digging
2. Install a test coupling and connect it to the

hydraulic pressure tester.

of 6 MPa {61 kg/cm2} .
3. Start and run the engine until the tempera-

ture of hydraulic oil rises within the operation
range.
4. Measure the pressure with the engine at

high idle speed and the control lever related
to the measured oil line in the neutral position
or at full travel position.
• If the measured output pressure complies

with the corresponding values listed below,
it is deemed as normal.
- 6-19
Control lever Hydraulic pressure

Neutral 0{0}
Approaches the
average initial
Full stroke control pressure
(See the Table of
Standard Values)

6.10 Adjustment of work equipment and swing pilot valve

If the free play of the work equipment or swing
control lever is too large, follow the proce-
dures below to make an adjustment.
1. Remove the work equipment and swing pi-

lot valve assembly.
2. Remove the rubber cover (1).
3. Loosen the lock nut (2), and turn the disc

(3) clockwise till it touches four heads of the
piston (4).
Note: Do not move the plunger in this

Fig.6-24
case.
4. Fix the disc (3), and tighten the lock nut (2)
to specified torque.
Lock nut: 98~127 Nm {10~13

kgm}
5. Install the rubber cover (1).
6. Install the work equipment and swing pilot

valve assembly.
6.11 Inspection of the drift of hydraulic cylinder for work equipment

If hydraulic cylinder drift occurs, follow the in-
spection procedures below to determine the
cause of the fault, either due to faulty cylinder
seal or defective control valve.
6-20 -
1. Inspection of boom and bucket cylinder
1） Position the machine the same as shown

in the figure on the right, and stop the engine.
• Fill the bucket with soil or apply the rated

load on the bucket.
2） Operate the control lever to raise the

boom and then tilt the bucket inward.
• If the lowering speed increases, it indicates

the cylinder oil seal is faulty.
• If the lowering speed is normal, it indicates Fig.6-25
the control valve is defective.
• Operate the control levers when the ignition
switch is in the ON position.
• If the pressure in the accumulator de-
creases, run the engine for about 10s to
pressurize the accumulator again.
2. Inspection of arm cylinder
1） Position the machine as shown in the fig-

ure on the right, operate the control lever to lo-
cate the arm cylinder at 100mm to the end of
the digging stroke, and stop the engine.
2） Operate the control lever to locate the

arm at the digging position.
• If the lowering speed increases, it indicates

the cylinder oil seal is faulty.
• If the lowering speed is normal, it indicates
Fig.6-26
the control valve is defective.
• Operate the control lever with the ignition
switch at the ON position.
[Reference] If the cylinder drift is caused by

faulty seal and when the operations described
above are performed, the lowering speed
would increase due to:
- 6-21
3） If the work equipment is positioned as de-

scribed above (with pressure applied to the
large chamber), the oil pressure will escape
from the large chamber to the small chamber,
and the inside pressure of the small chamber
will increases.
4） As the pressure in the small chamber in-

creases, the inside pressure of the large
chamber needs to rise for equilibrium. The
cycle will repeat until equilibrium is reached at
a certain pressure (according to the leakage
amount).
5） As an equilibrium is achieved, the lower-

ing speed becomes slow. If the above opera-
tion is performed, the oil line of the small
chamber will open to the bypass (while the
large chamber is closed by the check valve),
and the oil in the small chamber will flow to
the bypass, with the lowering speed
increased.
3. Inspection of pilot valve
When the accumulator is pressurized, meas-

ure the drift of the work equipment cylinder
with the safety lock control lever in the locked
position and the unlocked position
respectively.
• Operate the control levers when the ignition

switch is in the ON position.
• If the drift of the work equipment cylinder
differs when the safety lock control lever is
in the locked position and in the unlocked
position, it indicates the pilot valve is defec-
tive (internal).
6-22 -
6.12 Release of residual pressure from hydraulic lines
Before the pipes between cylinders or

between the hydraulic motor and the control
valve are removed or disconnected, follow the
procedures below to release the residual
pressure.
• Even if there is no residual pressure inside,

the oil lines of the swing motor and the trav-
el motor will still be affected by the pressure Fig.6-27
in the hydraulic tank. Therefore, be sure to
open the breather valve for pressure relief
before performing the following:
1. Stop the engine, loosen the butterfly nut of

the breather valve, and press down the re-
lease button to release the residual pressure
in the oil tank.
2. Turn the ignition switch to ON, and operate

the control levers several times.
• Be sure to electrify the pilot lockout valve,

and operate the control levers when the
ignition switch is in the ON position.
• Operate the control levers for 2-3 times to
release the pressure stored in the
accumulator.
3. Start the engine, allow it to run at low idle

Fig.6-28
speed for 10s, and then stop the engine.
4. Repeat the Step 2 and Step 3 for several

times.
- 6-23
6.13 Leakage measurement

1. Measurement of boom cylinder leakage
1）Start the engine and allow it to run until the

temperature of hydraulic oil rises to the opera-
tion range. Then extend the boom cylinder to
the end of its stroke.
Release the residual pressure from the

pipelines. Refer to “Release of residual pres-
sure from hydraulic lines” (Page 6-19).
2） Disconnect the hose (1) from the small

chamber, and install a blind plug at the hose Fig.6-29
end.
Do not disconnect the hose from the

large chamber.
3） Start the engine and apply relief pressure

to the large chamber when it runs at high idle
speed.
4） Measure the leakage amount within 1min

(appropriately 0.22ml/min) after 30s under
such condition.
5） After measurement, ensure that the ma-

chine is back to normal.
2. Measurement of arm cylinder leakage
1） Start the engine and allow it to run until

the temperature of hydraulic oil rises within
the operation range. Then extend the arm cyl-
inder to the end of its stroke.

sure from hydraulic lines”(Page 6-19).

chamber, and install a blind plug to the hose Fig.6-30
end.
6-24 -

large chamber.

speed.
4） After 30s, measure the leakage amount

within 1min.

3. Measurement of bucket cylinder leakage
1） Start the engine and allow it to run until

the temperature of hydraulic oil rises within
the operation range. Then extend the bucket
cylinder to the end of its stroke.

sure from hydraulic lines” (Page 6-19).

chamber, and install a blind plug to the hose Fig.6-31
end.

large chamber.

speed.
4） After 30s, measure the leakage amount

within 1min.

- 6-25
4. Measurement of swing motor leakage
1） Fully extend the work equipment with the

bucket on the ground, slightly lift the bucket,
and stop the engine.
2） Disconnect the drain hoses (4) and (5),

and install a blind plug at each hose end.
3） Start the engine. Apply a swing relief

pressure when the engine runs at high idle
speed, and measure the leakage.
4） Measure the leakage amount within 1min Fig.6-32

after 30s under such condition.
• After the first measurement, rotate the

superstructure by 180°, and conduct the
second measurement using the same
method.

6-26 -
5. Measurement of travel motor leakage
1） Remove the travel motor cover.
2） Start the engine and lock the travel

mechanism.
3） Disconnect the drain hose (6) from the

travel motor, and install a blind plug at the
hose end.
4） Start the engine, apply a travel relief pres-

sure when the engine runs at high idle speed,
and measure the leakage.
During measurement, incorrect operation

of the control levers may lead to serious acci- Fig.6-33
dents, so ensure all signals are correct.
• Keep the status of Step (4) for 30s, and

measure the leakage amount within 1min.
• Slightly rotate the motor to switch the posi-
tions of the port plate and the cylinder, and
the positions of the cylinder and the piston.
Repeat the measurement several times.

Fig.6-34
- 6-27
6.14 Bleeding air from each system
Note: Drain the oil from the housing, and bleed air from the swing motor and travel motor.
1. Bleeding air from the hydraulic pump.
1） Loosen the bleed screw (1) and confirm

that the oil leaks from the screw.
2） When oil comes out from the bleed screw,

tighten the bleed screw (1).
Bleed screw: 7.8~9.8 Nm {0.8~1.0

kgm}
• Precautions for starting the engine After

performing the above air bleeding opera-
Fig.6-35
tion, start the engine and allow it to run at
low idle speed for 10min.
2. Bleeding air from the hydraulic cylinders.
1）Start the engine and allow it to run at low

idle speed for 5min.
2） Raise and lower the boom for 4~5 times

with the engine running at low idle speed.
6-28 -
• Take care not to apply relief pressure. Stop

the piston rod approximately 100 mm be-
fore reaching the end of the stroke.
3）Allow the engine to run at high idle speed,

and repeat Step (2).
4） Return the engine to low idle speed, ex-

tend the piston rod to the end of its stroke,
and apply relief pressure.
5） Repeat the operation (Starting from pro-

cedure 2) to 4) for the arm cylinder and bucket
cylinder.
• When replacing a cylinder, it is recom-

mended to bleed air from the new cylinder
before installing it onto the work equipment.
Especially for the boom cylinder, once a
new boom cylinder without air bleeding is
installed to the work equipment, the piston
rod may not extend to the stroke end.
Therefore, be sure to bleed air from the cyl-
inder before installing it to the work
equipment.
• Notes: After the replacing the hydraulic oil
and when using an excavator not used for a
long time, perform at least 5 full-stroke ex-
tension-retraction actions of the boom, the
arm and the bucket cylinders slowly under
low speed without load so as to bleed the
air, and avoid operate directly with built-
pressure or load after changing oil.
3. Bleeding air from the swing motor.
1） Start the engine and allow it to run at low

idle speed.
2） Slowly rotate the superstructure to bleed

air from the motor.
4. Bleeding air from the travel motor
- 6-29
1） Start the engine and allow it to run at low

idle speed.
2） Loosen the bleed screw and confirm that

oil comes out from the screw.
3）When oil comes out from the bleed screw,

tighten the bleed screw.
Exhaust plug:： 27.5~35.3 Nm

{2.8~3.6 kgm}
6-30 -
SY365H(BH)-10 Hydraulic Excavator Fault diagnosis and troubleshooting
Fault diagnosis and

troubleshooting
7 Fault diagnosis and troubleshooting...................................................................7-1

7.1 Precautions during fault diagnosis......................................................................................7-5
7.2 Inspection before fault diagnosis ........................................................................................7-7
7.3 Fault-Find out the symptoms and fault diagnosis numbers ............................................7-8
7.4 Fault diagnosis of electrical system................................................................................. 7-14
7.5 Circuit Diagram of Electrical Control System ................................................................. 7-18
7.6 SWP connector................................................................................................................... 7-25
7.7 A/AMP connector ............................................................................................................... 7-26
7.8 DT connector....................................................................................................................... 7-27
7.9 Fault diagnosis with DTC displayed ................................................................................ 7-28
7.9.1 Information of the fault diagnosis table ................................................................. 7-28
7.9.2 DTC E006 (Internal failure of controller) ............................................................... 7-29
7.9.3 DTC E007 (Controller internal temperature abnormality alarm) ....................... 7-30
7.9.4 DTC E008 (Sensor power abnormality)................................................................ 7-31
7.9.5 DTC E043 (Memory error) ...................................................................................... 7-32
7.9.6 DTC E047 (CPU error) ............................................................................................ 7-33
7.9.7 DTC E001 (Power voltage too low) ....................................................................... 7-34
7.9.8 DTC E002 (Power voltage too high)...................................................................... 7-35
7.9.9 DTC H010 (hydraulic oil temperature too high) ................................................... 7-36
7.9.10 DTC P013 (Engine oil pressure too low) ............................................................ 7-37
7.9.11 DTC P086 (Coolant temperature too high)......................................................... 7-38
7.9.12 DTC P070 (Fuel level too low) ............................................................................. 7-39
7.9.13 DTC P072 (Air cleaner clogged).......................................................................... 7-40
7.9.14 DTC P197 (Water separator water level too high) ............................................ 7-41
7.9.15 DTC H011 (Pump 1 pressure abnormal) ............................................................ 7-42
7.9.16 DTC H012 (Pump 2 pressure abnormal)............................................................ 7-43
7.9.17 DTC H015 (Pump 1 proportional valve abnormal)............................................ 7-44
- 7-1
Fault diagnosis and troubleshooting SY365H(BH)-10 Hydraulic Excavator
7.9.18 DTC H016 (Pump 2 proportional valve abnormal)............................................ 7-45

7.9.19 DTC E004 (Throttle knob abnormality)............................................................... 7-46
7.10 Fault diagnosis of electrical system (mode E) ............................................................. 7-46
7.10.1 Fuse box wiring table............................................................................................. 7-46
7.10.2 Information of the fault diagnosis table ............................................................... 7-49
7.10.3 E-1 The engine cannot be started ....................................................................... 7-49
7.10.4 E-2 Irregular fluctuation of engine speed ........................................................... 7-52
7.10.5 E-3 Automatic idle is disabled .............................................................................. 7-53
7.10.6 E-4 The preheating function is disabled ............................................................. 7-53
7.10.7 E-5 No equipment works....................................................................................... 7-55
7.10.8 E-6 The boom lifting is slow and powerless ....................................................... 7-56
7.10.9 E-7 The arm movement is slow and powerless................................................. 7-58
7.10.10 E-8 The bucket movement is slow and powerless.......................................... 7-59
7.10.11 E-9 The traveling is slow and powerless .......................................................... 7-60
7.10.12 E-10 The display is blank.................................................................................... 7-61
7.10.13 E-11 The display has no display ........................................................................ 7-62
7.10.14 E-12 The high/low traveling speed is disabled ................................................ 7-64
7.10.15 E-13 The display of fuel level is inaccurate...................................................... 7-66
7.10.16 E-15 The wiper doesn’t work.............................................................................. 7-67
7.11 Table of Hydraulic and Mechanical System (mode H)................................................ 7-68
7.11.1 summarize............................................................................................................... 7-68
7.11.2 Information of the fault diagnosis table ............................................................... 7-70
7.11.3 H-1 The work equipment or carrier and superstructure work slowly .............. 7-71
7.11.4 H-2 The engine speed significantly drops or engine stalls............................... 7-71
7.11.5 H-3 The work equipment has no movement, and traveling or swing function
is disabled ...................................................................................................... 7-72
7.11.6 H-4 The hydraulic pump has unusual noise....................................................... 7-73
7.11.7 H-5 Automatic idling is disabled ........................................................................... 7-74
7.11.8 H-6 The boom moves slowly ................................................................................ 7-75
7.11.9 H-7 The arm moves slowly ................................................................................... 7-76
7.11.10 H-8 The bucket moves slowly ............................................................................ 7-77
7.11.11 H-9 The single cylinder of the work equipment has no movement ............... 7-78
7.11.12 H-10 The cylinder drift of the work equipment is too large............................. 7-78
7.11.13 H-11 The work equipment moves slowly .......................................................... 7-80
7.11.14 H-12 Other work equipment moves when a single oil line has an
overflow.......................................................................................................... 7-81
7.11.15 H-13 The traveling speed drops obviously during swing+traveling .............. 7-81
7.11.16 H-14 The machine has off-tracking during traveling ....................................... 7-82
7.11.17 H-15 The machine travels at low speed ........................................................... 7-83
7.11.18 H-16 The machine is hard to turn or powerless............................................... 7-84
7.11.19 H-17 The traveling speed cannot be shifted .................................................... 7-85
7-2 -
7.11.20 H-18 It cannot travel (only on one side)............................................................ 7-86

7.11.21 H-19 The machine cannot swing ....................................................................... 7-87
7.11.22 H-20 It has low swing acceleration performance or low swing
speed.............................................................................................................. 7-88
7.11.23 H-21 The overrun is too large when swing stops ............................................ 7-90
7.11.24 H-22 The impact is too large when swing stops .............................................. 7-91
7.11.25 H-23 The unusual noise is too loud when swing stops................................... 7-91
7.11.26 H-24 The natural drift during swing is too large ............................................... 7-92
- 7-3
WARNING
7-4 -
7.Fault diagnosis and troubleshooting

7.1 Precautions during fault diagnosis
Park the machine on the horizontal ground, and confirm the function of safety pin, cushion block
and parking brake.
During the collaborative operation, the signal shall be strictly unified and no irrelevant personnel
can be allowed to be close to it.
If the radiator cap is removed when the engine is hot, hot water will be sprayed and cause burn-
ing, so maintenance shall be carried out after the engine is cooled down.
Be careful not to touch any hot parts or hold any rotating parts.
When removing wires, be sure to remove the negative (-) terminal of the battery first.
When removing the internal oil pressure, water pressure or air pressure plug or cap, release the
internal pressure first. When installing the measuring equipment, ensure that the connection is
correct.
The fault diagnosis is intended to determine the root cause of the fault accurately, repair it quickly
and prevent it from reoccurrence.
During fault diagnosis, it is important to understand the structure and function.
However, in order to effectively diagnose the fault, it is also a shortcut to know the situation from
the operator so as to preliminarily understand the possible cause of the fault.
- 7-5
4. Confirm the fault

1. Do not disassemble parts immediately dur-
• Confirm the fault, and determine whether it
ing fault diagnosis.
is a true fault, whether there are problems in
If parts are disassembled immediately, it may
use and operation, etc.
cause:
★ When the machine is operated and the fault
• The parts that are disassembled are irrele- phenomenon reoccurs, no inspection or
vant to the fault, or the parts have been dis- measurement which will make the problem
assembled unnecessarily. more serious shall be carried out.
• The fault cause cannot be found out. 5. Troubleshooting
This will waste labor, parts, or oil and grease, • According to the inspection and test results
while losing the user or operator’s trust in the of 2-4 items, narrow the scope of fault
product. causes, and then determine the fault position
Therefore, during fault diagnosis, it is neces- according to the fault diagnosis flow chart.
sary to check in advance and make fault diag- ★ The basic procedure of fault diagnosis is as
nosis according to the specified procedures. follows:
1）Start with the easy problem
2. Issues to be asked from users or operators: 2）Start with the possible problem
3）Check other relevant content.
1) Are there any other unreported problems?
6. Method of eliminating root cause of fault
2) Was there any abnormality before the fault • Even if the troubleshooting is done but the
appeared? root cause is not eliminated, the same fault
will occur again.
3) Did the fault come up suddenly or follow
Therefore, it is necessary to find out the cause
some signs? of the fault and eliminate the root cause.
4) Under which circumstance the fault occurs?
5) Was the machine repaired before the fault

occurred? When was the machine repaired?
6) Did this fault once appear?
3. Check other inspection items.
1) Check the engine oil level.
2) Check for oil leakage from pipelines or hy-

draulic devices.
3) Check the lever travel.
4) Check the spool travel of the control valve.
5) Other daily maintenance items can be in-

spected from the appearance, so only those
deemed necessary can be checked.
7-6 -
7.2 Inspection before fault diagnosis

Judgment
Description Measures
Standard
1. Confirm fuel level and type — Refuel
2. Check the fuel for foreign matters — Clean and drain
3. Check the hydraulic oil level — Refuel
4. Check the hydraulic oil strainer — Clean and drain
Lubricat
5. Check oil level of superstructure — Refuel
ing oil,
coolant 6. Check the engine oil level (level in oil pan) — Refuel
7. Check the coolant level — Add coolant
8. Check the dust indicator for clogging — Clean or replace
9. Check the hydraulic oil filter element — Replacement
10. Check the level of final drive oil — Refuel
1. Check the looseness and corrosion of battery Tighten or
—
terminals and wires replace
Electri
cal 2. Check the looseness and corrosion of Tighten or
—
equip alternator terminals and wires replace
ment 3. Check the looseness and corrosion of starter Tighten or
—
motor terminals and wires replace
Check for abnormal noises and odors — Repair it
Hydraul
ic Check for oil leakage — Repair it
devices Bleed the air — Repair it
1.Check the battery voltage (with engine shut
20-30V Replacement
down)
2. Check for discolored, burnt or peeled wires — Replacement
3. Check for falling clamps or hanging wires — Repair it
Remove the
Electrici 4. Check whether the wire is wet (check
— connector and
ty and connectors or terminals carefully)
blow it dry
electric
equip 5. Check whether the fuse blows or rusts — Replacement
ment After running
6. Check the alternator voltage (with the engine for a few
Replacement
running under the condition of over half throttle) minutes:
27.5~29.5V
7. Check the working noise of battery relay (turn
— Replacement
the switch between ON/OFF)
- 7-7
7.3 Fault-Find out the symptoms and fault diagnosis numbers

Fault diagnosis
S/N Symptoms Electric fault Hydraulic (Engine)
Code display
category fault category
Measures to be taken in relation to service code, user code, and DTC
Display the
1 user code on
the display
After
checking the
fault record,
display the
2
service code
According to
in the
the displayed
electrical
code
system
After
checking the
fault record,
3 display the
DTC in the
mechanical
system
Engine-related fault
The engine
cannot be
started easily.
4 (It usually
takes some
time to start
the engine)
The engine
5 cannot be E-1
started
The exhaust
color is too
6 black
(incomplete
combustion)
The engine
7 acceleration
is poor
7-8 -
The engine
speed is
8 E-2
irregular
(fluctuation)
The engine
has
insufficient
9 H-2
output power
or it is
powerless
Automatic
10 idling is E-5 H-5
disabled.
The engine oil
consumption
is excessive
11
or there is
blue smoke in
the exhaust
The engine
12 has too early
contamination
The fuel
13 consumption
is excessive
The engine
coolant is
mixed with
14
engine oil, or
it is sprayed
or reduced
The engine oil
increases
15
(mixed with
water or fuel)
There is
16
unusual noise
It vibrates
17
violently
Fault related to work equipment, rotation and traveling
The complete
18 E-3
vehicle can't
- 7-9
be powered
off
The hydraulic
19 pump has H-4
unusual noise
The work
equipment
has no
movement,
20 H-3
and traveling
or swing
function is
disabled
The work
equipment or
carrier and
21 H-1
superstruc
ture work
slowly
The traveling
speed drops
obviously
22 H-13
during
swing+travel
ing
Fault related to work equipment
No equipment
23 E-7
works
The single
cylinder of the
work
24 H-9
equipment
has no
movement
The cylinder
drift of the
25 work H-10
equipment is
too large
The work
26 equipment H-11
moves slowly
7-10 -
Other work
equipment
moves when
27 H-12
a single oil
line has an
overflow
The boom
lifting is slow
28 E-8 H-6
and
powerless
The arm
movement is
29 E-9 H-7
slow and
powerless
The bucket
movement is
30 E-10 H-8
slow and
powerless
Fault related to traveling
The traveling
31 is slow and E-11 H-15
powerless
The high/low
traveling
32 speed E-14
function is
disabled
The machine
has off-
33 tracking H-14
during
traveling
The machine
34 is hard to turn H-16
or powerless
The traveling
35 speed cannot H-17
be shifted
It cannot
36 travel (only on H-18
one side)
Fault related to swing
- 7-11
The machine
37 H-19
cannot swing
It has low
swing
acceleration
38 H-20
performance
or low swing
speed
The overrun
is too large
39 H-21
when swing
stops
The impact is
too large
40 H-22
when swing
stops
The unusual
noise is too
41 H-23
loud when
swing stops
The natural
drift during
42 H-24
swing is too
large
Fault related to display
The display is
43 E-12
blank
The display
44 has no E-13
display
The display of
engine
45 E-15
coolant is
inaccurate
The display of
46 fuel level is E-16
inaccurate
The display of
arm digging
47 E-18
pilot pressure
is inaccurate
7-12 -
The display of
arm dumping
48 E-19
pilot pressure
is inaccurate
The display of
boom lifting
49 E-20
pilot pressure
is inaccurate
The display of
boom
50 dumping pilot E-21
pressure is
inaccurate
The display of
bucket
51 digging pilot E-22
pressure is
inaccurate
The display of
bucket
52 dumping pilot E-23
pressure is
inaccurate
The display of
swing pilot
53 E-24
pressure is
inaccurate
The display of
left traveling
54 E-25
pilot pressure
is inaccurate
The display of
right traveling
55 E-26
pilot pressure
is inaccurate
Others
The preheater
56 function is E-6
disabled
The wiper
57 E-17
doesn’t work
- 7-13
7.4 Fault diagnosis of electrical system

Connector Position Table and System Circuit Diagram
7-14 -
- 7-15
7-16 -
- 7-17
7.5 Circuit Diagram of Electrical Control System
7-18 -
Fig.7-1
★ This circuit has been edited by extracting the engine preheating, starting and speed governing
circuit system, pressure acquisition and solenoid valve control system from the general circuit
diagram.
Fig.7-2
- 7-19
Fig.7-3
7-20 -
Fig.7-4
- 7-21
7-22 -
Fig.7-6
- 7-23
Fig.7-7
7-24 -
7.6 SWP connector
- 7-25
7.7 A/AMP connector
7-26 -
7.8 DT connector
- 7-27
7.9 Fault diagnosis with DTC displayed

7.9.1 Information of the fault diagnosis table
7-28 -
7.9.2 DTC E006 (Internal failure of controller)
- 7-29
7.9.3 DTC E007 (Controller internal temperature abnormality alarm)
7-30 -
7.9.4 DTC E008 (Sensor power abnormality)
- 7-31
7.9.5 DTC E043 (Memory error)
7-32 -
7.9.6 DTC E047 (CPU error)
- 7-33
7.9.7 DTC E001 (Power voltage too low)
Fig.7-8
7-34 -
7.9.8 DTC E002 (Power voltage too high)
- 7-35
7.9.9 DTC H010 (hydraulic oil temperature too high)
Fig.7-9
7-36 -
7.9.10 DTC P013 (Engine oil pressure too low)
- 7-37
7.9.11 DTC P086 (Coolant temperature too high)
7-38 -
7.9.12 DTC P070 (Fuel level too low)
- 7-39
7.9.13 DTC P072 (Air cleaner clogged)
7-40 -
7.9.14 DTC P197 (Water separator water level too high)
- 7-41
7.9.15 DTC H011 (Pump 1 pressure abnormal)
Fig.7-10
7-42 -
7.9.16 DTC H012 (Pump 2 pressure abnormal)
Fig.7-11
- 7-43
7.9.17 DTC H015 (Pump 1 proportional valve abnormal)
Fig.7-12
7-44 -
7.9.18 DTC H016 (Pump 2 proportional valve abnormal)
Fig.7-13
- 7-45
7.9.19 DTC E004 (Throttle knob abnormality)
Fig.7-14
7.10 Fault diagnosis of electrical system (mode E)

7.10.1 Fuse box wiring table
★ This wiring table shows each power supply unit and the corresponding rated current.
7-46 -
★ If the power supply is normal, please check the fuse box and the fuse when troubleshooting the
electrical system.
- 7-47
Integrated fuse box

Fuse No. / relay No. Rated value system
F1 20A Start circuit
F4 5A Extinguishing delay
F5 10A Charging indicator
F7 10A Display power supply
F8 15A Diagnosis switch
F9 10A Radio
F10 5A Refueling pump
F11 10A Fuel filter pump
F12 10A Cigar lighter
F13 10A Controller
F14 20A Work light
F15 20A Cab ceiling lamp
F16 5A Alarm lamp
F17 5A Wiper/washer
F18 20A A/C
F19 5A GPS power supply
F20 30A ECM power
F22 10A Traveling alarm horn
F23 15A Horn
F24 5A Indoor lamp
F25 5A Access lamp
F26 10A Seat
K2 24V, 20A 5-PIN MICRO Standby relay
K3 24V, 20A 5-PIN MICRO Work light relay
K4 24V, 20A 5-PIN MICRO Cab ceiling lamp relay
K5 24V, 20A 5-PIN MICRO Traveling alarm relay
K8 24V, 20A 5-PIN MICRO Traveling alarm horn
K9 24V, 20A 5-PIN MICRO Horn relay
K10 24V, 20A 5-PIN MICRO Standby relay
K12 24V, 20A 5-PIN MICRO Shutdown delay relay
K16 24V, 20A 5-PIN MICRO Reserved
K17 24V, 20A 5-PIN MICRO Reserved
7-48 -
Fault information Fault information

Fault information Fault information
Predicted cause and Reason Standard value under

the standard value normal conditions and
under normal fault diagnosis
conditions reference value
1 Hypothetical cause of < Content included >
fault to be discussed • Standard values
(The serial number is under normal
for the convenience of conditions, which can
compilation and be used to determine
reference, but it if the assumption is
doesn’t represent any true.
priority) • Reference value,
which can be used to
pass the above
judgment.
< Wire harness fault >
• Open circuit
Poor contact with
connector or open
circuit of wire harness.
• Ground wire fault
A wire that shall not
be connected to a
ground wire circuit is
in contact with this
circuit.
• Short circuit
A wire that shall not
be connected to a 24
V circuit is in contact
with this circuit.
7.10.3 E-1 The engine cannot be started
Fault information The engine cannot be started (the engine

doesn’t rotate)
Relevant information
- 7-49
Standard value under normal conditions and

Reason
fault diagnosis reference value
★ Turn the engine starting switch to the OFF
Insufficient position for preparation, and keep it in the OFF
1 battery position for fault diagnosis.
capacity Battery Higher than
Voltage value
voltage 24 V
position for preparation, and keep it in the OFF
position for fault diagnosis.
OFF position:
Internal fault Between 22#
of engine Above 1MΩ
2 wire and 11#
starting switch wire Resistance
ON position: value
Between 22#
Below 1Ω
wire and 11#
wire
Predicted ★ Turn the engine starting switch to the OFF
cause and the position for preparation, and keep it in the OFF
standard position for fault diagnosis.
value under Unlocking
normal position of
conditions locking lever:
Below 1MΩ
Between 105
Pilot switch
3 # wire and 0#
fault
wire Resistance
Locking value
position of
locking lever:
Above 1Ω
Between 105
# wire and 0#
wire
position for preparation, and keep the engine
running during fault diagnosis (if all of the
power supply, grounding, and the generated
Starter motor signals and engine input are normal and only
4 the output of the engine is abnormal, the
fault
engine starter motor will be deemed to have a
fault.)
Engine starter
Key switch Voltage value
motor
7-50 -
Power supply:
B terminal 20—30V
and ground
Between Starting
engine input
20—30V
terminal S
and ground
position for preparation, and keep it in the ON
Starting
switch 22#
Wire harness wire and Below 1Ω
5 starting motor
open circuit
B terminal Resistance
Starting value
switch 11#
wire and Below 1Ω
starting relay
SW terminal
Battery “+”
terminal (20#
Resistance
6 Fuse F1 fault wire) and Below 1Ω
value
control knob
22# wire
● Turn the engine starting switch to the OFF
Between
Wire harness
starting relay
short circuit Above 1MΩ
7 SW terminal
(grounding
and ground Resistance
fault)
Between value
engine input
Above 1MΩ
terminal S
and ground
Turn the engine starting switch to the OFF
Internal fault
8 Between the
of alternator
alternator P
Voltage value Below 1 V
terminal and
ground
- 7-51
7.10.4 E-2 Irregular fluctuation of engine speed
Fault information The engine cannot be stopped

When turning the engine starting switch to the
OFF position, the engine is not stopped.

Reason
★Turn the engine starting switch to the OFF
OFF position:
Internal fault
Between 22#
Predicted of engine Above 1MΩ
1 wire and 11#
cause and the starting
wire Resistance
standard switch
ON position: value
value under
Between 22#
normal Above 1MΩ
wire and 11#
conditions
wire
The fault diagnosis cannot be carried out
Engine ECM because it is an internal fault. (If the fault is not
2
internal fault due to either of the above, the controller shall
be deemed to be defective)
3
4
Fig.7-15
7-52 -
7.10.5 E-3 Automatic idle is disabled
Fault information The engine has no automatic idle speed

In case of the automatic idle speed mode,
Relevant information when the handle is in the neutral position, the
engine has no deceleration

Reason
● Turn the engine starting switch to the OFF
position for preparation, and then restart it and
keep the engine running for fault diagnosis.
Turn the
control lever
to the neutral
position, and 0 KG
Predicted 1 Sensor fault transmit
cause and the pressure Pressure
standard signal value
value under
Operate the
normal
control lever,
conditions
and transmit 0~37 KG
pressure
signal
● The fault diagnosis cannot be carried out
Controller because it is an internal fault. (If the fault is not
2
fault due to either of the above, the controller or
program shall be deemed to be defective)
3
4
7.10.6 E-4 The preheating function is disabled
Fault information The engine preheating function is disabled

Pre dict ed Standard value under normal conditions and

Reason
cau se and fault diagnosis reference value
the stan dard
Failure of ★ Turn the engine starting switch to the OFF
valu e und er
1 preheate r position for preparation, and keep it in the OFF
nor mal con
fuse position for fault diagnosis.
ditio ns
- 7-53
Between 21#
wire and 3#
Resista nce
pin (contact) Below 1Ω
value
of preheater
relay
When preheating function is activated, If there
Failure of
is movement sound heard from the preheater
2 preheate r
relay contact, it indicates the relay works
relay
normally. Preheater switch OFF-ON-OFF.
Preheater
switch in OFF
position:
Above 1MΩ
Failure of Between 16#
3 preheate r wire and 17#
switch wire Resista nce
Preheater value
switch in ON
position:
Below 1Ω
Between 16#
wire and 17#
wire
Wire short
circuit Between 3#
4
(groundi ng) pin (contact)
Resista nce
of preheater Above 1MΩ
value
relay and
ground
5
7-54 -
Fig.7-16
7.10.7 E-5 No equipment works
After starting the machine, it has no movement

Fault information
after operation

Reason
position for preparation, and then restart it and
keep the engine running for fault diagnosis.
Safety lock
1 Measurement Safety control Resistance
switch fault
item lever value
Predi cted Between 105# Locking Below 1Ω

caus e and and 41# wires Release Above 1MΩ
the stand ard ★ Turn the engine starting switch to the OFF
value under position for preparation, and keep it in the OFF
Wire short
norm al condi position for fault diagnosis.
2 circuit
tions
(grounding) Between 105# Resistance
Above 1MΩ
and ground value
Fault of position for preparation, and keep it in the OFF
internal coil of position for fault diagnosis.
3 PPC locking
solenoid Between 1
Resista nce
valve and 2 of About 34Ω
value
solenoid valve
- 7-55

Between 1#
pin of pilot
solenoid valve
connector Resistanc e
Below 1Ω
YV1-F and value
101# pin of
Wire open
4 controller
circuit
ECU2
Between 2#
pin of pilot
switch
connector Resistanc e
Below 1Ω
SQ1-M and value
65# pin of
controller
ECU2
Fig.7-17
7.10.8 E-6 The boom lifting is slow and powerless
When excavator works, the boom moves

Fault information
slowly and the digging is powerless
The pilot pressure signal during boom
movement can be read from the display
Predicted cause and Standard value under

the standard value normal conditions and
Reason
under normal fault diagnosis
conditions reference value
7-56 -
★ Turn the engine

starting switch to the
OFF position for
preparation, and then
restart it and keep the
engine running for
fault diagnosis.
1 Sensor fault
Control lever in
neutral position, the
pilot pressure is 0KG
Operate the control
lever, and the pilot
pressure is within 0
~37KG
Check the engine
speed and
proportional solenoid
2 Engine speed fault
valve current; if the
speed is low, re-
calibrate the speed.
The fault diagnosis
cannot be carried out
because it is an
internal fault. (If the
3 Controller fault fault is not due to any
of the above, the
controller shall be
deemed to be
defective)
Fig.7-18
- 7-57
7.10.9 E-7 The arm movement is slow and powerless
The arm movement is slow and powerless

Fault information
when the excavator moves
The pressure signal during arm movement can
be read from the display
Standard value under

normal conditions and
Reason
fault diagnosis
reference value
★ Turn the engine
OFF position for
engine running for
fault diagnosis.
1 Sensor fault
Control lever in
Operate the control
Predicted cause and
the standard value
under normal
~37KG
conditions
Check the engine
speed and
speed is low, re-
The fault diagnosis
because it is an
of the above, the
controller shall be
deemed to be
defective)
7-58 -
Fig.7-19
7.10.10 E-8 The bucket movement is slow and powerless
The bucket movement is slow and powerless

Fault information
when the excavator moves
The pressure signal during arm movement can
be read from the display

Reason
fault diagnosis
reference value
★ Turn the engine
OFF position for
engine running for
fault diagnosis.
Predicted cause and
1 Sensor fault
the standard value Control lever in
under normal neutral position, the
conditions pilot pressure is 0KG
Operate the control
~37KG
Check the engine
speed and
speed is low, re-
- 7-59
The fault diagnosis

because it is an
of the above, the
controller shall be
deemed to be
defective)
Fig.7-20
7.10.11 E-9 The traveling is slow and powerless
The traveling is slow and powerless when the

Fault information
excavator moves
The pressure signal during traveling can be
read from the display

Reason
fault diagnosis
reference value
★ Turn the engine
Pre dict ed cau se and starting switch to the
the stan dard valu e OFF position for
und er nor mal con preparation, and then
ditio ns restart it and keep the
1 Sensor fault engine running for
fault diagnosis.
Control lever in
7-60 -
Operate the control

~37KG
Check the engine
speed and
speed is low, re-
The fault diagnosis
because it is an
of the above, the
controller shall be
deemed to be
defective)
Fig.7-21
7.10.12 E-10 The display is blank
The display is blank after the excavator is

Fault information
powered on
- 7-61

Reason
Turn the engine starting switch to the OFF
Predicted
Between 43#
cause and the
1 Fuse fault wire and About 24V
standard
ground
value under Voltage value
normal Between 29#
conditions wire and About 24V
ground
Display because it is an internal fault. (If the fault is not
2
screen fault due to either of the above, the display shall be
deemed to be defective)
Fig.7-22
7.10.13 E-11 The display has no display
The display is on, but there is no display

Fault information
information after the excavator is powered on
7-62 -

Reason
Resistance position for fault diagnosis.
1
fault
Between 1 Resistance
120Ω
and 2 of M09 value
Between 78#
pin of CN-
437M and B#
pin of CN-
452M, and
Below 1Ω
between 78#
pin of CN-
437M and 1#
Wire open pin of CN-
Predicted 2
circuit 101M
cause and the Resistance
Between 60#
standard value
pin of CN-
value under
437M and A#
normal
pin of CN-
conditions
452M, Below
1Ω and Below 1Ω
between 60#
pin of CN-
437M and 2#
pin of CN-
101M
Between 78#
pin of CN-
Wire short 437M and B#
3 pin of CN-
circuit
452M, and Resistance
Above 1MΩ
between 78# value
pin of CN-
437M and 1#
pin of CN-
101M
- 7-63
Between 60#
pin of CN-
437M and A#
pin of CN-
452M, and
Above 1MΩ
between 60#
pin of CN-
437M and 2#
pin of CN-
101M
Failure of
because it is an internal fault. (If the fault is not
4 display or
due to any of the above, the display or
controller
controller shall be deemed to be defective)
Fig.7-23
7.10.14 E-12 The high/low traveling speed is disabled
The excavator is only available for low

Fault information
traveling speed during operation
Operate the high/low traveling speed key of
the display to realize high/low speed switching
7-64 -

Reason
Fault of high/ position for preparation, and keep it in the OFF
low speed
1 traveling
solenoid Between 603
Resistance
valve and 0-YV of About 34Ω
value
YV2-F
Predicted Between
cause and the 603# wire of
Wire YV2-F and Below 1Ω
standard
2 disconnection 82# pin of
value under
fault controller Resistance
normal
conditions Between 0- value
YV# wire of
YV2-F and Below 1Ω
25# pin of
controller
Wire short
3 Between
circuit
603# wire of Resistance
Above 1MΩ
YV2-F and value
ground
4
Fig.7-24
- 7-65
7.10.15 E-13 The display of fuel level is inaccurate
The fuel level sensor of the engine cannot

Fault information
accurately reflect the current oil level
Relevant information The fuel level can be read from the display

Reason
Resistance
Oil level Pin Fuel level
1 value
sensor fault
Full (upper Empty (lower
Between limit) limit)
509# and
ground Empty (lower
85 ~ 95Ω
limit)
Predicted ★ Turn the engine starting switch to the OFF
cause and the position for preparation, and keep it in the OFF
standard position for fault diagnosis.
value under
Between
normal Wire
509# wire and
conditions 2 disconnection
11# pin of
fault Resistance
controller Below 1Ω
value
signal
acquisition
port
Wire short position for fault diagnosis.
3 circuit
(grounding) Between
Resistance
509# wire and Above 1MΩ
value
ground
7-66 -
Fig.7-25
7.10.16 E-15 The wiper doesn’t work
Fault information The wiper doesn’t work after operation


Reason
Internal fault position for fault diagnosis.
1
of wiper motor Between 25#
Resistance
wire of wiper Above 10Ω
value
and ground
Predicted position for preparation, and keep it in the OFF
cause and the position for fault diagnosis.
standard Between 25
value under of fuse F17
Below 1Ω
normal and 2 of CN-
conditions 117M
Wire Between
2 disconnection 35L# wire of
fault wiper switch Resistance Below 1Ω
and 5 of CN- value
117M
Between
35H# wire of
wiper switch Below 1Ω
and 4 of CN-
117M
- 7-67

Wire short Wire harness
3 circuit between 25 of
(grounding) fuse F17 and Resistance
Above 1MΩ
2 of CN-117M value
short to
ground
Fig.7-26
7.11 Table of Hydraulic and Mechanical System (mode H)

7.11.1 summarize
★The system table is drawn after simplification of the whole hydraulic lines table, which can be
used as a reference for fault diagnosis of hydraulic system and mechanical system.
7-68 -
Fig.7-27
- 7-69
Fig.7-28
★ The following information is included in the fault diagnosis table and relevant circuit diagram.
Carry out fault diagnosis only after the content is fully understood.
Fault information Phenomenon of the machine

Relevant information Information and diagnosis of existing fault
Standard value under normal conditions

Cause
Predicted and fault diagnosis reference value
cause and 1 Predicted fault cause < Content>
the standard 2 (The serial number is for ● The standard values under normal
value under the convenience of conditions can be used to determine if the
3
normal compilation and cause is ”good” or “poor”
conditions 4
reference, but it doesn’t ● The reference value can be used to
5 represent any priority) determine if it is ”good“ or “poor“
7-70 -
7.11.3 H-1 The work equipment or carrier and superstructure work slowly
● The work equipment or carrier and

Fault information
superstructure work slowly.
● Set working mode to the S mode and the
10th gear for fault diagnosis.
Standard value under normal conditions and fault diagnosis

Cause
reference value
★ Stop the engine for preparation. Start fault diagnosis
when the engine runs at high idle speed.
The main relief Control lever Pressure of main relief valve
Predict valve is Arm ”digging“ 33~34.3 MPa
1
ed improperly {337~350 kgf/cm²}
cause adjusted or fails
If the pressure cannot return to normal conditions after
and the adjustment, the main relief valve may fail or internal fault
stand may exist. In this case, check the valve.
ard
value
under
Failure of pilot
normal 2 Control lever Pilot control pressure
relief valve
condi All the control levers are in 3.9~4.1 MPa
tions the ”neutral position“ {40~42 kg/cm2}
The regulator may fail, and its servo mechanism shall be
3 Regulator failure
checked
The the above cause is not discovered, the piston pump
Piston pump
4 may have performance deterioration and failure or internal
failure
fault may exist.
7.11.4 H-2 The engine speed significantly drops or engine stalls
● The engine speed significantly drops or

Fault information
engine stalls
Relevant information —
- 7-71
Pr Standard value under normal conditions and fault

Cause
ed diagnosis reference value
ict
1 Fuel injection pump fault The fuel injection pump may have fault. Check it.
ed
ca The regulator may fail, and its servo mechanism
2 Regulator failure
us shall be checked.
e Blocking of fuel filter The fuel line blockage may be caused by blocking
3
an element of fuel filter element. Check it.
d Carbon deposit of fuel The fuel nozzle may have carbon deposit. Check
th 4
nozzle it.
e
The blocking of air cleaner may be caused by
st 5 Blocking of air cleaner
unsmooth intake. Check it.
an
da 6 Abnormal wear of engine The engine may have abnormal wear. Check it.
rd
va
lu
e
un
de
r
no 7 Fuel delivery pump fault The fuel delivery pump may have fault. Check it.
rm
al
co
nd
iti
on
s
7.11.5 H-3 The work equipment has no movement, and traveling or swing function is
disabled
● The work equipment has no movement, and

Fault information
traveling or swing function is disabled.
●Set working mode to the S mode and the
7-72 -

Cause
reference value
★Stop the engine for preparation. Start fault diagnosis when
the engine runs at high idle speed.
Failure of pilot Pilot safety lever Pilot relief pressure
1 safety solenoid
Locking 0 {0}
Predict valve
ed 3.9~4.1 MPa
Unlocking
cause {40~42 kg/cm2}
and the ★ Stop the engine for preparation. Start fault diagnosis
stand when the engine runs at high idle speed.
Fault of pilot
ard
2 pump relief Control lever Pilot relief pressure
value
valve All the control levers are in 3.9~4.1 MPa
under
normal the “neutral” position {40~42 kg/cm2}
condi The piston pump may have failure or internal fault.
tions Hydraulic pump Diagnose it through following methods.
3
fault ● Remove the oil pressure measuring plug and start the
engine. If oil flows out, it shall be normal.
The pump shaft cannot rotate due to internal fault of the
coupler, check the coupler.
4 Coupler fault
● If no oil flows out after the pilot pump outlet is released,
the coupler may have a fault.
7.11.6 H-4 The hydraulic pump has unusual noise
● Abnormal sound can be heard around the

Fault information
hydraulic pump.
Relevant information ——
- 7-73
Pre Standard value under normal conditions and fault

dict diagnosis reference valueStandard value under
Cause
ed normal conditions and fault diagnosis reference
cau value
se The hydraulic oil level
and 1 Visual inspection
drops
the
2 The hydraulic oil is poor The oil may be mixed with air. Visual inspection.
sta
nda The ventilator of the top cap of the hydraulic tank
rd Blocking of ventilator of the may be blocked, resulting in negative pressure in
val 3 top cap of the hydraulic the tank.
ue tank Press down the release valve of the breathing
un valve, and check the sound disappears.
der The strainer of the hydraulic tank may be
nor Blocking of strainer of the blocked, resulting in negative pressure in the
mal 4
hydraulic tank suction tank.
con Carry out visual inspection.
di
tion The piston pump may have internal fault. Check
5 Piston pump fault
s it.
7.11.7 H-5 Automatic idling is disabled
Fault information ● Automatic idling is disabled.


Cause
reference value
Predict
ed All the control levers Pilot valve output pressure
cause 1 Sensor failure
”Neutral position“ 0 {0}
and the
stand 3.5~4.1MPa
Operation
ard {36~42 kg/cm²}
value ★ Stop the engine for preparation. Start fault diagnosis
under when the engine runs at high idle speed.
normal
Pilot valve All the control levers Pilot valve output pressure
condi 2
tions failure ”Neutral position“ 0 {0}
3.5~4.1MPa
Operation
{36~42 kg/cm²}
3 Controller fault The controller may have fault. Check it.
7-74 -
7.11.8 H-6 The boom moves slowly
Fault information ● The boom moves slowly.


Cause
reference value
Failure of right
pilot valve (on Boom control lever Pilot valve output pressure
1
the boom oil ”Neutral position“ 0 {0}
line)
3.5MPa or above
”Lifting“ or ”Lowering“
{36 kgf/cm2}
Pressure sensor when the engine runs at high idle speed.
2
fault
Replace the old part with a new one for inspection
Predict
Failure of boom
ed The boom control valve spool may have failure. Check the
3 control valve
cause valve.
(spool)
and the
stand Failure of boom
The holding valve of the boom control valve may have
ard 4 control valve
failure. Check the valve.
value (holding valve)
under Boom control
normal valve (relief
condi The relief valve and refilling valve of the boom control valve
valve and
tions 5 may have failure or the seal may have fault. Check these
refilling valve)
valves.
failure or seal
failure
The bucket load is about 1,260 kg load. Cut off the oil line
on high pressure cavity side of the cylinder, disconnect its
Boom cylinder connection with the main valve, and measure the piston
6
fault displacement for 15 minutes after cylinder becomes stable.
If its value is larger than 10 mm, the cylinder seal fault can
be determined. For detailed measurement methods, see the
―Inspection of Hydraulic Drift of Work Equipment‖ (Page 6-
17).
- 7-75
7.11.9 H-7 The arm moves slowly
Fault information ● The arm moves slowly.


Cause
reference value
Failure of left Arm control lever Pilot valve output pressure
1 pilot valve (arm
oil line) ”Neutral position“ 0 {0}
3.5MPa or above
“Digging” or “Dumping”
{36 kg/cm²}
Pressure sensor when the engine runs at high idle speed.
2
fault
Predict
ed Failure of arm
The arm control valve spool may have failure. Check the
cause 3 control valve
valve.
and the (spool)
stand Failure of arm
ard control valve The regeneration valve of arm control valve may have
value 4
(regeneration failure. Check the valve.
under valve)
normal
condi Failure of arm
tions control valve
The relief valve and refilling valve of the arm control valve
5 (relief valve and
may have failure or the seal may have fault. Check it.
refilling valve) or
fault of seal
For detailed measurement methods, see the ”Inspection of
Hydraulic Drift of Work Equipment“ (Page 6-17). Cut off the
Arm cylinder
6 oil line on high pressure cavity side of the cylinder,
fault
disconnect its connection with the main valve, and measure
the piston displacement for 15 minutes after cylinder
becomes stable. If its value is larger than 10 mm, the
cylinder seal fault can be determined.
7-76 -
7.11.10 H-8 The bucket moves slowly
Fault information ● The bucket moves slowly.


Cause
reference value
Failure of right Bucket control lever Pilot valve output pressure
1 pilot valve
(bucket oil line) ”Neutral position“ 0 {0}
3.5MPa or above
”Digging” or “Dumping”
{36 kg/cm²}
Predict Pressure sensor when the engine runs at high idle speed.
2
ed fault
cause
and the Failure of bucket
The bucket control valve spool may have failure. Check the
stand 3 control valve
valve.
ard (spool)
value Failure of bucket
under control valve
The relief valve and refilling valve of the bucket control valve
normal 4 (relief valve and
may have failure or the seal may have fault. Check it.
condi refilling valve) or
tions fault of seal
The bucket load is about 1,260 kg load. Cut off the oil line
on high pressure cavity side of the cylinder, disconnect its
Bucket cylinder connection with the main valve, and measure the piston
5
fault displacement for 15 minutes after cylinder becomes stable.
If its value is larger than 10 mm, the cylinder seal fault can
be determined. For detailed measurement methods, see the
“Inspection of Hydraulic Drift of Work Equipment” (Page 6-
17).
- 7-77
7.11.11 H-9 The single cylinder of the work equipment has no movement
● The boom cylinder has no movement in case

of independent operation.
● The arm cylinder has no movement in case
Fault information
of independent operation.
● The bucket cylinder has no movement in
case of independent operation.

Cause
reference value
Predict when the engine runs at high idle speed.
ed Joystick Pilot valve output pressure
Pilot valve
cause 1
failure “Neutral position” 0 {0}
and the
stand 3.5MPa or above
“Digging” or ‘Dumping”
ard {36 kg/cm²}
value
under Pressure sensor
2 when the engine runs at high idle speed.
normal fault
condi Replace the old part with a new one for inspection
tions Failure of work
equipment The work equipment control valve spool may have failure.
3
control valve Check the valve.
(spool)
7.11.12 H-10 The cylinder drift of the work equipment is too large
Fault information (1) ● The boom sinks too quickly.

Predicted Standard value under normal conditions

Cause
cause and and fault diagnosis reference value
the standard
★ Stop the engine for preparation. Start
value under
1 Boom cylinder fault fault diagnosis when the engine runs at high
normal
idle speed.
conditions
7-78 -
The bucket load is about 1,260 kg load. Cut

off the oil line on high pressure cavity side
of the cylinder, disconnect its connection
with the main valve, and measure the piston
displacement for 15 minutes after cylinder
becomes stable. If its value is larger than 10
mm, the cylinder seal fault can be
determined. For detailed measurement
methods, see the ―Inspection of Hydraulic
Drift of Work Equipment‖ (Page 6-17).
The boom holding valve and pilot valve may
2 Boom holding valve fault
be worn out or seized. Check it.
Failure of seal of boom The seal of the relief valve and refilling
3 control valve (relief valve of the boom control valve may have
valve and refilling valve) failure. Check it.
The boom valve spool may be worn out.
4 Boom valve spool fault
Check it.
Fault information (2) ● The arm sinks too quickly


Cause
and fault diagnosis reference value
★ Stop the engine for preparation. Start
fault diagnosis when the engine runs at high
Predicted idle speed.
cause and For detailed measurement methods, see
the standard the “Inspection of Hydraulic Drift of Work
value under Equipment” (Page 6-17). Cut off the oil line
1 Arm cylinder fault
normal on high pressure cavity side of the cylinder,
conditions disconnect its connection with the main
valve, and measure the piston displacement
for 15 minutes after cylinder becomes
stable. If its value is larger than 10 mm, the
cylinder seal fault can be determined.
- 7-79
The seal of the relief valve and refilling

valve of the arm control valve may have
failure. Check it.
Failure of seal of the
★ The failure of the seal can be determined
2 arm control valve (relief
by replacing with other relief valves and
valve and refilling valve)
refilling valves. (Do not replace it with the
boom “Drop” relief valve and refilling valve,
for the setting pressure is different.)
The arm holding valve and pilot valve may
3 Arm holding valve fault
be worn out or seized. Check it.
The arm valve spool may be worn out.
4 Arm valve spool fault
Check it.
Fault information (3) ● The bucket sinks too quickly.


Cause
reference value
Bucket cylinder
ed 1
fault Bucket control lever Oil leakage of cylinder
cause
Digging overflow 20 ml/min
and the
stand The seal of the relief valve and refilling valve of the bucket
Failure of seal of
ard control lever may have failure. Check the seal.
the bucket
value ★ The failure of the seal can be determined by replacing
2 control valve
under with other relief valves and refilling valves. (Do not replace it
(relief valve and
normal with the boom “Drop” relief valve and refilling valve, for the
refilling valve)
condi setting pressure is different.)
tions Failure of seal of
the bucket The seal of the bucket control valve spool may have failure.
3
control valve Check it.
(spool)
7.11.13 H-11 The work equipment moves slowly
Fault information ● The work equipment moves slowly

7-80 -

Cause
Arm regeneration valve The arm regeneration valve may have
1
Predicted failure failure. Check it.
cause and The relief valve and refilling valve of the
the standard control valve may have failure. Check it.
value under ★ For the arm and boom, the failure of the
normal Failure of the control
valve can be determined by replacing with
conditions 2 valve (relief valve and
other relief valves and refilling valves.
refilling valve)
(Do not replace it with the boom “Drop”
relief valve and refilling valve, for the setting
pressure of each valve is different.)
7.11.14 H-12 Other work equipment moves when a single oil line has an overflow
● Other work equipment moves when a single

Fault information oil line of the specific work equipment has an
overflow.
● Set working mode to the S mode for fault
diagnosis.

Cause
the standard
value under Failure of seal of the The seal of the control valve may have
normal 1
control valve failure. Check it.
conditions
7.11.15 H-13 The traveling speed drops obviously during swing+traveling
● The traveling speed drops obviously during

Fault information
swing+traveling
● If the traveling speed is low in a single
Relevant information traveling operation, the H-15 inspection can be
carried out first.

Cause
Straight and fault diagnosis reference value
travel valve The straight travel valve has no movement,
fault Straight travel valve
1 check the valve spool and the logical oil line
fault
outlet
- 7-81
7.11.16 H-14 The machine has off-tracking during traveling
● The machine has off-tracking tendency

Fault information
during traveling

Cause
reference value
Travel lever Pilot valve output pressure
Traveling pilot
1 3.5~3.9 MPa
valve failure Forward or backward
{ 36~40 kg/cm²}
The left/right outputs are 0.4 MPa {4 kg/cm²}
different
Failure of pilot Control oil line source
Predict 2 Control lever
relief valve pressure
ed
All the control levers are in 3.5~3.9 MPa
cause
the “neutral position” { 36~40 kg/cm²}
and the
stand It can be checked by exchanging the front and rear
3 Regulator fault
ard regulators
value ★ Stop the engine for preparation. Start fault diagnosis
under when the engine runs at high idle speed.
normal Seizure of
condi Proportioning valve output
4 proportional Travel lever
tions pressure
solenoid valve
The difference is not larger
Operate both sides
than 0.1 MPa
Seizure of
5 traveling valve Check whether the valve spool moves flexibly
spool
Internal leakage
6 of central swing It can be checked by exchanging the pipes
connector
Travel motor
7
failure Travel lever Oil leakage of travel motor
Traveling overflow 27.2 ml/min
7-82 -
The final drive may have internal fault. Check inside of the
final drive directly.
8 Final drive fault ★ The internal failure of the final drive can be determined by
unusual noise, abnormal heat and metal powder or debris in
the oil.
Fault of traveling The 3.5~3.9 MPa is
9 pilot pressure Forward or backward displayed on the display
sensor { 36~40 kg/cm²}
The left/right outputs are
0.4 MPa {4 kg/cm²}
different
It can be checked by exchange
7.11.17 H-15 The machine travels at low speed
Fault information ● The machine has low traveling speed.


Cause
reference value
★ Stop the engine for preparation. Start fault diagnosis when the
Pre engine runs at high idle speed.
dict Pilot valve output
ed Traveling Travel lever
pressure
caus 1 pilot valve
failure 3.5~3.9 MPa
e and Forward or backward
{ 36~40 kg/cm²}
the
stand The left/right or front/rear outputs are 0.4 MPa {4 kg/cm²}
ard different
value ★ Stop the engine for preparation. Start fault diagnosis when the
under engine runs at high idle speed.
nor Failure of
Control oil line source
mal 2 pilot relief Control lever
pressure
condi valve
tions All the control levers are in the “neutral 3.5~3.9 MPa
position” { 36~40 kg/cm²}
3 Sensor fault
engine runs at high idle speed.
- 7-83
The pressure is
Traveling speed Travel lever displayed on the
display
3.5~3.9 MPa
Low speed Operation
{ 36~40 kg/cm²}
3.5~3.9 MPa
High speed Operation
{ 36~40 kg/cm²}
It can be checked by exchanging the parts
Failure of
traveling
The traveling control valve spool may have failure. Check the valve
4 control
spool.
valve
(spool)
Failure of
traveling
control The refilling valve of the traveling control valve may have failure.
5
valve Check the valve.
(refilling
valve)
engine runs at high idle speed.
Travel
6 Oil leakage of travel
motor fault Travel lever
motor
The final drive may have internal fault. Check inside of the final drive
Final drive directly.
7
fault ★ he internal failure of the final drive can be determined by unusual
noise, abnormal heat and metal powder or debris in the oil.
7.11.18 H-16 The machine is hard to turn or powerless
Fault information ● The machine is hard to turn.

7-84 -

Cause
reference value
Traveling pilot
1 On “neutral position” on both 0 {0}
valve failure
sides
3.5~3.9 MPa
Operate only on one side
{ 36~40 kg/cm²}
Predict Solenoid valve output
ed Failure of Travel lever
pressure
cause 2 traveling pilot
and the pressure sensor 3.5~3.9 MPa
Operate both sides
stand { 36~40 kg/cm²}
ard 3.5~3.9 MPa
Operate only on one side
value { 36~40 kg/cm²}
under Failure of
normal The traveling control valve spool may have failure. Check
3 traveling control
condi the valve spool.
valve (spool)
tions
Failure of
traveling control The refilling valve of the traveling control valve may have
4
valve (refilling failure. Check the valve.
valve)
The internal seal of the relief valve of the travel motor may
Failure of travel
have failure. Check the seal.
5 motor (relief
★ Failure of the seal can be determined by switching front/
valve)
rear or left/right motors.
The internal seal of the check valve of the travel motor may
Failure of travel
have failure. Check the seal.
6 motor (check
★ Failure of the seal can be determined by switching front/
valve)
rear or left/right motors.
7.11.19 H-17 The traveling speed cannot be shifted
Fault information ● The traveling speed cannot be shifted.

● Set working mode to the S mode and the 10th gear
for fault diagnosis.
- 7-85

Pre Cause
reference value
dict
ed ★ Stop the engine for preparation. Start fault diagnosis when the
caus Failure of engine runs at high idle speed.
e and high/low Traveling speed Travel lever Solenoid valve output
the speed pressure
1
stand changeover
Low speed Operation 0 {0}
ard solenoid
value valve 3.5~3.9 MPa
High speed Operation
under { 36~40 kg/cm²}
nor Fault of
mal travel motor The travel motor may have speed shift fault Directly check the speed
condi 2
(speed shift part.
tions shift)
7.11.20 H-18 It cannot travel (only on one side)
Fault information ● The track shoe can't turn (only on one side).

Cause
reference value
The relief valve
seat of the travel
The refilling valve seat of the traveling control valve may
1 motor may have
have fault. Check the valve seat.
fault. Check the
Predict valve seat.
ed
Fault of travel
cause The relief valve seat of the travel motor may have fault.
2 motor (refilling
and the Check the valve seat.t.
valve) seat
stand
ard Deceleration of The check valve seat of the travel motor may have fault.
3
value the travel motor Check the valve seat.
under ★ Stop the engine for preparation. Start fault diagnosis
normal when the engine runs at high idle speed.
Deceleration of
condi 4
the travel motor Travel lever Oil leakage of travel motor
tions
The final drive may have internal fault. Check inside of the
final drive directly.
5 Final drive fault ★ The internal failure of the final drive can be determined by
unusual noise, abnormal heat and metal powder or debris in
the oil.
7-86 -

The 3.5~3.9 MPa is
Fault of pilot
6 Forward or backward displayed on the display
pressure sensor
{ 36~40 kg/cm²}
The left/right outputs are
0.4 MPa {4 kg/cm²}
different
It can be checked by exchange
7.11.21 H-19 The machine cannot swing
Fault information (1) ● The machine cannot swing left and right.

Cause
reference value
Failure of swing
The parking brake part of the swing motor have failure.
1 motor (parking
Check it directly.
brake)
Predict
ed The swing motor Swing control lever Swing relief pressure
cause (relief valve) is 25.5~28.5 MPa
2 Swing overflow
and the improperly {260~291 kg/cm²}
stand adjusted or fails
If the oil pressure cannot return to normal conditions after
ard
adjustment, the relief valve may fail or internal fault may
value
exist. Check the valve.
under
normal ★ Stop the engine for preparation. Start fault diagnosis
condi when the engine runs at high idle speed.
Swing motor
tions 3
fault Swing control lever Oil leakage of swing motor
Swing overflow Above 10 ml/min
The superstructure may have internal fault. Directly check
inside of the superstructure.
Superstructure
4 ★ The internal failure of the superstructure can be
fault
determined by unusual noise, abnormal heat and metal
powder or debris in the oil.
- 7-87
Fault information (2) ● The machine cannot swing in one direction.


Cause
reference value
ed
Pilot valve Left control lever Pilot valve output pressure
cause 1
and the failure “Neutral position” 0 {0}
stand Above 3.5MPa {above 36
ard Swing operation
kgf/cm2}
value
Failure of the
under The swing control valve spool may have failure. Check the
2 swing control
normal valve spool.
valve (spool)
condi
tions The seal of the swing motor refilling valve may have failure.
Failure of seal of
Check the seal.
3 the swing motor
★ Determine whether the seal fails by switching left/right
(refilling valve)
refilling valves and observing for changes.
7.11.22 H-20 It has low swing acceleration performance or low swing speed
● It has low swing acceleration performance or

Fault information (1)
low swing speed

Cause
reference value
Predict Failure of swing
ed The parking brake part of the swing motor have failure.
1 motor (parking
cause Check it directly.
brake)
and the
stand ★ Stop the engine for preparation. Start fault diagnosis
ard when the engine runs at high idle speed.
value The swing motor Swing control lever Swing relief valve
under (relief valve) is 25.5~28.5 MPa
normal 2 Swing overflow
improperly {260~291 kgf/cm²}
condi adjusted or fails
tions If the oil pressure cannot return to normal conditions after
adjustment, it can be predicted that the relief valve may fail
or internal fault may exist. Check the valve.
7-88 -

Swing motor
3
fault Swing control lever Oil leakage of swing motor
Swing overflow Below 10ml/min
Blocking of the
4 brake control Remove and clean it for inspection.
pipe
● It has low swing acceleration performance

only on one side or low swing speed

Cause
reference value
Pilot valve Swing control lever Pilot valve output pressure

1
failure “Neutral position” 0 {0}
Predict
Above 3.5MPa {above 36
ed Left or right
kgf/cm2}
cause
and the Failure of swing
stand motor (pressure The pressure compensation valve of the swing motor may
2
ard compensation have failure. Check it.
value valve)
under The seal of the swing motor refilling valve may have failure.
normal Failure of seal of
Check the seal.
condi 3 the swing motor
tions (refilling valve)
refilling valves.
Unilateral
leakage of
4 shuttle valve of Swing control lever Pilot valve output pressure
the swing pilot “Neutral position” 0 {0}
pressure sensor
Left or right 3.5~3.9MPa {36~40 kgf/cm²}
- 7-89
7.11.23 H-21 The overrun is too large when swing stops
● When the superstructure stops swinging, the

overrun is too large on both sides.

Cause
reference value
Predict
ed
cause The swing motor Swing control lever Swing relief pressure
and the (relief valve) is 25.5~28.5 MPa
1 Swing overflow
stand improperly {260~291 kg/cm²}
ard adjusted or fails
If the oil pressure cannot return to normal conditions after
value
adjustment, it can be predicted that the relief valve may fail
under
or internal fault may exist. Check the valve.
normal
condi ★ Stop the engine for preparation. Start fault diagnosis
tions when the engine runs at high idle speed.
Swing motor
2
fault Control lever Oil leakage of swing motor
Swing overflow Below 10ml/min
● When the superstructure stops swinging, the

overrun is too large on one side.

Cause
Predict reference value
ed ★ Stop the engine for preparation. Start fault diagnosis
cause when the engine runs at high idle speed.
and the
stand Pilot valve Swing control lever Pilot valve output pressure
1
ard failure “Neutral position” 0 {0}
value
Above 3.5MPa {above 36
under Left or right
kgf/cm2}
normal
condi Failure of the
tions 2 swing control The swing control valve spool may have failure. Check it.
valve (spool)
7-90 -
The seal of the swing motor refilling valve may have failure.
Failure of seal of
Check the seal.
3 the swing motor
(refilling valve)
refilling valves.
7.11.24 H-22 The impact is too large when swing stops
● It will generate too large impact when swing

Fault information
stops.

Cause
reference value
Predict ★ Stop the engine for preparation. Start fault diagnosis
ed when the engine runs at high idle speed.
cause Swing control lever Pilot valve output pressure
Swing pilot
and the 1
valve failure “Neutral position” 0 {0}
stand
ard Above 3.5MPa {above 36
Left or right
value kgf/cm2}
under The swing damping valve may have failure. Check the
normal Failure of swing valve.
condi 2
damping valve ★ The failure of the valve can be determined by replacing
tions old valves with new ones.
Failure of swing
3 The swing relief valve is worn out or seized.
relief valve
7.11.25 H-23 The unusual noise is too loud when swing stops
● The unusual noise is too loud when swing

Fault information
stops.

Cause
the standard Backpressure valve The backpressure valve may have failure.
1
value under failure Check it.
normal Failure of swing motor The relief valve of the swing motor may
conditions 2
(relief valve) have failure. Check it.
- 7-91
The seal of the swing motor refilling valve

Failure of swing motor may have failure. Check the seal.
3
(refilling valve) ★ Determine whether the seal fails by
switching left/right refilling valves.
The swing mechanical device may have
internal fault. Check inside of the swing
mechanical device.
Swing mechanical
4 ★ The internal failure of the superstructure
device fault
can be determined by unusual noise,
abnormal heat and metal powder or debris
in the oil.
7.11.26 H-24 The natural drift during swing is too large
● The natural drift during swing is too large

(when the swing parking brake is applied).
● The swing is fixed by the disc brake when
the swing and parking brake works.

Predicted Cause
cause and
Fault of the swing brake The swing brake control pipe and brake
the standard 1
control pipe pilot valve may have fault. Check it.
value under
normal The parking part of the swing motor may
Failure of swing motor
conditions 2 have failure or internal fault may exist.
(parking brake part)
Check it.
● The natural drift during swing is too large

(when the parking brake is released).
● The swing can only be kept by hydraulics for
the swing and parking brake is released.

Cause
Predicted
cause and Failure of the swing The seal of the swing control valve spool
1
the standard control valve (spool) may have failure. Check it.
value under Fault of the swing motor The seal of the relief valve of the swing
normal 2
(relief valve) motor may have failure. Check it.
conditions
Fault of the swing motor The seal of the refilling valve of the swing
3
(refilling valve) motor may have failure. Check it.
7-92 -
SY365H(BH)-10 Hydraulic Excavator Removal and Installation
Removal and Installation

8 Removal and Installation ............................................................................................8-1
8.1 Tips..........................................................................................................................................8-5
8.2 Precautions during operation ..............................................................................................8-6
8.3 Removal and installation of starter motor assembly ........................................................8-9
8.4 Removal and installation of flywheel ............................................................................... 8-10
8.5 Removal and installation of cylinder head cover ........................................................... 8-12
8.6 Removal and installation of oil pan.................................................................................. 8-13
8.7 Removal and installation of rear oil seal of crankshaft ................................................. 8-14
8.8 Removal and installation of fuel injector ......................................................................... 8-16
8.9 Removal and installation of EGR valve and EGR cooler ............................................. 8-20
8.10 Removal and installation of radiator assembly............................................................ 8-22
8.11 Removal and installation of engine and hydraulic pump assembly ......................... 8-27
8.12 Removal and installation of final drive assembly ........................................................ 8-32
8.13 Disassembly and reassembly of final drive assembly ................................................ 8-34
8.14 Removal and installation of swing motor and swing mechanism assembly............ 8-46
8.15 Disassembly and reassembly of swing motor and swing mechanism
assembly.................................................................................................................... 8-47
8.16 Disassembly and reassembly of idler assembly ......................................................... 8-58
8.17 Removal and installation of driving wheel .................................................................... 8-62
8.18 Removal and installation of track assembly................................................................. 8-62
8.19 Removal and installation of swing bearing assembly................................................. 8-65
8.20 Removal and installation of turntable assembly.......................................................... 8-66
8.21 Removal and installation of center swivel joint assembly .......................................... 8-70
8.22 Disassembly and reassembly of center swivel joint assembly.................................. 8-73
8.23 Removal and installation of hydraulic tank assembly................................................. 8-75
8.24 Removal and installation of control valve assembly ................................................... 8-78
8.25 Removal and installation of hydraulic pump assembly .............................................. 8-84
8.26 Removal and installation of oil seal in the input shaft of hydraulic pump................. 8-89
8.27 Disassembly and reassembly of pilot valve assembly of work equipment.............. 8-90
- 8-1
Removal and Installation SY365H(BH)-10 Hydraulic Excavator
8.28 Disassembly and reassembly of travel pilot valve assembly..................................... 8-91

8.29 Disassembly and reassembly of hydraulic cylinder assembly .................................. 8-92
8.30 Removal and installation of work equipment assembly ........................................... 8-103
8.31 Removal and installation of A/C assembly................................................................. 8-107
8.32 Removal and installation of counterweight assembly ...............................................8-111
8.33 Removal and installation of cab assembly ..................................................................8-113
8.34 Removal and installation of cab windows....................................................................8-117
8.35 Removal and installation of front window assembly ................................................. 8-132
8.36 Removal and installation of display screen................................................................ 8-141
8.37 Removal and installation of controller assembly ....................................................... 8-142
8.38 Radio................................................................................................................................ 8-143
8.39 Battery ............................................................................................................................. 8-145
8.40 Ignition key switch.......................................................................................................... 8-148
8.41 Fuse box.......................................................................................................................... 8-151
8.42 Wiper................................................................................................................................ 8-152
8.43 Relay................................................................................................................................ 8-155
8.44 Sensor ............................................................................................................................. 8-157
8.45 Terminal insertion and removal.................................................................................... 8-159
8-2 -
8-3 -
WARNING
8-4 -
8.Removal and Installation

8.1 Tips
Removal and installation of assembly
Special tool Installation of parts
• Special tools for removing and installing the • Parts should be installed in the reverse order
parts are listed of removal unless otherwise specified.
• The necessities of tools are explained in the • The mark used in Section ―Installa-
catalog of tools: tion‖ indicates the rules and precautions for
installation.
■： A special tool that is irreplaceable and
indispensable. • The various symbols used in Section “Instal-
lation” are as follows:
●： Very important tool that may be replaced
with the purchased one.
Removal of parts
This symbol indicates the relevant safety
• Section “Removal” involves the procedures, precautions that must be observed at work.
precautions, and the volume of oil or water
to be discharged. This symbol lists the instructions and pre-
• The various symbols used in Section “Re- cautions in the operation procedures.
moval” and their meanings are as follows:
This symbol indicates that the specified
coating agent must be used.
precautions that must be observed at work.
This symbol means the required
lubricant.
This symbol lists the instructions and pre-
cautions in the operation steps. This mark indicates the specified
torque.
This symbol indicates the relevant rules
and precautions that must be observed during
installation. This symbol indicates the volume of oil
or water to be filled.
This mark indicates the volume of oil or
water to be discharged.
Disassembly and reassembly of assembly
- 8-5
Special tool Reassembly
• The special tools necessary for the disas- • Section “Reassembly” involves the proce-
sembly and reassembly are listed in this dures, precautions, technical requirements
section. and the volume of oil or water to be filled.
• The necessities of tools are explained in the • The various symbols used in Section “Reas-
catalog of tools: sembly” are as follows:
■： A special tool that is irreplaceable and

indispensable.
●： Very important tool that may be replaced
with the purchased one and disassembled This symbol lists the instructions and pre-
cautions in the operation procedures.
Disassembly
This symbol indicates that the specified
• Section “Disassembly” involves the proce- coating agent must be used.
dures, precautions, and the volume of oil or
This symbol means the required
lubricant.
• The various symbols used in Section “Disas-
sembly” and their meanings are as follows: This mark indicates the specified
torque.
This symbol indicates the volume of oil
This symbol lists the instructions and pre- or water to be filled.
cautions in the operation steps.
This symbol indicates the relevant rules

and precautions that must be observed at
installation.
This mark indicates the volume of oil or

8.2 Precautions during operation

The following precautions must be observed during the removal or installation (disassembly or re-
assembly) of the equipment.
1. Precautions for removal

• If the engine coolant contains antifreeze, it should be treated properly.
8-6 -
• After disconnecting hoses or pipes, be sure to cap them or install blind plugs to them, preventing
dirt or dust from entering inside.
• Before draining oil, prepare an appropriate container to catch it.
• Before removal operation, make marks where necessary to prevent mismatch during
installation.
• Do not tug wires or cables, otherwise they may come off from the contacts. To avoid heavy ten-
sile load, always grip the connector when disconnecting a wire or cable.
• Tag wires and hoses to indicate their installation positions, preventing mismatch during
installation.
• Record and check the numbers of gaskets with different thickness, and keep them at a proper
place.
• Use a reliable crane or other lifting equipment with sufficient strength to lift part(s).
• When using forcing screws to remove parts, evenly tighten them in order.
• Before removing the equipment, clean the surrounding area; after removal, cover it to prevent
dust or dirt from entering.
★ Precautions for handling hoses during disassembly
After disconnecting hoses in disassembly operation, install the following blind plugs to the hose
ends.
A．Hoses with threaded connection
Hose ID（mm） No. Name

Light duty thread
6 B210780001189 Hose end plug
22 60056667 Hose end plug
Heavy duty thread
16 60002397 Hose end plug
B． Transition fittings with threaded connection (hoses and transition fittings are matched with
each other into a complete set)
- 8-7
Hose ID（mm） No. Name No. Name

Light duty thread
6 B210780000903 Cone plug 23002925 Nut
8 B210780001146 Plug B210770000011 Nut
10 B210780000088 Plug B210334000011 Nut
12 B210780000089 Plug B210334000012 Nut
15 B210780000882 Plug B210334000004 Nut
20 B210780000090 Plug B210334000010 Nut
22 B210780000091 Plug B210780000112 Nut
Heavy duty thread
12 B210780001143 Plug B210780000406 Nut
16 A820205001523 Plug B210780000405 Nut
20 B210780000902 Plug B210780000904 Nut
25 B210780001172 Plug B210334000006 Nut
2. Precautions for installation

• Tighten all bolts and nuts (sleeve nuts) to the specified torques.
• No twist or interference is allowed when installing hoses.
• Replace every removed bushing, O-ring, cotter pin and locking plate.
• Bend each split pin or locking plate properly.
• Clean the part to ensure it is free of oil and dust, and then apply a small amount of adhesive onto
the thread.
• Clean oil and dust off the surface, check for dirt or damage, and then evenly apply gasket seal-
ant to the surface.
• Remove any damage, dent, burr or rust on parts.
• Lubricate all movable and sliding parts with oil.
• Be sure to install all snap rings into the grooves properly.
• Eliminate oil, dirt or water from wire connectors, and then firmly connect them.
• Before using eye bolts, check if they are deformed or damaged, and then screw them down and
align them with the hook.
• Tighten split flanges evenly in order, avoiding excessive tightness on one side.
★ Bleed air as follows from the repaired cylinders, pumps or other hydraulic equipment after rein-
stalling them for use:
• Start the engine and allow it to run at low idle speed.
• Operate the work equipment control lever to move the cylinder back and forth 4~5 times, and
stop the cylinder at 100 mm of the end of its stroke.
• Continue to operate the cylinder 3~4 times, and stop it at the stroke end.
• After the above operation, run the engine at normal speed.
8-8 -
★ When reusing the machine after repair or long-term storage, follow the same procedures above.
3. Precautions after completing operations

• After draining engine coolant, screw down the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant in the system, and check the coolant level again.
• After removing the hydraulic equipment and refitting them, add hydraulic oil to the specified lev-
el. Run the engine to circulate the hydraulic oil in the system, and check the oil level again.
• Bleed air from the pipelines or hydraulic equipment after removing, repairing and installing them.
★ Refer to “Bleeding air from each equipment”(Page 6-23).
• Add grease (molybdenum disulfide) of specified amount to the parts of work equipment.
8.3 Removal and installation of starter motor assembly
• Removal sequence
1 Nut
2 Nut
3 Starter relay
4 Bolt
5 Nut
6 Starter
*a Flywheel housing
B：Terminal B
S：Terminal S Fig.8-1
CAUTION
• Before removing the starter 6, disconnect
the battery terminals and wrap them with
insulating tape.
• It is dangerous to not disconnect the bat-
tery terminals because there is always a
battery voltage at each terminal B.
• Installation sequence
Perform installation in reverse order of the

removal.
- 8-9
8.4 Removal and installation of

flywheel
1. Remove the starter motor according to Sec-

tion ―Removal and installation of starter mo-
tor assembly‖.
2. Remove the crankshaft position sensor 4.
• Remove the sensor to prevent the damage

to contact when removing the flywheel.
• Do not drop the sensor because it tends to
be damaged.
Fig.8-2
3. Remove the washer 3 and flywheel 2.
• Install the crankshaft stop to the installation

point of flywheel housing on the starter.
• Gradually loosen the mounting bolts of fly-
wheel in the sequence as shown in the fig-
ure so that the flywheel does not rotate.
• After loosening all the bolts, detach the stop
to remove the flywheel.
4. Take out the ring gear.
• Place a pry bar on the ring gear and tap it

with a hammer to remove the ring gear.
Fig.8-3
8-10 -
1. Install the ring gear.
• After heating the ring gear evenly with gas

welding, load it into the flywheel.
• Keep the ring gear flat by applying a weight
of 68.6 kN when it is at cold shrinkage.
CAUTION
• Install the ring gear so that the side with
section mould faces forward.
• Install the hot ring gear to the flywheel.
• Make sure that the flywheel and ring gear
Fig.8-4
are fully attached.
2. Install the flywheel.
3. Install the washer.
• Install the flywheel to align with the thrust

pin of crankshaft and then tighten it accord-
ing to the sequence as shown.
• Apply the molybdenum disulfide to the
thread and fixing face of the bolt.
• Install the crankshaft stop to the installation
point of flywheel housing on the starter.
4. Install the crankshaft position sensor and

tighten it according to the specified torque.
Tightening torque: 8 N●m Fig.8-5
5. Install the starter motor onto the flywheel

housing with nuts and tighten the nuts accord-
ing to the specified torque.
Tightening torque: 76 N ● m
• Install the grounding cable of starter motor.
- 8-11

cylinder head cover
1. Remove the cylinder head cover 1.
2. Remove the gasket 2.
Fig.8-6
3. Remove the fuel injector harness connector

5.
4. Remove the cover housing 3.
5. Remove the gasket 4.
Fig.8-7
1. Install the gasket 4 on the lower cover.。
2. Install the cover housing 3.
3. Install the fuel injector harness connector 5.
4. Install the gasket 2 on the cover.

Fig.8-8
5. Install the cover 1 and tighten it according
to the sequence as shown.
8-12 -

oil pan
1. Drain the oil
2. Remove the oil pan 1.
Fig.8-9
3. Remove the coarse filter 3.
4. Remove the O-ring 4.
Fig.8-10
- 8-13
1. Install the O-ring with coarse filter on the

crankcase.
Tightening torque:
M8 bolt: 24 N ● m
M10 bolt: 48 N ● m
2. Install the washer.
• Install the oil pan

• Apply the liquid seal with 3mm bead diame-
ter on the joint with flywheel housing be- Fig.8-11
tween the cylinder block and front cover.
• Install the gasket and oil pan with the studs
of crankcase, flywheel housing and front
cover as the guide. Install the rubber as-
sembly onto the oil pan and secure it with
nuts and bolts.

rear oil seal of crankshaft
1. Remove the hydraulic pump assembly ac-

cording to Section “Removal and installation
of hydraulic pump assembly”
2. Remove the flywheel 1 according to Sec-

tion ―Removal and installation of flywheel‖
3. Remove the rear oil seal 2 of crankshaft
• Remove the rear oil seal with a screwdriver

or similar tool to avoid the damage to the oil
seal contact surface on the flywheel hous- Fig.8-12
ing and shaft.
8-14 -
4. Remove the oil retainer 3 with the special

detacher. Detacher of crankshaft oil seal: 1-
8521-0027-0:60116841
CAUTION
• If the oil seal has been removed, the oil
seal and oil retainer shall be replaced as a
set.
Fig.8-13
1. Install the front oil retainer with the installer

and positioning tool. 6HK installer of crank-
shaft oil seal: 8-94396-856-0:60197990
• Install the oil retainer (1) to the end of con-

nector (2). Install the connector on the
crankshaft (3).
• Install the oil retainer sleeve (4) on the con-
nector. Tighten the center bolt (5) until the
sleeve contacts the connector stop. Fig.8-14
• After fitting the oil retainer, guarantee the

specified clearance A between the end sur-
face of crankshaft and the oil retainer.
Clearance (A): 17 ± 0.3 mm
CAUTION
• Be sure to replace the oil retainer and oil
seal as a set.
Fig.8-15
- 8-15
2. Install the rear oil seal of crankcase
• Install the rear oil seal with special installer

and positioning tool.
• Place the spacer 4 on the fixing bolt and fit
the connector to the crankshaft 1.
• Apply oil to the lip of oil seal and place it into
the rear connector 7.
• Place the rear connector into the sleeve 6
and place the sleeve on the connector and
secure it with the center bolt.
Fig.8-16
• Tighten the center bolt until the sleeve con-
tacts the connector to fit the oil seal 2.
• After fitting the rear oil seal, confirm the di-
mensions as shown (the depth from the end
surface of crankshaft to the oil seal 3: 7.5 ±
0.15 mm).
3. Install the flywheel 1 according to Section

“Removal and installation of flywheel”.
4. Install the hydraulic pump assembly ac-

of hydraulic pump assembly”.

fuel injector
8-16 -
- 8-17
1. Remove the engine harness, EGR valve,

pressure sensor and all fuel injector
connectors.
2. Remove the EGR valve and EGR

connector.
3. Tape the hole baffle of EGR housing to pre-

vent the foreign matter.
4. Remove the cylinder head cover.
5. Loosen the injector terminal nut alternately

in sequence. It is necessary to loosen the nut
in steps.
6. Loosen the injector harness support bolts.

Remove the inner connector and harness
support.
7. Remove the injector drain pipe.
8. Remove the lower cover.
9. Remove the fuel injector clip and pipe.
10. Loosen the fixing bolts of fuel injector

clamp and remove the injector. Fuel injector
detacher: 5-8840-2623-0: 60197994 Fig.8-17
If it is not easy to remove the fuel injector, use

the injector detacher 2.
Install the detacher on the connection point of

drain pipe on the fuel injector 3. Separate the
clamp with injector with sliding weight 1.
Fuel injector detacher: 5-8840-2623-0:

60197994
Sliding weight: 5-8840-0019: 60084476
CAUTION
• Do not remove the fuel injector sleeve
11. Label each fuel injector with the number of

cylinder which has been removed. Store the
8-18 -
fuel injector in a safe place. Place the injector

so that the nozzle is well protected.
CAUTION
• Do not damage the electromagnetic part of
fuel injector. The deterioration of electro-
magnetic function may cause the malfunc-
tion of injector.
Important:
Install each injector at its original position.

(the cylinder that has been removed)
1. Install the new gasket 1 and O-ring onto

each fuel injector clamp 4.
2. Apply the molybdenum disulfide grease on

the thread and seat face of clamp bolt.
3. Install the fuel injector clamp to the cylinder

head.
4. Tighten the clamp bolt 3 temporarily.
5. Apply a thin layer of oil on the outer surface

of the sleeve nut at the side of injector.
6. Install the fuel injector pipe.
7. Carefully tighten the sleeve nut with a

wrench until the fuel injector pipe touches the Fig.8-18
fuel injector and common oil sump.
8. Tighten the fuel injector pipe clip to the

specified torque.
Finally tighten 4 bolts of fuel injector clamp to

the specified torque
- 8-19
10. Tighten the fuel injector pipe to the speci-

fied torque.
11. Install the nozzle drain pipe with the new

gasket. Tighten the pipe to the specified
torque.
12. Install the fuel injector harness connector.

Install it from the inside.
13. Install the harness support and tighten the

bolts to the specified torque.
Fig.8-19
14. Install the fuel injector terminal nut 3 on

the fuel injector.
15. Tighten the nuts alternately by 2-3 turns

each time to the specified torque.
16. Install the gasket on the cylinder head

cover.
17. Install the cylinder head cover and tighten

the bolts to the specified torque.
18. Install the gasket onto the EGR valve and

tighten the bolts to the specified torque. Fig.8-20
19. Install the fuel injector harness connector.

Install it from the inside.
20. Install the engine harness connector.

When the connector is securely installed, the
connectors of each combination will beep.

EGR valve and EGR cooler
• Removal and installation of EGR valve and EGR cooler

8-20 -
1. Drain the coolant.
2. Disconnect the EGR valve connector.
3. Remove the EGR pipe.
4. Remove the cooling water pipe.
5. Remove the EGR connector
6. Remove the ERG cooler
7. Remove the EGR valve
Fig.8-21
CAUTION
After removing the EGR valve and EGR connector, seal them to prevent the impurities.
- 8-21
1. Install the EGR valve
• Insert the gasket and temporarily fix the

EGR valve.
Note：Tighten the bolt temporarily.
2. Install the ERG cooler
• Fix the EGR cooler to the support

temporarily.
3. Install the EGR connector
• Temporarily fix the EGR joint between the

EGR cooler and exhaust manifold.
4. Install the EGR pipe.
• Install the gasket between the both ends of

EGR pipe and fix it temporarily.
5. Tighten the nuts and bolts to the specified Fig.8-22

torque.
Tightening torque:
1 and 2: 28 N● m
3, 4, 5 and 6：28 N●m
8.10 Removal and installation of radiator assembly

Removal
1. Open the pressure cap (1), and drain the

engine coolant through the drain valve at the
bottom of coolant tank.
Remove the outlet (2) and inlet (3) from the

hydraulic oil cooler, and plug the hydraulic
system to avoid leakage.
Fig.8-23
Coolant: about 26L
8-22 -
Fig.8-24
Fig.8-25
- 8-23
3. Remove the outlet (2) and inlet (3) from the

hydraulic oil cooler, and plug the hydraulic
system to avoid leakage.
Fig.8-26
4. Drain the hydraulic oil cooler.
Hydraulic oil radiator: about 8 L
5. Remove the hose (4) from the coolant tank.
Fig.8-27
6. Remove the water inlet hose (5) and water

outlet hose (6) from the water cooler.
Fig.8-28
8-24 -
7. Remove the air inlet pipe (7) and outlet pipe

(8) of intercooler.
Fig.8-29
8. Remove four bolts (9) from the A/C radiator,

and then remove the radiator and place it at
an appropriate place.
Fig.8-30
9. Remove the fan cover (10) of the radiator.
Fig.8-31
- 8-25
10. Remove four mounting bolts (11) at the

bottom of the radiator.
Fig.8-32
11. Remove the mounting bolts (12) and EGR

degassing pipes (13) on the left and right
supports.
12. Lift the radiator assembly via the lifting

hole above.
★ When lifting the radiator assembly, move

the assembly axially till the fan is away from
the fan cover, and then lift the radiator Fig.8-33
assembly.
Mounting
• Carry out the installation in reverse order of

the removal.
★ Adjust the clearance a between the fan and

cover so that the clearance remains even
around.
★ Check the clearance a measured respec-

tively at up, down, left and right sides as
follows:
Fig.8-34
• Standard clearance a (around): 10 mm
• Fan diameter b: ø850 mm
• Inner diameter c of wind guide cover: ø870
mm
8-26 -
• Add engine coolant and hydraulic oil again.
Add coolant and hydraulic oil of specified

amount, start the engine to circulate them,
and check the coolant/oil level.
Engine coolant: about 26 L
Hydraulic oil cooler: about 8 L
8.11 Removal and installation of engine and hydraulic pump assembly

Removal
Lower the work equipment safely to the

ground, stop the engine, and remove the ca-
ble from the negative terminal of the battery.
Loosen the butterfly nut of the breather

release the pressure inside.
★ Mark the pipelines to avoid mismatch in

case of installing them.
1. Remove the suction filter from the hydraulic

tank, and plug the oil outlet.
2. Drain the engine coolant.
Coolant: about 26L
3. Open the engine hood.
Fig.8-35
- 8-27
4. Remove the pipelines (1), (2) and (3).
Fig.8-36
5. Remove the pipelines (4), (5), (6), (7), (8)

and (9).
Fig.8-37
6. Remove the harness clips of main pump

(10) and (11).
7. Removal the main pump harnesses (12)

and (13).
Fig.8-38
8-28 -
Fig.8-39
Fig.8-40
8. Remove the main pump PSV pipeline (15).
Fig.8-41
9. Remove the diesel inlet and outlet pipelines

(16) and (17) as well as the oil inlet and outlet
pipelines (18) and (19).
Fig.8-42
- 8-29
10. Disconnect the engine control harness

(20).
Fig.8-43
11. Remove the compressor cable and pipe-

lines (21), (22) and (23).
Fig.8-44
12. Remove the starter motor cable (24).
13. Remove the generator cable (25).
Fig.8-45
8-30 -
14. Remove the pipelines (26), (27), (28), (29)

and (30).
15. Remove the pipeline (31).
Fig.8-46
16. Remove the wind guide cover (32).
Fig.8-47
- 8-31
17. Remove four fixing bolts (33) of engine

and lift the engine.
Engine and main pump assembly:

900kg
Fig.8-48
Mounting
• Carry out the installation in reverse order of the removal.

• Open the coolant tank cap of the radiator, refill with coolant, and add coolant to the reserve tank.
Engine coolant: about 26 L

• Add hydraulic oil to the hydraulic tank.
Hydraulic tank: about 380 L

★ Start the engine to circulate the coolant and bleed air, and then check the coolant level.
★ Start the engine to circulate the oil in the hydraulic system, and then check the oil level.
•Bleed air.
Refer to ―Bleeding air from each equipment‖ described in pages 6-23.
Note: For removal and installation as well as repair of engine, Please refer to Maintenance
Manual of Isuzu Engine.
8.12 Removal and installation of final drive assembly

Removal
8-32 -
1. Remove the driving wheel according to

Section “Removal and installation of driving
wheel” (pages 8-46)

for safety, stop the engine, and operate the
breather valve to release the pressure inside.
2. Remove the motor cover (1).
Fig.8-49
3. Remove the travel motor hose (2) and the

fittings.
4. Remove the connecting bolt (3) between

the final drive assembly and track frame, and
then lift the final drive assembly (4) to remove
it.
★ Be careful not to damage the sealing sur-

face at the hose base.
★ When lifting the final drive assembly, do not

employ the threaded holes to lift the cover.
Fig.8-50
- 8-33
Fig.8-52
• Mounting
• Carry out the installation in reverse order of

the removal.
Fig.8-51
Mounting bolts of final drive as-
sembly :245~ 309 N·m {25~ 31 kgf·m}
• Refill hydraulic oil
Add hydraulic oil to the specified level through

the oil filler, start the engine to circulate the oil
in the hydraulic system, and then check the oil
level.
• Bleed air.
Refer to “: Bleeding air from each equipment”

described in pages 6-23.
8.13 Disassembly and reassembly of final drive assembly

1. Preparation of tool
8-34 -
2. Disassembly
2.1 General Precautions
Combustible materials such as kerosene are used for the cleaning of parts.
Since flammable materials may cause fires, the care shall be taken in handling.
The disassembled parts are glued with gear oil and are very easy to slip off.
Sliding parts may cause the personal injury and damage to parts. Therefore the care shall be taken
in handling.
1）Hydraulic equipment is relatively precise and has many small gaps in construction. It needs to
be disassembled and assembled in a dustless and clean place. The tools and cleaning oil shall al-
so be clean and handled with great care.
- 8-35
2）After removing it from the machine, clean all the interfaces and then remove the plug. Be sure
to prevent the dust, water, etc. from entering the motor.
3）Before the disassembly, study the profile and prepare the necessary parts according to the dis-
assembly. Disassembled sealing adhesive, O-ring, etc. shall not be used again. Moreover, certain
parts shall not be supplied separately and shall be replaced in sets. Please confirm the parts list in
advance.
4）The piston and cylinder block are not paired. When you want to use it again, mark the piston
and cylinder block when you remove the same for matching when assembling.
5）Prevent the hands from being caught in the parts and the feet from being hit by the lifted parts.
2.2 Disassembly essentials
（1）Disassembly of auxiliary valve
Remove the auxiliary valve before detaching the motor.
Note: According to the purpose of removal, it is preferably to not remove the auxiliary valve outside
the disassembly scope. However, the motor may not be disassembled with the brake valve (42)
not removed.
Note: Due to the risk of burns, the motor may

be disassembled only after the temperature
drops to normal value.
1）Remove the brake valve (42).
2）Remove the pivot valve (41).
3） Remove the check valve (17) and check

valve spring (28).
4）Remove the relief valve (40).
Note: During the removal process of relief

valve (40), the valve seat (40-3) may easily
Fig.8-53 Removal of auxiliary valve
slip off. Be sure to check for the falling or loss.
5）Remove the connector(10)
Note: Prevent the hands from being caught in

the parts and the feet from being hit by the
lifted parts.
（2）Remove the connector(10)
1）Place the motor shaft horizontally, and remove the hexagonal bolt M18×50 (33), but leave two
at up and down diagonal positions
8-36 -
2） Load two guide bars at the diagonal

position.
(Purpose: Prevent slipping when removing

it, and guide when assembling it)
3） Slowly loosen two hexagonal bolts

M18×50 (33).
4） Remove R/C (2) and brake spring (30).

Prevent the cylinder block (3) from being
brought out with R/C (2).
Note: Prevent the hands from being caught

in the parts and the feet from being hit by
the lifted parts.
Note: prevent the port plate (8), brake

spring (30) bearing sleeve, gasket (32), O- Fig.8-54 Removal of rear single cover
rings (36) (38) (39), etc. from falling on the
ground.
Note: There is a gasket (20) inside the

bearing sleeve. Do not miss it during the
removal process.
5） When removing the port plate (8), do

not bring out the cylinder block (3).
Note: Mark the port plate (8) and R/C (2).

Be sure to reassemble it according to the
correct sequence.
Press the cylinder block (3) with the tool to

expose the inner race of bearing (32). Be
sure not to damage the surface of cylinder Fig.8-55 Removal of bearing
block (refer to Fig.8-55)
Note: To protect the surface of cylinder

block (3), place a rubber pad between the
surface of cylinder block and tool.
7） Pull out the inner race of bearing (32)

with a puller.
- 8-37
8）It can be pulled out with a tool. Remove

the brake piston by inserting the tool into
the M6 screw hole on the surface of brake
piston (6). Roll the paper into a cylindrical
shape and insert it into the plunger hole as
a sign, and mark the outer surface of
cylinder.
9） Lower swivel component cylinder

block (3), plunger (14), set plate (4), thrust
Fig.8-56 Casing binding surface enlargement
ball (24), spring seat (13) and cylinder
block spring (29).
Note: Prevent the hands from being caught

in the parts and the feet from being hit by
the lifted parts.
10） Remove the engaging piece (7) and

friction plate (5).
11）Take the plunger (14), set plate (4) and

thrust ball (24) out of the swivel
component.
12）Take the spring seat (13) and cylinder

block spring (29) out of the cylinder block.
Note: Put the plunger (14) into the cylinder

(3) according to the mark. Ensure that the
plunger is inserted into the same hole as
before it was disassembled.
Note: Do not damage the contact surfaces.

If damaged, it shall not be used again.
Note: The plunger and piston shoe are

pressed together and cannot be
disassembled
Reference: The above disassembly is de-

scribed separately for the motor head. The
assembled reducer may also be Fig.8-57 Removal of cylinder block
disassembled.
Since the spindle does not shake sharply,

it is easier to disassemble with a reducer.
8-38 -
13）Take out the swashplate (11).
14）Generally it is unnecessary to remove

2-speed plungers (21), (22) and (23). If it is
unavoidable to remove it, hold the piston
by hand and blow it out with gas from the
passage hole.
DANGER: Air pressure may push out the

2-speed plunger (21). It is very dangerous
and special attention shall be paid.
15）Pull out the spindle (9).
16） If the bearing (31) shall be replaced,

pull out the inner race of bearing with a
puller and replace it with a new one.
Fig.8-58 Casing binding surface enlargement
Note: If the parts with relation to the bear-

ing, such as the bearings (31) and (32),
spindle (9), casing (1) and motor cover (2),
shall be replaced, the gasket (20) shall be
used for adjustment. To accurately meas-
ure the clearance of gasket (20), replace
the gasket with the corresponding one.
Adjust the clearance of bearings to be 0-
0.1mm. (refer to the next page)
Note: Generally it is unnecessary to re-

move the ball hinge (12). If it is unavoid-
able to remove it, mark the corresponding
swashplate (11).
Note: Generally it is unnecessary to re-

move the oil seal (27). If it is unavoidable
Fig.8-59 Removal of swashplate
to remove it, it shall be replaced with a
new one. First remove the circlip and then
the oil seal.
- 8-39
Fig.8-60 Removal of swashplate
17）Calculate the thickness of gasket (20) of tapered bearing
Note: This operation shall be carried out whenever any of the motor casing (1), rear cover
(2), spindle (9) and bearings (31) and (32) is replaced.
1）Determine the dimension E as shown in above figure.
Note: Make sure that the spindle (9) is not tilted
2）Determine the side dimension F of R/C (2)
Note: Conduct four measurements around the circumference and take the average.
3） If the thickness of shim (20) is defined as S, the clearance Y may be calculated as

follows:
4) Make sure that the clearance Y is within 0-0.1mm and select 1 or 2 gaskets (20).
（3）Disassembly of relief valve
Note: Relief valve (40) is an important part in terms of performance and safety, and it is diffi-
cult to reset the pressure. Therefore, please do not disassemble it in case of defect, and di-
rectly replace the assembly of relief valve.
8-40 -
Fig.8-61 Disassembly of relief valve
Note: Valve seat (40-3) fits into the inner hole of sleeve (40-1). It is a simple removal. Take
care to prevent the valve seat (40-3) from falling when taking the relief valve out of motor
cover.
In addition, apply the grease to the engaging place to prevent the valve seat (40-3) from fall-
ing off before assembling the relief valve (40) into the motor cover (2).
Fig.8-62 Engaging point of valve seat
3. Reassembly 3.1 General precautions
- 8-41
3.1 General precautions
1）Wash the parts thoroughly with a cleaning

solution and dry it with air gun.
2） Be sure to assemble the moving parts

after applying the operating oil.

lifted parts.
3.2 Reassembly essentials
1） Apply the grease to the outer ring of oil

seal (27) and the inner ring of casing (1).
Evenly tap the oil seal (27) into the casing (1)
Fig.8-63 Reassembly of oil seal
with the insertion tool.
2） Install the retaining ring (19) to fix the oil

seal (27)
3）Insert the outer race of front bearing (31) into the casing (1) (clearance fit). Press the inner race
into the spindle (9) (interference fit).
Note : Heat the inner race to 100 degrees (be-

low) to facilitate the pressfit.
Note: Be sure to avoid the burns.
4） Install the spindle (9) to the casing (1).

Meanwhile, apply the grease to the lip of oil
seal (27).
5） Reassemble 2-speed plungers (21), (22)

and (23). Note: Insert the 2-speed plunger up-
rightly. Note: Apply the grease to the plunger
seal (22) when inserting 2-speed plunger, and
be sure to avoid any bump.
6） Assemble the ball hinge (12) at the side

with the identification corresponding to swash-
plate (11). In addition, if it has been operating
for a long time, install it with the folding trace
on the spherical surface corresponding to the Fig.8-64 Installation of swashplate
contact trace on the swashplate (11).
8-42 -
Three spherical places of swashplate (11)

shall be coated with sufficient grease before
the assembly.
8） Plunger assembly (14), set plate (4), ball

(24), spring seat (13), cylinder block spring
(29) and cylinder block (3) shall be inserted in-
to the spindle (9) after the reassembly.

lifted parts.
Note: Plunger assembly (14) shall be inserted

into the same hole as before the cylinder
block is disassembled.
Fig.8-65 Reassembly of plunger assembly
9） Install the inner race of front bearing into
the spindle (9) with the special insertion tool
(A1, A2).
10）Reassemble the engaging piece (7) and

friction plate (5) alternatively. The engaging
piece (7) shall be placed first and last.
11）Install the brake plunger (6) with the D-rings (15) and (16) into the casing (1) with the insertion
tool.
Note: Apply the grease to the D-rings (15) and (16).
- 8-43
Note: Insert the brake plunger (6) evenly with

the insertion tool. Brake plunger (6) is
equipped with large and small D-rings (15)
and (16). First install the large D-ring (15), and
then the small D-ring (16). The mounting sta-
tus of small D-ring (16) cannot be visually con-
firmed. Therefore do not install it forcibly. The
hole on the casing (1) may be scraped off with
a sharp device.
Note: For replacing the parts related to the

adjustment of gasket (20), be sure to adjust
the gasket (20).
Determine the thickness of gasket (20) in the

item (2)-18 “specified thickness of gasket for
tapered roller bearing” in 4-2-2 of Disassem-
bly Essentials before the reassembly.
12）Install the guide pin at the diagonal posi-

tion 2 of the casing (1).
13）Install the port plate (8) in the motor cov- Fig.8-66 Reassembly of the brake plunger
er (2) according to the matching mark for dis-
assembly, and then insert the gasket (20),
outer race of front bearing (32), brake spring
(30) and O-rings (36), (38) and (39).
8-44 -
14）Insert the motor cover (2) into the casing

(1) along the guide pin. Tighten it with hex
bolts M18×50 (33) to install the motor cover in
parallel at the upper and lower diagonal posi-
tions 2. And then, tighten the hex bolts other
than the guide pin 2 and remove the guide pin
and screw down the hex bolts at the remain-
ing two points.

lifted parts.
Note: When installing the outer race of front

bearing (32), do not forget to assemble the
gasket (20). Make sure that the O-rings (39),
(36) and (38) are assembled in the motor
cover. Fig.8-67 Reassembly of piston brake
Note: The tightening torque of hex bolt

M18×50 (33) is 324±32.4N·m.
15) Install the coupling (10).
16) Install the relief valve (40)

Note: Valve seat (40-3) is engaged at the clearance fit. Apply the grease to the engaging surface
before the installation to prevent it from falling off.
Note: The tightening torque of relief valve

(40) is 98.1~118N·m.
17）Install the check valve (17) and the check

valve spring (28).
18）Install the pilot valve (41).
Note:： Torque of the joint M8×30 (41-9) for

pilot valveis 19.6±2.0N·m.
19）Install the brake valve (42).
Note: Torque of the joint of brake valve

M12×110 (42-14) is 78.5±7.8N·m. Fig.8-68 Reassembly of relief valve
4. Initial operation
1）Drain and fill the oil.
- 8-45
Fill the motor casing with operating oil after the disassembly and reassembly.
2）Implement the initial operation.
Please check for the noise or external leakage and other abnormalities at the first speed and 5min
after the start of engine.
8.14 Removal and installation of swing motor and swing mechanism

assembly
Removal

hydraulic lines. Refer to Section “Release of
residual pressure from hydraulic lines” in pa-
ges 6-19.

hydraulic lines. Refer to Section ―Release of
residual pressure from hydraulic lines‖ in pa-
ges 6-19.
1. Remove the hose (1) through (7)

respectively.
（1）： Between the tank and swing motor

(port Dr)
Fig.8-69
（2）： Between the center swivel joint and
swing motor (port Dr)
（3）： Between the swing motor and main

valve (port M)

valve (port A)

valve (port B)
（6）： Between the swing motor and sole-

noid valve block (port PG)

valve port PX (port SH)
8-46 -
2. Remove the 14 fixing bolts (8).
3. Lift the swing motor and swing mechanism

assembly (9) for removal.
★ Slowly lift the swing motor and swing mech-

anism assembly, avoiding damaging hoses
and other parts.
Swing motor and swing mechanism

assembly: 425.5 kg
Mounting
• Perform the installation in reverse order of

the removal.
Fig.8-70
Mounting bolts of the swing mo-

tor and swing mechanism assembly:
490~608 Nm {50~62 kgm}

the oil filler cap, start the engine to circulate
the oil in the hydraulic system, and check the
oil level again.
• Air bleeding
Refer to “Bleeding air from each equipment”

8.15 Disassembly and reassembly of swing motor and swing mecha-

nism assembly
Disassembly
1. Drain oil
Loosen the drain plug, and drain oil from the

swing mechanism case.
Swing mechanism case: about 10.5 L
- 8-47
2. Swing motor assembly
1) Place the swing motor and swing mecha-

nism assembly to the frame, and be careful
not to damage the drive gear or touch the
ground.
2) Remove the 4 mounting bolts (1) and re-

move the swing motor assembly (2).
Swing motor assembly: 67.5 kg
Fig.8-71
3. No. 1 sun gear
1) Remove the No.1 sun gear (2).
Fig.8-72
8-48 -
4. No.1 planetary carrier assembly
1) Remove the No.1 planetary carrier assem-

bly (3) and backing plate (4).
Fig.8-73
2) Disassemble the No.1 planetary carrier.
First loosen the riveted portion of the shaft (8),

remove the shaft (8), and then remove the
gear (6), bearing (9) and backing plate (7)
successively.
Fig.8-74
5. Ring gear
Remove the mounting bolts and then the ring

gear (10).
Fig.8-75
- 8-49
6. No. 2 sun gear
Remove the No. 2 sun gear (11).
Fig.8-76
1) Remove the No.2 planetary carrier assem-

bly (12).
Fig.8-77
2) Disassemble the No.2 planetary carrier as-

sembly with hand as follows.
i) Tap the pin (13) into the shaft 14 with the

awl to disengage the shaft (14) from the plan-
etary carrier (19).
★ Tap out the pin (13) after the removal of

shaft.
Fig.8-78
8-50 -
ii) Remove the thrust washer (16) and gear

(17).
iii) Insert the pin (15), remove the bearing (18)

from the shaft, and pull out the pin (15).
8. Snap ring
Remove the snap ring (20).
Fig.8-79
9. Disassembly of main shaft
1) Set the shaft housing assembly on the

press equipment, and push the shaft assem-
bly (21) out of the shaft housing assembly
(22).
Fig.8-80
- 8-51
2) Disassemble the shaft assembly as follows.
Remove the bearing (23) from the shaft (24).
Fig.8-81
10. Bearing
Withdraw the bearing (25) and oil seal (26)

from the housing (27).
Fig.8-82
Reassembly
★ Clean all parts, check for dirt or damage,

and apply oil to the sliding surface of the
parts before reassembly.
5. 1. Bearing
Fit the bearing (23) to the housing (27).
Fig.8-83
8-52 -
2. Oil seal
Fit the oil seal (26) to the housing (27).
Oil seal installation surface:

Gasket sealant (LOCTIT 515)
Fig.8-84
3. Housing assembly
1) Set the plate (28) on the shaft (24).
2) Set the housing (22) on the shaft (24), and

fit the bearing.
Fig.8-85
4. Bearing
Fit the bearing (25).
★ When fitting the bearing, press the inner

race and the outer race at the same time,
and do not press the inner race only.
★ After fitting the bearing, check if the

housing rotates freely.
Fig.8-86
- 8-53
1) Reassemble the No.2 planetary carrier as

follows:
i) Install the backing plate (16) to the planetary

carrier (19).
ii) Install the gear (17) to the planetary carrier

(19). Fit the bearing (18) to the shaft (14). Fig.8-87
Align the pin holes, and gently knock in the
pin (15) using a rubber hammer. Note that the
pin (15) shall not extrude from the bearing
(18).
iii) Push the shaft assembly into the planetary

carrier (19), avoiding damaging the gear and
the backing plate. Align the pin holes on the
shaft and the planetary carrier, and carefully
knock the pin (13) into the pin hole with a rub-
ber hammer.
★ When installing the shaft, rotate the

planetary gear. Be careful not to damage
the thrust washer.
6. Successively install the snap ring (20),

No.2 planetary carrier and No.2 sun gear
(11).
Fig.8-88
8-54 -
7. Install the ring gear.
Apply sealant to the mating face C as shown

in the figure, and fix it with a screw.
Be careful not to apply sealant to the ring gear

(10).
Mating face: Sealant (LOCTITE

515).
Fig.8-89
1) Reassemble the No.1 planetary carrier as

follows:
i) Set the backing plate (7) on the planetary

carrier (5).
ii) After installing the bearing (9) to the gear, Fig.8-90

set the gear (6) on the backing plate.
iii) Fit the shaft (8) to the gear (6) and plane-
tary carrier (5), and rivet the end of the shaft.
★ Check if the gear is able to rotate freely.
- 8-55
2) Install the No.1 planetary carrier assembly

(3) and backing plate (4).
Fig.8-91
9. No. 1 sun gear assembly
Install the No. 1 sun gear (2).
Fig.8-92
8-56 -
10. Installation of the swing motor

assembly
After applying sealant to the contact surface

between the ring gear and the motor cover, in-
stall the swing motor assembly.
Mating face: Sealant (LOCTITE

515)
Swing motor assembly: 67.5 kg
Mounting bolts of the swing

motor:
156±5 Nm {16±0.5 kg}
★ The 14 mounting holes of the swing motor

and swing mechanism assembly are not uni-
formly distributed. Their aligning is unique, as
shown in the right figure. When mounting the
swing motor, be sure to correctly align the
threaded holes.
11. Refilling with lubricating oil
Tighten the drain plug, and add lubricating oil

to the specified level (“High” scale of the oil
dipstick) from the oil filler cap.
Fig.8-93
Swing mechanism case: about 4 L
- 8-57
8.16 Disassembly and reassembly of idler assembly

Disassembly
1. Remove the locating pin (1) and support

(2).
2. Remove the floating seal (3) from the sup-

port (2) and idler (4).
3. Remove the O-ring (11), and remove the id-

ler (4) from the shaft (5) and support assembly
(7).
★ Before disassembling the idler, drain the ac-

commodated oil (about 80 ml). Lay a cloth on
the floor to prevent the contamination of floor.
Fig.8-94
4. Remove the other floating seal (6) from the

idler (4), shaft (5), and support assembly (7).
Fig.8-95
5. Remove the locating pin (8), and remove

the support (7) from the shaft (5).
6. Remove the busings (9 and 10) from the id-

ler (4).
Fig.8-96
8-58 -
Reassembly
1. Fit the bushings (9 and 10) to the idler (4).
Fig.8-97
2. Install the O-ring, and install the support (7)

to the shaft (5) using the locating pin (8).
Fig.8-98
3. Install the floating seal (6) to the idler (4),

shaft (5) and support assembly (7).
★ Floating seal
Before installing the floating seal, eliminate

the grease on the contact surface between
the O-ring and the floating seal (hatched area
in the figure). Besides, make sure there is no
dust on the contact surface of floating seals. Fig.8-99
- 8-59
★ After installing the floating seals, check that

the seal ramp is not more than 1 mm, and
check that the projection a is kept within 5-7
mm.
Fig.8-100
4. Install the shaft (5) and support assembly

(7) to the idler (4).
Fig.8-101
8-60 -
5. Install the floating seal (3) to the idler (4)

and support (2).
★ Apply oil to the sliding surface of the floating

seal, and make sure it is free of dirt or dust.
★ Eliminate oil and dust from the contact sur-

face between the O-ring and the floating seal.
Fig.8-102
Fig.8-103
6. Install the O-ring, and install the support (2)

using the locating pin (1).
7. Add oil and tighten the plug.
Oil: about 80 ml (No.18 hypoid gear oil)
Plug: 205.8 ±49 N·m {21 ±5

kgf·m}
Fig.8-104
- 8-61
8.17 Removal and installation of driving wheel

Removal
1. Remove the track shoe assembly. Refer to

Section “Removal and installation of track as-
sembly” in pages 8-47 for details.
Swing the work equipment by 90°, push up

the chassis with the work equipment, and
place the block ①between the track frame
and the track shoe.
Remove the driving wheel (1)
Fig.8-105
Driving wheel: 98.4 kg
Mounting
• Perform installation in reverse order of the

removal.
Threads of mounting bolts of

driving wheel:
Thread locking adhesive (Tianshan 1277)
Mounting bolts of driving wheel:
927±103 N·m {94.6±10.5 kgf·m}
8.18 Removal and installation of track assembly

Special tool
Part Necessi
Symbol Quantity
name ty
Manual
and
electric
M ● 1
hydraulic
track pin
press
8-62 -
Removal of track shoe assembly
1. Select a field which has enough space to

spread the track. Stop the machine when the
king pin is located in the middle of the idler
and the carrier roller.
2. Lower down the work equipment, loosen

the oil nipple (1), and release the track
tension.
Keep the cylinder in extreme high pres-

sure through adjustment. Loosen the oil nipple Fig.8-106
by not more than one turn. If no oil flows out,
move the machine back and forth.
3. Pull out the main pin (2) using the tool M.
Fig.8-107
4. Remove the tool M, move the machine for-

ward till the temporary pin ② is in front of the
idler, and place the block ①.
5. Remove the temporary pin ②, remove the

dust seal, and move the machine backward to
spread the track (3).
Fig.8-108
- 8-63
Mounting

the removal.
★ Refer to “Inspection and adjustment of track

tensioner” in pages 6-8.
• The installation procedures for track shoe

bolt and nut
1) Turn the R side of the track shoe nut (1) to

the surface of the link rod seat. The track shoe
shall be so installed that the two seat surfaces
contact closely.
★ If the track shoe bolt is installed in reverse,

the corner of the nut will interfere with the sur-
face of the link rod seat, leading to rise of the
nut and looseness of the bolt.
2) Tighten the track shoe bolt to the following

torque.
Track shoe bolt:
1029±60N·m {105±6kgf·m}
Fig.8-109
★ Use the tool M to fit the king pin, satisfying

the projection dimension a.
Projection a of the king pin: 4.2±2mm
★ Before installing the dust seal, apply grease

(No.2 Lithium base grease) to the contact sur-
face of the dust seal and bushing.
Fig.8-110
8-64 -
8.19 Removal and installation of swing bearing assembly

Removal
1. Remove the turntable assembly according

to Section “Removal and installation of turnta-
ble assembly” in pages 8-52.
2. Remove the 40 mounting bolts (1), and re-

move the swing bearing assembly.
Fig.8-111
3. Lift the swing bearing assembly (2).
Swing bearing assembly: 544 kg
Fig.8-112
Mounting

the removal.
Threads of mounting bolts of

swing bearing:
Mounting bolts of swing bearing:
Step 1:
Use a pneumatic wrench to tighten the bolts.
Step 2:
Tighten it to 927±103N·m {94.6±10.5kgf·m}
- 8-65
1) When using a torque wrench to tighten the

bolts, first tighten the bolts at four corners,
and mark them.
2) The remaining bolts shall be tightened in

an clockwise or anticlockwise order. Tighten
one bolt, then tighten the other diagonally op-
posite, and mark them.
3) Follow the above manner till the bolts are

all tightened.
★ As shown in the figure, install the swing

bearing to the track frame, with the mark S on
the inner race soft zone facing right.
★ Apply grease to the ring rear of the swing

bearing.
• Gears shall be fully applied with grease.
Swing bearing: Fig.8-113
Grease (Molybdenum disulfide lithium base

grease) 15L
8.20 Removal and installation of turntable assembly

Removal
Fully extend the stick and bucket, lower

the work equipment to the ground, and place
the safety lock control lever in the locked
position.
1. Disassemble the work equipment assembly

according to Section “Removal and installa-
tion of work equipment assembly” in pages 8-
84.
2. Remove the counterweight assembly ac-

of counterweight assembly” in pages 8-91.
8-66 -
3. Remove 4 hoses (1) from the boom

cylinder.
★ Plug the hoses to prevent oil from

escaping.
Fig.8-114
4. Lift the boom cylinder assembly (2).
Fig.8-115
5. Remove the plate (3) and pin (4), and lift

the boom cylinder assembly (2) for removal.
★ Remove the other boom cylinder in the

same manner.
Boom cylinder assembly: 264 kg
Fig.8-116
- 8-67
6. Remove the plate (5), air inlet hose (6) and

fan cover (7).
★ When removing the turntable, remove other

parts that would interfere with its lifting.
Fig.8-117
7. Remove the 6 hoses above the rotary joint Fig.8-118

assembly on the side of swivel joint.
（8）： Between the center swivel joint (port

A) and the left travel control valve (port BTL)
（9）： Between the center swivel joint (port

C) and the left travel control valve (port ATL)
（10）：Between the center swivel joint (port

F) and the solenoid valve

G) and the swing motor (port T)

D) and the right travel control valve (port ATR)

B) and the right travel control valve (port BTR)
8. Remove the fixing bolt (14).
8-68 -
9. Remove 35 mounting bolts of the turntable,

remove the turntable assembly (15), and then
lift and move it away.
★ First remove two front and rear mounting

bolts, use a lever block to adjust the turntable,
making it balanced horizontally and vertically,
and then remove the remaining two bolts.
When removing the turntable, avoid

bumping with the center swivel joint assembly.
Fig.8-119
Turntable assembly
Only
Assembly
Model turntable
（kg）
（kg）
SY365H-10 14,755 3,040
Mounting

the removal.
Clamping screw of air inlet hose:
5.4~6.4 Nm {0.55~0.65 kgm}
Swing bearing mating face:
Flange sealant (Tianshan 1596)
Threads of the mounting bolts of

turntable:
Mounting bolts of the turntable:
Step 1: Use a pneumatic wrench to tighten

the bolts.
- 8-69
Step 2: Tighten the bolts again.
927±103 N·m {94.6±10.5 kgf·m}

the oil filler, start the engine to circulate the oil
in the hydraulic system, and then check the oil
level.
• Bleed air
Bleed air from travel motor according to

“Bleeding air from each equipment” in pages
6-23.
8.21 Removal and installation of center swivel joint assembly

Removal

hydraulic lines according to Section “Release
of residual pressure from hydraulic lines” in
pages 6-19.
Fig.8-120
★ Tag all pipelines for easy installation.
1. Disconnect the following 8 hoses (1) ~ (8)

from the center swivel joint of travel motor.
(1)： Between the center swivel joint (port T)

and the left travel motor (port T)

and the right travel motor (port T)
(3)： Between the center swivel joint (port B)

and the left travel motor (port PA) Fig.8-121
8-70 -
(4)： Between the center swivel joint (port D)

and the right travel motor (port PB)
(5)： Between the center swivel joint (port A)

and the left travel motor (port PB)
(6)： Between the center swivel joint (port C)

and the right travel motor (port PA)
(7)： Between the center swivel joint (port E)

and the left travel motor (port X)
(8)： Between the center swivel joint (port E)

and the right travel motor (port X)
2. Disconnect 6 hoses from (9) through (14).

and the swing motor (port Dr)
(10)：Between the center swivel joint (port E)

and the solenoid valve (port PT)
(11)：Between the center swivel joint (port C)

and the left travel control valve (port BTL)
(12)：Between the center swivel joint (port A)

and the right travel control valve (port ATL)
(13)：Between the center swivel joint (port D) Fig.8-122

and the left travel control valve (port BTR)
(14)：Between the center swivel joint (port B)

and the right travel control valve (port ATR)
3. Remove 2 pin rolls (16) and take down the

check plate (15).
Fig.8-123
- 8-71
4. Remove 4 fixing bolts (13) of check plate

seat and take down the check plate seat (14).
5. Remove 4 mounting bolts (17).
Fig.8-124
6. Remove the central swivel joint assembly

(18).
Center swivel joint: 45 kg
Fig.8-125
Mounting

the removal.
Install the center swivel joint in such a way

that it faces the direction indicated in the fig-
ure. (The figure is the top view of the
machine))
• Refill the oil (hydraulic tank)
★ Add oil through the oil filler cap to the speci-

fied level. Start the engine to circulate the oil Fig.8-126
in the system. Check the oil level again.
8-72 -
• Air bleeding
★ Bleed air from travel motor according to

“Bleeding air from each equipment” in pages
6-23.
8.22 Disassembly and reassembly of center swivel joint assembly

Disassembly
1. Remove the fixing bolt (1).
2. Remove the cover (2).
3. Remove the swivel shaft from the swivel ro-

tor (6).
★ Be careful not to damage the sliding sur-

face of the swivel shaft(12).
4. Remove the O-ring (8), oil seal (8) and re-

tainer ring of hole (7) from the swivel rotor (6).
5. Remove the rotary seal ring (9) and O-ring

(10) from the swivel rotor (6).
6. Remove the oil seal (11) from the swivel

shaft (12).
- 8-73
Fig.8-127
Reassembly
1. Install the oil seal (11) onto the swivel shaft

(12).
★ Install the dust-proof seal with the lip facing

the swivel rotor.
2. Install the O-ring (10) and rotary seal ring

(9) into the swivel shaft (6).
3. Fix the swivel shaft (12) to the work bench. Fig.8-128

Install the swivel rotor (6) to the swivel shaft
(12).
The clearance between the swivel rotor (6)

and the swivel shaft (12) is about 0.1 mm.
8-74 -
Therefore, the swivel shaft must be inserted

vertically and slowly in the axial direction. Be
careful not to damage the rotary seal and O-
ring.
4. Strike the swivel rotor (6) with a rubber

hammer to fit it to the swivel shaft in place.
5. Install the O-ring (3) and retainer ring of

hole (7) to the swivel shaft (12).
6. Install the cover (2), and tighten the fixing

bolt (1).
Fixing bolt: 49 N·m
8.23 Removal and installation of hydraulic tank assembly

Removal
1. Drain oil from the hydraulic tank.
Hydraulic oil: about 340 L
2. Open the engine hood.
1. 3. Remove the engine hood (1), beam (2)

and control valve cover (3).
Fig.8-129
- 8-75
4. Remove the covering part (4) and upper

partition of main pump (5)
5. Remove the bracket (7) on the side of the

engine partition (6) and hydraulic tank.
Fig.8-130
6. Remove the oil return steel pipe (8) and

hose (9) of hydraulic tank
Fig.8-131
7. Remove the 7 rubber hoses.
(10): Oil drain hose of solenoid valve
(11): Oil drain hose of main valve Dr1
(12): Two oil drain hoses Dra and Drb of main

valve
(13): Oil return hose of main valve XBp1
(14): Oil drain hose of main valve Dr2
(15): Oil drain hose of pilot block T

Fig.8-132
(16): Two oil drain hoses of main valve
★ Attach the hoses with identification tags.
8-76 -
★ Use sleeve nuts to protect pipe joints and

cone seals against damage.
8. Remove the oil suction tube (17) at the bot-

tom of hydraulic tank and the oil suction hose
(18) connecting with suction tube of main
pump.
9. Remove 10 mounting bolts (19) at the bot-

tom of hydraulic tank, and lift the hydraulic
tank assembly.
10. Lift and move away the hydraulic tank as-

sembly for removal Fig.8-133
Hydraulic tank assembly: 234 kg
Mounting

the removal.
Hydraulic tank drain plug:
58.8~78.5 Nm {6.0~8.0 kgm}
★ After tightening the hose clamping screw,

check that the screw is located within the indi-
cated range as shown in the figure.
Hose clamping screw:
8.8±0.5 Nm {0.9±0.05 kgm}
Fig.8-134
- 8-77
★ Install the hose clamp and tighten the

clamping screw as shown in the right figure.
Mounting bolts:
245.2~308.9 Nm {25~31.5 kgm}
★ Add oil through the oil filler cap to the speci-

Fig.8-135
fied level. Start the engine to circulate the oil
in the system. Check the oil level again.
• Air bleeding
★ Refer to ―Bleeding air from each equip-

ment‖ described in Page 6-21.
8.24 Removal and installation of control valve assembly

Removal

for safety, and stop the engine. After the
power-on pressure relief, use the breather
valve to release the residual pressure from
the oil tank, and place the safety lock control
lever in the LOCK position.
★ Tag each pipeline for easy installation.
1. Open the engine hood (1).
2. Remove the center cover plate (2) over the Fig.8-136

control valve.
8-78 -
3. Remove the side partition of engine (3).
Fig.8-137
4. Remove the cover plate (4) at the bottom of

main valve.
Fig.8-138
- 8-79
5. Remove and tag 17 pilot pipelines.
(5): Two bucket unloading hoses (left travel)
(6): Three boom descending hoses (right

travel)
(7): Three boom raising hoses
(8): one bucket digging hose
(9): Two boom raising hoses
(10): Two arm unloading hoses
(11): Three arm digging hoses
(12): One left swivel hose

Fig.8-139
6. Remove and tag two pilot pipelines on the

control valve.
(13): Right travel forward hose
(14): Left travel forward hose
Fig.8-140
7. Remove the PG hose (15) and SH hose

(16) of swing motor.
Fig.8-141
8-80 -
8. Remove the inlet hose(17) and return hose

(18) of breaking hammer and cap the joints.
Fig.8-142
9. Remove the pipes (19 and 20) between the

main valve and boom cylinder and cap the
joints.
Fig.8-143
10. Remove the bucket hoses (21 and 22),

and cap the joints.
11. Remove the arm hoses (23 and 24), and

cap the joints.
Fig.8-144
- 8-81
12. Remove the hoses (25, 26, 27 and 27) be-

tween the center swivel joint and main valve,
and cap the joints.
13. Remove the swing motor hoses (29 and

30), and cap the joints.
14. Remove the hose (31) from the control

valve to port M of swing motor and the hose
(32) from the swing motor to oil tank.
Fig.8-145
15. Remove the pipe clip (33) and pipe (34) of

swivel radiator.
Fig.8-146
16. Remove the hose (35) between the main

valve and hydraulic tank, and cap the joint.
17. Remove hoses (36 and 37) from the hy-

draulic pump and cap the joint.
Fig.8-147
8-82 -
18. Remove two travel hose clips (38 and 39)

fixed on the platform.
Fig.8-148
(40) and (41): Travel backward hose
Fig.8-149
19. Remove and tag the harness and hose of

solenoid valve.
(42): Return hose of solenoid valve
(43): Inlet hose of solenoid valve
(44): Hose between the solenoid valve and

center swivel joint
(45): Inlet hose between the solenoid valve

and PT block
(46): Solenoid valve harness
Fig.8-150
- 8-83
21. Remove the fixing bolts of control valve

assembly (47) and lift the assembly for
removal
Control valve assembly: 380 kg
Fig.8-151
Mounting
• Perform the installation in reverse order

of the removal.。
★ Add oil through the oil filler cap to the
specified level. Start the engine to circulate
the oil in the system. Check the oil level
again.
• Air bleeding
★ Bleed air from the circuit between the
valve and hydraulic cylinder. Refer to
―Bleeding air from each equipment‖ in
Page 6-21.
8.25 Removal and installation of hydraulic pump assembly

Removal

and stop the engine. Press down the release
button of the breather valve on the hydraulic
tank to release the pressure inside of the
tank.
Before operation, remove the cable from

the negative terminal of the battery.
8-84 -
★ Tag all pipelines for easy installation.
Fig.8-152
1. Remove the suction filter from the hydraulic

tank, and use a stopper to prevent oil from
escaping.
★ If the stopper is not available, remove the

drain plug, and drain oil from the hydraulic
tank and pipelines.
2. Open the engine hood (1).
Fig.8-153
3. Remove the engine hood strut (2) and

mounting screw (3).
Fig.8-154
- 8-85
4. Remove the right cover (4) and black hood

of silencer
Fig.8-155
5. Remove the inlet hose (5) of proportional

valve and outlet hose (6) of pilot pump, and
cap the joints.
Fig.8-156
6. Remove the screw (7) and pin roll on the

door.
7. Remove the right door (8).
8. Remove the hydraulic pump cover (9).
Fig.8-157
8-86 -
9. Remove the drain hose (10) and cap the

joints.
10. Remove the high-pressure hoses (11 and

12) to the control valve, and cap the joints.
Fig.8-158
11. Remove the pressure sensor harness

(13).
12. Remove the suction hose (14) from the pi-

lot pump and cap the joint.
13. Remove the suction pipe (15) from the hy-

draulic pump and seal the ports.
Fig.8-159
- 8-87
14. Remove the solenoid valve harnesses (16

and 17).
Fig.8-160
15. Remove the 4 fixing bolts (18) of hydraulic

pump, and lift the hydraulic pump assembly
(19) for removal.
Hydraulic pump assembly: 186 kg
Fig.8-161
Mounting

the removal.
★ After tightening the hose clamping screw,

check that the screw is located as shown in
the right figure.
Clamping screw of the suction Fig.8-162

hose:
10~13 N·m {1.0~1.3 kgf·m}
8-88 -
★ Install the hose clamp and tighten the

clamping screw as shown in the right figure.
Mating face of hydraulic pump

housing:
Gasket sealant (LOCTIT 515)

Fig.8-163
Add oil through the oil filler to the specified
level. Start the engine to circulate the oil in the
system. Check the oil level again.
• Air bleeding
Refer to “Bleeding air from each equipment”

8.26 Removal and installation of oil seal in the input shaft of hydraulic
pump
Removal
1. Remove the hydraulic pump assembly (1)

according to Section “Removal and installa-
tion of hydraulic pump assembly” in pages 8-
68
2. Remove the screw (2), and separate the

bearing cover plate (3).
3. Use a screwdriver to pry the oil seal (4) out.
★ When prying the oil seal out, be careful not Fig.8-164

to damage the shaft.
- 8-89
Mounting

the removal.
Oil seal lip: Grease (No.1 Calci-

um-based grease)
Oil seal periphery: Grease (No.1

Calcium-based grease)
Fig.8-165
★ Apply a thin coat of grease to oil seal
periphery.
8.27 Disassembly and reassembly of pilot valve assembly of work

equipment
★ This section will only focus on the precautions that should be observed when reassembling the
pilot valve assembly of work equipment.
Fig.8-166
Reassembly ★ Apply thread-locking adhesive(Tianshan

• Reassemble the pilot valve assembly of 1277) to the two inner threaded points
work equipment. indicated in the figure below, 0.02g for each.
1. Install the connecting plate (9) to the valve
Joint (3):
housing (8) installed with O-ring, and tighten
98~133 Nm {10~13.5 kgm}
the socket head screw (10).
★ Be sure to tighten the joint to the specified
Socket head screw: torque.
25~33 Nm {2.55~3.36 kgm}
8-90 -
2. Install the spring (7) into the spool cavity of

the housing (8), and insert the spool (6) into
the spring. Install the push rod (5) on the
spool, and press the push rod (5) into the
spool cavity.
3. Install the fixing plate (4) to the push rod

(5), and tighten the joint (3).
4. Install the circular plate (2) and adjust it

properly. Tighten the set nut (1). Fig.8-167
Set nut:
98~133 Nm {10~13.5 kgm}
★ The position of each oil port is stamped at

the bottom of the valve body. Contact surface between the
push rod (5) and circular plate (2):
Push rod (5) periphery: Grease 0.3~0.8cc (G2-L1)
Grease (No.1 Calcium-based grease) ★ After the reassembly of disc, refer to Section
―Adjustment of work equipment and swivel
Moving surface of the joint (3):
pilot valve‖ in pages 6-16.
Grease (No.1 Calcium-based grease)
Inner threads of valve housing:

8.28 Disassembly and reassembly of travel pilot valve assembly

★ This section will only focus on the precautions that should be observed when reassembling the
travel pilot valve assembly.
Fig.8-168
- 8-91
Reassembly
• Reassemble the foot controlled pilot valve assembly.
1. Install the springs (8) into the spool cavity of the body (9), insert the spools (7) into the springs.
Set the body (6) on the top of the spools, and hold the body (6) with hand.
2. After aligning the mounting holes, install the cover plate (4) and tighten the socket head screws
(1).
Socket head screw: 98~114 Nm {10~11.6 kgm}
3. Install the dust rings (3) to the push rods. Install the cams (2), and fix them with the camshafts
(5).
Contact area between the push rod and dust ring (5): Grease (No.1 Calcium-based
grease)
8.29 Disassembly and reassembly of hydraulic cylinder assembly

Special tool
8-92 -
Quanti
Tool name Sketch Necessity
ty
Bushing
removal and ■ 1
installation
Dust ring
■ 1
installation
Seal
installation
■ 1
and
correction
Cylinder head
■ 1
installation
Piston
■ 1
installation
- 8-93
Disassembly
1. Drain oil and remove all connected pipes/

hoses.
2.Secure the cylinder.
★ Secure the cylinder horizontally or verti-

cally. A cylinder secured vertically is easier for
disassembly and reassembly.
★ Install a pin roll to the pin hole on the larger

chamber against rotation.
★ If the pipes/hoses would interfere with the

above operation, they shall be removed in
advance.
Fig.8-169
3. Removal of the cylinder head
★ Use a hex wrench to loosen and remove

the bolts.
★ As shown in the right figure, use a hex

wrench with an extension handle to loosen
bolts easily.
Fig.8-170
8-94 -
4. Withdraw the piston rod.
★ Confirm that the covers of all attached

pipes/hoses have been removed.
★ Prepare a container to catch the oil drained

from the ports.
★ Withdraw the piston rod (1) to the limit posi-

tion, and slowly separate the cylinder head.
★ Withdraw the piston rod (1) and cylinder

head (2) together, and place them on wooden Fig.8-171
blocks.
5. Secure the piston rod.
★ Secure the piston rod by using the pin holes

or plane area at the end to prevent rotating.
Fig.8-172
- 8-95
6. Removal of the piston nut (5)
1) Remove the set screw (3) of the piston nut.
★ Two positions on the outer periphery of the

set screw shall be punched to avoid loose-
ness. Use a hand drill to remove the riveted
part, and loosen and remove the set screw
(3).
2) Remove the ball (4) from the set screw.
3) Remove the piston nut (5).

Fig.8-173
★ The piston nut (5) has been tightened to a
large torque. To loosen the piston nut (5), pre-
pare a power wrench with a hydraulic jack or
a cylinder. To loosen the nut using a manually
operated wrench, prepare an extension rod
prior to the operation.
Fig.8-174
7. Remove the piston and others.
Successively remove the piston (7), buffer

bushing (6) and cylinder head (2).
Fig.8-175
8-96 -
8. Removal of the buffer bushing (8) on the

rodless chamber side
1) First remove the piston nut (5). Otherwise,

the removal would not continue.
2) Without damaging the piston rod and buffer

bushing (8), use a rubber hammer or other
tools to strike the circlip (9) and remove it.
3) Slide the buffer bushing (8) in the direction

of the piston threads, and remove the split
type stop ring
Fig.8-176
4) Remove the buffer bushing (8).
5) The buffer seal (10) has an opening. Em-

ploy this opening to remove it.
9. Remove the piston seal.
1) Remove the slide ring (12) and guard ring

(13).
2) Use a hammer to strike a flat screwdriver

vertically, and cut off the seal ring (14).
3) Pry the O-ring (15) out.
★ The removed seal would not be used

anymore.
Fig.8-177
10. Removal of the buffer ring (16)
★ The buffer ring (16) is installed in the inner

groove of the cylinder head. When removing
the buffer ring, use a pointed tool to pry it up,
and then insert a spatula to remove it.
11. Remove the U-ring (17) and dust ring (18).
1) Remove the U-ring (17) with tools, like a

screwdriver.
2) Use a screwdriver or other tools to pry the

dust ring (18) off by striking the screwdriver. Fig.8-178
★ The removed seal would not be used
anymore.
- 8-97
12. Removal of the bushing (19)
1) Use a screwdriver to remove the circlip (20)

from the cylinder head (2).
2) Push out the bushing (19) with the fixture

and press equipment
13. Removal of the pin bushing (21)
1) Use a screwdriver to remove the dust ring

(22) on the cylinder tube and piston rod side.
The operation is the same as the removal of
the cylinder head dust ring.
2) Use a proper block to remove the pin bush-

ing (21).
Fig.8-179
Reassembly
1. Installation of pin bushing (21)
1) Use the installation tool to press it into the

bushing on the piston rod and cylinder tube
side (applied with hydraulic oil prior to installa-
tion) .
2) Use a proper block to install the dust ring

(22). Fig.8-180
8-98 -
2. Reassembly of the cylinder head assembly

(2)
1) Use the press equipment to press the bush-

ing (19) in place.
★ Apply hydraulic oil to the cylinder head prior

to the operation, and check the installed bush-
ing (19) for uneven shoulders.
Fig.8-181
2) Use the press equipment to press the dust

ring (18) in place.
3) Successively install the guard ring and U-

ring (17) to the U-ring groove.
★ First check that the U-ring (17) is free of

damage, and then install the U-ring as per the
correct direction.
★ Installation in reverse direction would lead

Fig.8-182
to oil leak.
★After installation, check the U-ring (17) for

wrinkle, permanent deformation, etc.
4) Install the buffer ring (17).
★ Note that the installation direction of the

seal ring shall be correct. If the ring is installed
in the reverse direction, the extremely high
pressure formed between the ring and the U-
ring (17) would lead to cylinder deformation or
damage.
5) To prevent the fall-off of the bushing (19), Fig.8-183

be sure to install the circlip (20).
- 8-99
3. Reassembly of the piston assembly
1) Install the seal ring (14).
★ Install the O-ring and guard ring (13) to the

piston, place the piston on the press equip-
ment, and install the seal ring (14) as shown
in the right figure.
2) Correct the seal ring (14) installed.
★ After installing the seal ring (14) and the

guard ring (13) on the other side, be sure to
correct the installed seal ring (14) immedi-
ately. Since the seal ring (14) is expanded
during installation, the piston rod would not be
Fig.8-184
inserted into the cylinder tube successfully if
the seal were not corrected properly.
3) Install the slide ring (12).
★ Using hands, expand the slide ring with

minimum effort and install it axially. Expanding
with too much effort would lead to failure of
installation.
4. Reassembly of the piston rod assembly
1) Secure the piston rod (1).
2) Install the cylinder head (2) to the piston

rod.
★ Note that the lips of the dust ring and U-ring

shall not be held against by the projected
shoulder. Use the tool to install the cylinder
head and piston rod. Fig.8-185
8-100 -
3) Except the bucket cylinder, If there is a buf-

fer on the rodless chamber side, install the
buffer bearing and buffer seal in the following
order.
i) Install the buffer seal (10) into the groove,

with the clearance facing the piston.
ii) The plane machining part of the buffer

bushing (8) should be installed as shown in
the right figure.
iii) Install the stop ring (11) into the groove.

Press the buffer bushing (8) to the end in the
direction of the stop ring, and install the circlip.
To avoid damaging the piston rod and buffer
Fig.8-186
bearing, use a rubber hammer to strike gently.
4) If there is buffer on the rod chamber side,

install the buffer bushing (6) and buffer seal
(23) in the following order.
i) Install the buffer bearing prior to the installa-

tion of the piston nut. Otherwise, the buffer
bearing cannot be installed anymore.
ii) Install the buffer seal (23) into the groove,

with the clearance facing the piston.
iii) The plane machining part of the buffer

bushing (6) should be installed as shown in
the right figure.
Fig.8-187
5) Tighten the piston nut (5).
Piston nut (arm):
9600 Nm {979.6 kgm}
Piston nut (boom and bucket):
6200 Nm {632.6 kgm}
★ Insufficient tightening torque would lead to

internal leakage, nut looseness and thread
damage. On the other hand, excessive tight-
ening torque would lead to buffer bearing
- 8-101
expansion or the side contacting the piston

deformed.
★ Clean and degrease the threads of the pis-

ton, nut and piston rod (with banana oil or
alike), and then tighten the nut.
6) Perform anti-looseness treatment to the

piston.
★ After tightening the piston nut (5), install the

ball (4), tighten the set screw (3), and rivet it at
two positions on the periphery with a punch
pin.
Set screw (3):
66.9 Nm {6.8 kgm}
Fig.8-188
8-102 -
5. Insert the piston rod into the cylinder tube.
1) Secure the cylinder tube vertically or

horizontally.
2) Insert the piston rod into the cylinder tube.
★ If the cylinder tube is secured vertically, the

piston rod enters the cylinder tube by means
of its dead weight.
★ When the piston enters the cylinder tube,

note that the slide ring shall not fall off.
Fig.8-189
6. Cylinder head tightening
Refer to the cylinder head assembling figure,

and tighten the bolts in the order as shown in
the right figure.
Bolts:267 Nm {27.2 kgm}
7. Install all necessary pipes/hoses.
Fig.8-190
8.30 Removal and installation of work equipment assembly

Removal
- 8-103
Fully extend the arm and bucket, lower

the work equipment to the ground, and place
the safety lock control lever in Lock position.

hydraulic lines according to Section “Release
of residual pressure from hydraulic lines” in
pages 6-19.
1. Disconnect the grease line (1).
2. Lift the boom cylinder assembly (2), and re-

move the bolt (3).
3. Remove the plate (4) and then the pin roll
★ Gaskets are installed. When removing

them, be sure to check their quantity and
thickness, and store them at a proper place.
4. Start the engine and retract the piston rod.

Fig.8-191
★ Attach the piston rod with a cable to prevent
it from sliding out, and lower the hydraulic cyl-
inder to the workbench or place a support
under the cylinder. When placing a support
underneath, first remove the grease line joint
at the bottom of the cylinder.
★ Remove the other boom cylinder in the

same manner.
8-104 -
5. Remove the hose (6) from the bucket cylin-

der, and remove the hose (7) from the arm
cylinder.
★ Plug the hoses to prevent oil from escaping,

and secure them to the valve side.
6. Remove one work lamp connector (8).
Fig.8-192
7. Lift the work equipment, remove the plate

(9), and remove the pin roll (10) at the bottom.
★ Gaskets are installed. Remember to check

their quantity and record their installation
positions.
Fig.8-193
8. Lift the work equipment assembly (11) for

disassembling.
Work equipment assembly:
Model Weight
SY365H-10 7,102 kg
Fig.8-194
- 8-105
Mounting

the removal.
★ When tightening the lock nut, the clearance

a between the plate and nut shall be main-
tained within 0.5- 1.5 mm.
Apply grease after installing the

pin: Fig.8-195
Grease (Molybdenum disulfide lithium base

grease)
When aligning with pin holes, never put

finger(s) into any pin hole.
★ Adjust gasket thickness, satisfying the

specified clearance a between the piston rod
head(12) and plate(4): 0.5＜a＜1 mm.
★ Thickness of standard gasket: 1.0 mm and

2.0 mm。
Apply grease after installing the

pin:
Grease (Molybdenum disulfide lithium base Fig.8-196

grease)
When aligning with pin holes, never put

finger(s) into any pin hole.
• Refilling of hydraulic oil

Add hydraulic oil to the specified level, start
the engine to circulate the oil in the hydraul-
ic system, check the oil level again, and
add hydraulic oil if necessary.
• Bleed air
8-106 -
Bleed air from travel motor according to

―Bleeding air from each equipment‖ in pa-
ges 6-23.
8.31 Removal and installation of A/C assembly

Special tool
Sym Part Neces Quanti

Model
bol name sity ty
Refrig
erant
charg
S - ● 1
ing
ma
chine
Removal
First remove the cable from the negative

terminal of the battery.
1. Drain the cooling water.
Coolant: about 22.5 L
2. Use the tool S to collect refrigerant from the

A/C.
Fig.8-197
3. Remove the floor liner (1).
Fig.8-198
- 8-107
4. Open the rear left cover of the cab with the

ignition key, and remove the air cleaner ele-
ment (2).
Fig.8-199
5. Remove the cover (1) and (4) of monitor.
★ Before removing the cover (3), remove the

cable M19 of cigarette lighter.
6. Remove the right air duct hood (5) and air

duct inside.
Fig.8-200
7. Remove the rear cover (6).
Fig.8-201
8-108 -
8. Remove the rear air duct (7).
9. Remove the left air duct (8).
10. Remove the plate (9).
11. Remove the right air duct (10).
Fig.8-202
12. Remove the cover (11).
13. Remove the cab center connector (12).
14. Remove the radio
Fig.8-203
15. Remove the air duct (14) and the control-

ler wire connector (15), disconnect the wire
connector (16), remove the two A/C relays
(17), remove the 3 mounting bolts (18), and
remove the mounting plate (19). antenna (13).
Fig.8-204
- 8-109
16. Remove the A/C water pipes (20 and 21)

from the bottom plate, and remove the drain
pipe (22).
Fig.8-205
17. Remove the A/C unit (23).
★ When removing the A/C unit, remember to

connect the 2 A/C hoses at the bottom.
Fig.8-206
Mounting
• Perform the installation in reverse order of the removal.
★ When installing the A/C hoses, be careful not to allow dirt, dust and water to enter the hoses.
★ Check if the O-ring is installed in place before connecting each A/C hose.
★ Check O-rings for damage or deformation.
★ Apply compressor oil (ND8#) to the threads of refrigeration pipe fittings, and tighten the pipe us-
ing a double ended wrench.
Hose clamp screw: 8.83~ 14.7 N·m {0.9~ 1.5 kgf·m}
Pressure plate bolts: 13.5±1.2 N·m {1.38±0.12 kgf·m}
8-110 -
• Charging with refrigerant
Use the equipment S to charge the A/C circuit with refrigerant (HFC-134a).
8.32 Removal and installation of counterweight assembly

Removal
1. Fit a hanger pin (1) on the lug of counter-

weight, and fasten the wire rope (2) and hang
the counterweight with hoisting equipment.
Fig.8-207
2. Remove 4 mounting bolts (3) and gaskets
of counterweight
3. Lift the counterweight with the hoisting
equipment.
★ Be careful not to collide with the engine, ra-

diator and cooler.
Counterweight assembly: 6800kg
Fig.8-208
Mounting

the removal.
Threads of counterweight
mounting bolts:
- 8-111
Counterweight mounting bolts:
2,295±200 N·m {214~255 kgf·m}
★ Installation and adjustment of

counterweight
1) Use a crane to lift the counterweight to a

proper place on the frame.
2) Move the counterweight, install the mount-

ing bolts, and satisfy the following dimensions
through adjustment.
• Clearance between the counterweight and Fig.8-209
the turntable:
• 10±5mm (left and right)
• Clearance between the counterweight and
the machine door: 10±2 mm (left and right)
• The step difference between the counter-
weight and the turntable in the left and right
directions b: Maximum 5 mm
weight and the machine door in the left and
right directions a：10±4
weight and the roof cover in the upward and
downward directionsc：Maximum 5 mm
8-112 -
8.33 Removal and installation of cab assembly

Removal

1. Remove the floor liner (1).
Fig.8-210
2. Remove the rear plate (2 and 3).
Fig.8-211
3. Disconnect the left harness (4), display wire

connector (5) and windshield washer harness
(6).
4. Remove the right air duct (7).
Fig.8-212
- 8-113
5. Remove the exterior air cleaner element

(8).
Fig.8-213
6. Remove the exterior air duct (9).
Fig.8-214
7. Remove the armrest storage box (10).
Fig.8-215
8-114 -
8. Disconnect the radio connector (11).
9. Remove the radio harness (12).
Fig.8-216
10. Remove the windshield washer fluid reser- Fig.8-217

voir (13).
11. Remove the windshield washer fluid hose

(14).
Fig.8-218
12. Remove the trim cover (15).
Fig.8-219
- 8-115
13. Remove 4 mounting nuts (16) and 5

mounting bolts (17).
★ Check the length of the bolts in advance.
Fig.8-220
14. Lift the cab assembly (18) for removal.
Cab: 105 kg
Fig.8-221
Mounting

the removal.
Mounting bolts: 200 Nm {20.4

kgm}
Mounting nuts: 210 Nm {21.4

kgm}
8-116 -

cab windows
Fig.8-222
Removal
- 8-117
When removing broken or cracked

glasses, avoid being hurt by sharp glass
pieces. Secure the broken or cracked glass
using tapes or alike before removal to avoid
being hurt. Be sure to remove the broken
pieces. Protective measures shall be taken
before the disassembly, and the glass shall be
reinforced with tape or the like to facilitate the
safe removal.
1. Removal of the glass (3)

Fig.8-223
The glass is held in place with weatherstrips.
To remove it, slowly pull the glass out from the
bottom up.
2. Removal of the glass (4) and glass (6)
1） Remove the weatherstrips from the win-

dow frames and doors.
2） Gradually push the window frame from

the inside of the door to remove the frame and
glasses (4 and 6) as a whole.
Fig.8-224
3） Remove the glasses (4 and 6) from the

window frame using a screwdriver.
Fig.8-225
8-118 -
3. Removal of the glass (8)
1） Remove the stopper (rubber groove) with

a general screwdriver.
2） Insert a pieces of bamboo stick into Posi-

tion A of the rubber strip, and pry the rubber
strip off.
3） Tap the glass with your palm from the in-

side of the cab to remove the glass. This oper-
ation needs to be completed by two persons.
Fig.8-226
4. Removal of the glasses (1, 2, 5, 7 and 9)
Fig.8-227
1） Remove the resin plate, trim strips,

blocks, etc. around each glass.
2） Penetrate into the adhesive with an awl

(or knife) to make a hole.
Fig.8-228
- 8-119
3） Thread a piece of piano wire (or steel

wire) through the hole.
Fig.8-229
4） Bind both ends of the piano wire on two

screwdrivers. Pull the piano wire back and
forth to cut the adhesive between the cab and
the glass, and remove the glass from the cab.
This operation needs to be completed by 2~ 3
persons in cooperation.
• Be sure to cut the middle position of the ad-

hesive between the glass and the cab.
When the piano wire becomes hot, it is in-
clined to be broken. Therefore, be sure to
change the contacting point of the wire
Fig.8-230
while cutting the adhesive.
Mounting
• Install the glasses (3), (4), (6) and (8) ac-

cording to the reverse sequence of removal;
and install the glasses (1), (2), (5), (7) and
(9) according to the following sequence:
1. Use a knife and spatula 5 to remove resid-

ual adhesive and rubber seal from the metal
panel (surface sticked with glass).
★ Clean off the adhesive and rubber seal until

they would not affect the application of new
adhesive. Be careful not to scratch the
painted surface (or the adhesion of adhesive
would decrease).
Fig.8-231
8-120 -
2. Use unleaded gasoline to remove oil, dust,

dirt, etc. from the surface of the cab (8) and
glass (9).
1. ★ If the surface is not clean, the glass will

not be held in place with adhesive.
2. ★Clean the black part on the back of the

glass.
3. ★ After cleaning the surface, leave the

glass for at least 5 min, allowing it to dry.
Fig.8-232
Fig.8-233
3. Apply the primer (10).
★ The primer should be used within 4 months

starting from its manufacturing date. Do not
use the primer of which the storage time ex-
ceeds this limit.
★ After being unpacked, the primer should be

used up within 2 hours.
★ Even if the primer is re-packed immediately

after being unpacked, it should be used within
24 hours starting from the time when the pri-
mer is unpacked. (After being unpacked for Fig.8-234
more than 24 hours, the primer should be dis-
carded. ）
- 8-121
1） Stir the primer (either applied to the cab

or glass) thoroughly before it is applied.
★ If the primer is kept in a refrigerator, leave it

under room temperature conditions for at least
half a day before stirring it.
(If the primer is unpacked just after being tak-

en out from a refrigerator, condensed water
forms in the primer. Therefore, it is required to
leave the primer under room temperature con-
ditions for a sufficient period of time.)
4.
2） The primer brush (11) should be cleaned

in unleaded gasoline prior to being reused.
★ After cleaning the brush, check for dirt and

foreign materials.
★ Prepare two brushes to apply the primer to

the cab and glass respectively.
3） Apply the corresponding primer to the ad-

hesive surface of rubber seal and the exterior
adhesive surface of the cab (8) .
Primer: Sunrise MSI primer 24 Fig.8-235
★ The coats of primer shall not exceed 2.
(If the primer is applied more two times, its

performance would decrease.)
★ Application position: Covering the full size

of (a) Application dimension(a): 25mm
Fig.8-236
8-122 -
★ Note: Except for the above position, apply

the primer to the right side glass and lower
door glass.
• Application range on the right side glass:

(b)
• Application range on the lower door glass:
(c)
★ After applying the primer, leave it for at least

5 min (within 8 hours), allowing it to dry up.
Fig.8-237
★ Do not apply the wrong primer. If the glass
surface primer is wrongly applied, use un-
leaded gasoline to remove it.
Fig.8-238
4) Apply the glass surface primer to the adhe-

sive surface of glass (9).
Glass surface primer: Sunrise MSI pri-

mer 35
★ The coats of primer shall not exceed 2.
(If the primer is applied more two times, its

performance would decrease.)
Fig.8-239
- 8-123
★ Application position: area around the adhe-

sive surface of the glass (9), for the installa-
tion position of the rubber seal (6) and the cab
(8)
★ Do not apply the primer to edges approxi-

mately 5 mm wide between the black part and
the transparent part of the glass.
★ After applying the primer, leave it for at least

5 min (within 8 hours), allowing it to dry up. Fig.8-240
★ Do not apply the wrong primer.
If the glass surface primer is wrongly applied.

Use unleaded gasoline to remove it.
4. Install the rubber seal (6) along the inner

edge of glass adhesive (between adhesive
strips).
★ Before installing the glass, do not remove

the separation strip for the rubber seal on the
glass.
★ When installing the rubber seal, avoid

touching the cleaned surface.
★ Do not allow the rubber seal on each corner

to rise.
Fig.8-241
★ When installing the rubber seal (6) along

the frame periphery, do not overlap the two
ends. Instead, the clearance (e) between the
two ends of the rubber seal shall be main-
tained as about 5mm.
1) Install the rubber seal (6) of the right side

glass to the position indicated in the right
figure.
Fig.8-242
8-124 -
★ Install an additional rubber seal (6a) to the

right side glass.
• The installation position of the additional

rubber seal (6a) :
(f)：50 mm
(g)：90 mm
(h)：250 mm
Fig.8-243
2） Install the rubber seal (6) of the left side

figure.
Fig.8-244
3) Install the rubber seal (6) of the lower door

figure.
Fig.8-245
- 8-125
★ Install an additional rubber seal (6b) to the

lower door glass.
• The installation position of the additional

rubber seal (6b) :
（j）：110 mm
（k）：90 mm
（m）：200 mm 4）
Fig.8-246
4）Install the rubber seal (6) of the front wind-

shield glass to the position indicated in the fol-
lowing figure.
Fig.8-247
★ Different from other installation of rubber

seals (6), the rubber seal (6c) shall be in-
stalled along the external edge of the lower
front windshield frame. (If it is installed along
the inner edge, it will be seen through the
transparent glass from outside.)
Fig.8-248
8-126 -
5. Locate the newly installed glass
1） Check the upper, lower, left and right

clearance between the glass and the cab, and
then locate the glass, ensuring even
clearances.
2） Stick a piece of tape (6) to the connection

between the glass (9) and cab (8), and draw a
locating line (n).
★ To locate the glass, stick three pieces of

tape [6] to properly locate the left, right and
Fig.8-249
lower position of the right side glass, rear left
glass and lower door glass.
3） Use a knife to cut the strip between the

glass(9) and cab (8), and remove the glass.
★ Before installing the glass, do not remove

the strip on the left side of the glass.
Fig.8-250
★ When locating the front windshield glass

(4), the horizontal position shall be set to the
frame width;
The vertical position shall be so set that the

height difference (p) between the frame top
and the front windshield glass is 3 mm.
Fig.8-251
- 8-127
6. Apply adhesive.
★ The adhesive shall be stored in a dark

place where the temperature is lower than
25℃.
★ Do not heat the adhesive to 30℃ or above.
★ When reusing the adhesive, eliminate the

hardened adhesive on the nozzle.
1) Break the aluminum seal (13) at the outlet

of the adhesive bottle (12), and install the
nozzle. Fig.8-252
Adhesive: Sunrise MSI SR sealant

U90 4463876
2） The tip of the adhesive nozzle (14) shall

be cut to cut the dimensions (q) and (r) as
shown in the figure
Dimension (q): 10 mm
Dimension (r): 5 mm
Fig.8-253
3) Set the adhesive bottle (12) on the caulking

gun [7] and screw down the nozzle.
★ Electronic or pneumatic caulking gun will

be more efficient
Fig.8-254
8-128 -
4） Remove the separation strip for the rub-

ber seal on the glass.
5） Apply the adhesive (15) to the outer side

of the rubber seal (6).
Fig.8-255
★ Apply the adhesive (15) to the cab (8) rub-

ber seal (6) with the dimensions (s) and (t).
Dimension(s): 10 mm
Dimension(s): 15 mm
★ The coat of adhesive (15) applied shall be

higher than the rubber seal (6).
★ The adhesive should be applied evenly,

and the coat of adhesive should be in the
same level.
Fig.8-256
★ Apply the adhesive (15) to the additional

rubber seal (6a) and (6b) respectively of right
window glass and lower door window glass.
Fig.8-257
- 8-129
Fig.8-258
7. Install the glass.
1) Install the window glass(9), and align it with

the locating lines drawn in step 5.
★ It is not allowed to adjust or remove the im-

properly installed glass. Therefore, ensue that
the glass is successfully installed at one time.
★ Install the glass within 5 min after the appli-

cation of the adhesive.
2） After sticking the glass (9), press the edge

of the glass till it tightly sticks to the rubber Fig.8-259
seal.
★ Press each corner of the glass with force.
8-130 -
★ After installing the front windshield glass, fill

the clearance between the glass and the cen-
ter adjusting seal (16) within the scope (s) to
the dimensions (t) and (u). After applying the
primer to the glass (4) of Section A-A, apply
the adhesive.
Caulking dimension(t): 2 mm
Caulking dimension(t): 5 mm
★ When doing the caulking, use a rubber

spatula to cover the glass side and trim the
adhesive.
★ Wipe off excessive adhesive.
Glass surface primer: Sunrise MSI pri-

mer 35
Adhesive: Sunrise MSI SR sealant

U90 4463876
Fig.8-260
8. Secure the glass.
1) After installing the right side glass (1) to the

cab, insert the locating tape (1~2 pieces) into
the bottom of the glass to secure the glass.
Fig.8-261
- 8-131
2) Use styrofoam blocks (9) and rubber bands

(10) to secure the glass and the rubber seal to
complete the installation.
9. After the installation is completed, eliminate

excessive primer and adhesive on the cab
and glasses.
★ Before the adhesive dries up, use unleaded

gasoline to remove them.
★ During cleaning operation, do not apply

compact force to the glasses.
Fig.8-262
10. Protect the installed glasses.
1） Keep the locating tape, styrofoam blocks

and rubber bands in place for 10 hours.
(Under conditions: Temperature 20℃; humid-
ity 60%)
2） After removing the locating tape, styro-

foam blocks and rubber bands, wait at least
14 hours before operating the machine.

front window assembly
Lower the work equipment to the

ground and stop the engine.
★ When replacing the front windshield glass

(2), remove the font window assembly from
cab. Remove and install front windshield glass
assembly (front frame and front windshield
glass) according to the following method.
8-132 -
Removal
1. Lift and level the front windshield assembly

with the roof, and secure it by the rear locks
(on both sides of the cab).
2. Remove the left gusset (1) and right gusset

(2).
★ The mounting bolt (4) and washer (3) of the

left-hand gusset will be used to hang the pull-
up lever in step 6.
Fig.8-263
3. Unlock the rear locks on the cab.
4. Carefully lower the front windshield assem-

bly a little bit. Take out and hold the lower roll-
ers (5 and 6) on both side of the front
windshield from the place where the the gus-
sets are removed in step 2 (where the guide
rail opens).
5. Remove the lower rollers (5 and 6) on both

sides of the front windshield assembly.
Fig.8-264
6. Remove the lower left pin (7).
★ After the lower left pin (7) is removed, the

plate (8) at the end of the pull-up lever (9) is
separated.
★ Hang the plate (8) on the mounting bolt of

the left-hand gusset, and secure the plate in
place (with washer).
A load of 58.8N {6kgf} is applied to

the rear of the cab. Therefore, be careful to Fig.8-265
separate the pull-up lever (9) by removing
the lower left pin (7).
- 8-133
Fig.8-266
7. Pull out the bottom of the front windshield

assembly (10) from the open part of the guide
rail, and lower it down gradually.
Fig.8-267
8. Fully lower the front windshield assembly

(10).
★ Avoid colliding with the display.
Fig.8-268
8-134 -
Twist the front windshield assembly (10), re-

move the two upper roller (11 and 12), and
then remove the front windshield assembly
(10).
Fig.8-269
Fig.8-270
Mounting

the removal.
• Adjust the opening and closing of the front

windshield assembly as follows.
1. Open and close the front windshield as-

sembly, check that it does not interferes with
the guide rail, and check that the rollers do not
get caught.
Fig.8-271
2. If any problem is found, loosen the mount-
ing bolt of the roller adjusting bracket (13), ad-
just the front windshield, and tighten the
mounting bolt again.
- 8-135
★ The support (13) shall be installed properly.

No angle is allowed.
Mounting bolts: 34.3 N·m {3.5 kgf·m}
3. Lift the front windshield assembly, and se-

cure it by the rear locks (on both sides of the
cab).
★ Check that the rear locks in the cab are

locked firmly.
4. Install the right-hand gusset (2).
★ After adjusting the ―locked‖ position in the

following step 6, tighten the gusset securely.
★ Install the right-hand gusset, ensuring the

Fig.8-272
clearance (a) between the guide rail and the
right-hand gusset (2) is within 0– 2.0 mm.
★ Install the right-hand gusset, ensuring there

is no level difference on the roller surface (R).
Fig.8-273
8-136 -
5. Install the left-hand gusset (1).
★ After adjusting the “locked” position in the

following step 6, tighten the gusset securely.
★ Install the left-hand gusset, ensuring the

clearance (b) between the guide rail and the
left-hand gusset (1) is within 0–2.0 mm.
★ Install the left-hand gusset, ensuring there

is no level difference on the roller surface (R).
(Refer to the figure above.)
Fig.8-274
6. Adjust the “locked” position of the locks of

front window assembly as follows.
1) Tighten the left-hand and right-hand gus-

sets (1) and (2) to the proper position, allow-
ing the front windshield (14) to rest against
the adjusting seal (15) on the cab side.
Fig.8-275
2） When opening and closing the front wind-

shield assembly, check that the left and right
locks (16 and 17) work normally.
• If the locks (16 and 17) do not work

normally.
i) loosen the mounting bolt (19), move the lock

(16) forward, and tighten the bolt again.
★ The adjustment operation of the right lock is

the same as the above.
Fig.8-276
ii) After moving the lock forward, recheck that
the front windshield (14) fits the adjusting seal
(15) on the cab side (the same as step 1).
• Repeat step i) and ii) until the front wind-

shield fits the locks (16 and 17), and then
tighten the mounting bolts.
- 8-137
7. After performing the adjustment, pour water

on the front windshield, and check that no
water leaks in to the cab.
Fig.8-277
8. Adjust the “locked” position of the locks of

front window assembly.
1）After adjusting the “locked” position of the

locks of front windshield assembly in step 6
and step 7, lift and level the front windshield
assembly with the roof.
2） With the rear locks on both sides of the

cab at “locked” position, check the following
items. Fig.8-278
• Check that the left and right locks (16 and

17) work normally as above.
• The front windshield assembly must contact
the left and right rubber stop blocks (18),
and pushes the stoppers back by 1.5– 3.0
mm.
• The front windshield assembly must push
the limit switch back by 4– 7 mm.
8-138 -
3） Close the front windshield assembly (10).
4） Loosen the lock nuts (20) on the left and

right sides of the rubber stop block (18), and
then pull back the two rubber stop blocks (18),
ensuring they do not conflict with the front
windshield assembly which is at the “open”
position.
Fig.8-279
5) Adjust the position of the striker bolt (21).
★Striker bolt (21): M10; ID of the plate (23):

ø14.5 mm
Fig.8-280
6 Adjustment of left and right rubber stop

blocks (18)
i) Allow the unlocked front windshield assem-

bly (10) to contact the left and right rubber
stop blocks (18)
Fig.8-281
- 8-139
ii) Close the front windshield assembly (10).
iii) Rotate the left and right rubber stop blocks

(18) anticlockwise by one and a half turns.
★ Rotating the rubber stop block (18) anti-

clockwise by one turn corresponds to squeez-
ing the rubber by approximately 1.5 mm.
★ When the front windshield assembly is at

“open” position, it shall push the left and right
rubber stop blocks (18) by 1.5– 3.0 mm.
Fig.8-282
iv) Tighten the lock nuts (20) on both sides of

the rubber stop block (18).
Fig.8-283
9. Adjust the stopper (24) of front windshield

assembly.
1) Adjust and lock the stopper (24), ensuring

that when the front windshield assembly (10)
is lifted the surface (d) of stop block D con-
tacts the surface(c) of stopper (24).
Fig.8-284
8-140 -
Fig.8-285
10. Check the function of front window

assembly
1) After the operation of step 6 through step 9

is completed, check that the locking forces of
left and right locks (16 and 17) are uniform.
★ Check the locking force at the “closed” side

(in front of the cab) and at the “open” side (at
the rear of the cab) respectively.
Fig.8-286
Lower left pin: 27 – 34 N·m {2.75 –

3.47 kgf·m}
Mounting bolt: Adhesive (LT-2)
8.36 Removal and installation of display screen

Removal

1. Remove the 3 mounting bolts (4), and re-

move the mounting plate and display compo-
nents from the support (3).
2. Loosen the set nut (1) and washer (2), and

remove the display (5) from the mounting
Fig.8-287
plate.
Mounting
- 8-141

the removal.
8.37 Removal and installation of controller assembly

Removal

1. Remove the rear plate (1 and 2).
Fig.8-288
2. Remove the controller wire connectors (3

and 4).
3. Remove 4 mounting bolts and remove the

controller assembly (3).
4. Remove the engine controller wire connec-

tors (5 and 6).
5. Remove 4 mounting bolts and remove the

engine controller assembly (8).
Fig.8-289
Mounting

the removal.
8-142 -
8.38 Radio
Structure
1. Main structure
Fig.8-290
2. Wiring
- 8-143
Fig.8-291
Installation and removal
Removal
1. Remove the cover of the armrest box.
CAUTION
● Turn off the radio prior to the removal.
Fig.8-292
8-144 -
2. Remove the radio connector CN-003F.
Fig.8-293
3. Remove the four mounting bolts and wash-

ers, and remove the radio and radio support
from the cover of the armrest box.
4. Remove the four set screws and washers,

and remove the radio from the support.
Mounting

the removal.
Fig.8-294
Connector model and wiring
Fig.8-295
8.39 Battery
Structure
- 8-145
Fig.8-296
CAUTION
● Turn the key switch to OFF prior to the removal.
● Do not remove the SOC hydrometer. If it is loose, use a suitable tool to turn it clockwise.
8-146 -
1） Remove the battery ground wire.
• Open the waterproof cap, loosen the fixing

bolt, and remove the battery terminal.
WARNING
● Battery gas can explode. Keep sparks and
flames away from the battery.
Fig.8-297
2） Remove the battery cable and breaker.
Fig.8-298
3） Remove 4 mounting bolts and gaskets,

remove the battery casing from the bottom
plate, and remove the battery.
Mounting

the removal.
Fig.8-299
Replacement
The machine is installed with two 12V batteries, with the negative terminal grounded. If one of
them fails, and the other one is in good condition,, it is required to replace the battery with a new
one of the same type. Different types of batteries may have different charging rates. This differ-
ence may cause one of the batteries to lose its function due to overload.
- 8-147
CAUTION
● The battery terminals should be painted with vaseline against corrosion.
8.40 Ignition key switch

Structure
Fig.8-300
8-148 -
Removal
1） Remove the screw, and then remove the

cover of the armrest box.
Fig.8-301
2） Remove two fastening screws, and re-

move the mounting plate and key switch from
the cover of armrest box.
CAUTION
● Remove the key switch connector prior to
the removal.
Fig.8-302
- 8-149
3） Remove the nut, and remove the key

switch from the mounting plate.
Fig.8-303
Key switch electrical schematic and wiring
Electrical schematic
Fig.8-304
Wiring
Fig.8-305
8-150 -
8.41 Fuse box

Removal
1） Remove the fastening screw, and then re-

move the cover of electric cabinet.
Fig.8-306
2）Remove the connecting line of fuse box.
Fig.8-307
- 8-151
3） Screw off the fixing bolt and remove the

fuse box.
Fig.8-308
8.42 Wiper
Main structure and principle
Constitution
Fig.8-309
Electrical schematic
8-152 -
Fig.8-310
Removal
1） Remove the interior trim clip, and remove

the interior trim.
Fig.8-311
- 8-153
2） Remove the actuating mechanism and

motor.
• Remove the bolts, and remove the wiper

motor and actuating mechanism from the
cab.
Fig.8-312
3） Remove the wiper arm and blade.
• Loosen the set nut, and remove the wiper

arm and blade from the cab.
Mounting

the removal.
Fig.8-313
8-154 -
Adjustment of swing angle of wiper arms
• As soon as the blade reaches the mechani-

cal limit, the arm shall stop moving.
• If the arm continues to move when the
blade has reached the limit, or if the arm
has stopped moving while the blade does
not reach the limit, please adjust the moving
angle of the wiper to avoid being burnt out.
• The adjustment method is to loosen the
lock nut and adjust the moving angle of the
wiper arm according to specific conditions.
The objective of the adjustment is that the
wiper motor just stops as soon as the wiper
blade reaches the mechanical limit.
Fig.8-314
8.43 Relay
Engine relay
1） Inspection of starter relay
• Check the connectivity and function. If any

fault is found, replace the relay.
Fig.8-315
- 8-155
2） Inspection of main power relay

Fig.8-316
3） Glow plug relay

Fig.8-317
4）Safety relay
Measure the resistance between the terminal

2 and terminal 3.
Standard value About 200W

8-156 -
8.44 Sensor
1） Inspection of water temperature sensor
• Place the sensor in a container filled with

oil.
• Raise the oil temperature to the specified
value while stirring the oil.
• Measure the resistance between the termi-
nal 1 and body .
Fig.8-318
• If the measured value exceeds the standard

value, replace the sensor. (Refer to Section
6-5)
2）Inspection of engine speed sensor
Measure the resistance between the terminal

1 and terminal 2.
• If the measured value exceeds the standard

value, replace the sensor.
CAUTION
● If the tightening torque of engine speed Fig.8-319
sensor is insufficient, the sensor may have
no output signal. Tighten the engine speed
sensor to the specified torque. (Refer to Sec-
tion 6-2)
- 8-157
3） Inspection of pressure sensor
• Input voltage: 4.75~ 5.25VDC

• Output voltage: 0.5~ 4.5V
• Output voltage: 0.5~ 4.5V
Fig.8-320
4） Inspection of fuel level sensor
• Move the float upward and downward, and

measure the rotating angle of the lever in
effective radius. The rotating angle of the
line between the float and the rotating point
shall be 105 degrees.
• Move the float upward and downward, and
measure the vertical distance between the
highest point and lowest point where the
float can arrive, which shall be 500 mm.
• Move the float up to the top, and use a mul-
timeter to measure the resistance between
the sensor terminal R and the ground. The
resistance Ru shall not be more than 9.6Ω.
• Move the float down to the bottom, and use Fig.8-321
a multimeter to measure the resistance be-
tween the sensor terminal R and the
ground. The resistance Rd shall not be less
than 86Ω.
8-158 -
8.45 Terminal insertion and removal

Terminal insertion
1. Grasp the terminated wire at about 25 mm

behind the crimped terminal.
Fig.8-322
2. Grasp the connector, with the back seal fac-

ing you.
Fig.8-323
3. Align the crimped terminal with one cavity

in the back seal, and insert the terminal into
the cavity, completely and vertically. Verify
proper terminal seating with a light tug on the
wire.
Fig.8-324
- 8-159
Terminal removal
1. Grasp the connector, with its back facing

you. Select a removal tool which is suitable for
the wire, and use the removal tool to hold the
wire inside.
Fig.8-325
2. Push the removal tool into the connector,

allowing the tool to disengage the terminal
lock and reach the terminal flange.
Fig.8-326
3. Pull out the removal tool, removing the ter-

minal with the wire.
Fig.8-327
8-160 -
SY365H(BH)-10 Hydraulic Excavator Hydraulic and Electrical Diagrams
Hydraulic and Electrical

Diagrams
9 Hydraulic and Electrical Diagrams........................................................................9-1

9.1 Hydraulic oil circuit diagram.................................................................................................9-3
9.2 Electrical diagram of body....................................................................................................9-4
9.3 Electrical diagram of control switch ....................................................................................9-5
9.4 Electrical diagram of cab......................................................................................................9-6
9.5 Electrical diagram of A/C group ..........................................................................................9-7
9.6 Electrical diagram of display screen...................................................................................9-8
- 9-1
Hydraulic and Electrical Diagrams SY365H(BH)-10 Hydraulic Excavator
WARNING
9-2 -
9.Hydraulic and Electrical Diagrams

9.1 Hydraulic oil circuit diagram
- 9-3
9.2 Electrical diagram of body
9-4 -
9.3 Electrical diagram of control switch
- 9-5
9.4 Electrical diagram of cab
9-6 -
9.5 Electrical diagram of A/C group
- 9-7
9.6 Electrical diagram of display screen
9-8 -

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Quality Changes the World

2.4 Precautions for maintenance............................................................................................ 2-14

4 Structure and Function................................................................................................4-1

4.2.2 Travel reducer assembly .............................................................................................4-8

4.9.6 Compressor.............................................................................................................. 4-127

5 Standard values of components ............................................................................5-1

6 Test and adjustment ......................................................................................................6-1

7 Fault diagnosis and troubleshooting...................................................................7-1

7.10.1 Fuse box wiring table.............................................................................................. 7-46

8 Removal and Installation ............................................................................................8-1

8.35 Removal and installation of front window assembly ................................................. 8-132

9 Hydraulic and Electrical Diagrams........................................................................9-1

1. Constitution of the manual

Structure, function and maintenance standard

Standard values of components

Test and adjustment

Fault diagnosis and troubleshooting

Disassembly and reassembly

Hydraulic and electrical diagrams

2. Revision and distribution

Symbol Description Remarks

Lubricant This symbol means the required lubricant.

Locations where oil, water, etc. shall be

1.2 Notes on standard terminology for maintenance

1. Standard size and tolerance

• To be exact, the machining dimensions of

• he tolerance with + or - is indicated on the

Standard size Tolerance

• A tolerance may be indicated by a “stand-

For example: Fig.1-1

2. Standard clearance and standard value

• The clearance occurring in assembly of a

• If the size of a hole is less than that of a

4. Repair limit and allowable value

• Changes will occur to the sizes of parts dur-

• Parts can be used until the clearance be-

• These parts must be replaced or repaired if

• The maximum allowable interference be-

1.3 Treatment of electrical and hydraulic components

1.3.2 Precautions for treatment of electrical components

1. Handling of wires and connectors.

A harness consists of wires from a component

Compared to electrical components in boxes

For this reason, harnesses must be handled

2. Main faults in harness

1） Poor contact between connectors (poor

Poor contact may occur when a male connec-

2）Edge curling or brazing fault

When the pins (1) of male and female connec-

If you hold the wire while pulling out the con-

4）High pressure water in the connector

The connector is of a waterproof structure, but

5） Oil or sludge on the connector

Contact fault may occur when oil or grease

• When wiping the mating part of the connec-

2. 3. Removal, refitting and drying of connec-

1） Disconnection of the connector

• Hold the connector when disconnecting it.

For connectors fixed by screws, loosen the

• Removal from the clamp

Both the connector (1) and the clamp (2) have

To remove a connector (1) from a clamp, pull

Note: If the connector is twisted up and down