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Crawler Hydraulic
Crawler Hydraulic Excavator

Shop Manual SY365(B)H-9
Excavator
SY365H-9
SY365BH-9
SANY HEAVY MACHINERY LIMITED
318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P.R. of China 201413
Tel: (86) 21 5700 8518

Service hotline: (86) 4006 098 318
E-mail: [email protected]
Documentation No.: B06T03ENAN1-SY365(B)H-9
Shop Manual
SY365(B)H-9 Crawler Hydraulic Excavator
SY365(B)H-9
Crawler Hydraulic Excavator
Shop Manual
WARNING
● Read and follow the safety precautions and instructions in this manual and on the ma-
chine decals. Failure to do can cause serious injury, death or property damage. Keep
this manual with the machine for reading and future reference.
Shop Manual - April 2014
Find manuals at https://best-manuals.com

SY365(B)H-9 Crawler Hydraulic Excavator
Sany Group
Sany Heavy Machinery Limited
318A, Lianggang Avenue, Lingang Industrial Park,
Fengxian District, Shanghai, P. R. of China 201413
http://www.sanygroup.com
Tel: 0086-21-57008518 Fax: 0086-21-58596210

Service hotline: 0086-21-58592902
Complaint hotline: 0086-21-58590631
E-mail: [email protected]
© 2012 by Sany Group. All right reserved. No part of this publication may be reproduced,
used, distributed or disclosed except during normal operation of the machine as de-
scribed herein. All information included within this publication was accurate at the time
of publication. Product improvements ,revisions, etc., may result in differences between
your machine and what is presented here. Sany Group assumes no liability. For more in-
formation, Contact Sany Group.
Shop Manual - April 2014

SY365(B)H-9 Crawler Hydraulic Excavator Table of Contents
Table of Contents
1 Introduction
1.1 How to Read the Manual ......................................................................................... 1-3
1.1.1 Shop manual organization ............................................................................. 1-3
1.1.2 Revision and distribution ................................................................................ 1-4
1.1.3 Symbols ......................................................................................................... 1-5
1.1.4 Units ............................................................................................................... 1-5
1.2 Technical Terms ....................................................................................................... 1-6
1.2.1 Standard size and tolerance .......................................................................... 1-6
1.2.2 Standard clearance and value ....................................................................... 1-7
1.2.3 Standard interference .................................................................................... 1-7
1.2.4 Repair limit and allowable value .................................................................... 1-8
1.2.5 Clearance limit ............................................................................................... 1-8
1.2.6 Interference limit ............................................................................................ 1-8
1.3 Handling Electrical and Hydraulic Components....................................................... 1-9
1.3.1 Points to remember when handling electric components .............................. 1-9
1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9
1.3.1.2 Main failures occurring in wiring harness ............................................ 1-10
1.3.1.3 Removing, installing, and drying connectors and wiring harnesses ... 1-12
1.3.1.4 Handling the integrated control monitor .............................................. 1-16
1.3.1.5 Electric circuits troubleshooting precautions ....................................... 1-17
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18
1.3.2.1 Be careful of the operating environment ............................................. 1-18
1.3.2.2 Disassembly and maintenance work in the field ................................. 1-18
1.3.2.3 Sealing openings ................................................................................ 1-18
1.3.2.4 Do not let any dirt or dust get in during refilling operations ................. 1-19
1.3.2.5 Change hydraulic oil when the temperature is high ............................ 1-19
1.3.2.6 Flushing operations............................................................................. 1-19
1.3.2.7 Cleaning operations ............................................................................ 1-20
1.4 Hose Connector ..................................................................................................... 1-20
1.4.1 Type of hose connector................................................................................ 1-21
1.4.2 Hose connector tightening torque table ....................................................... 1-21
1.4.3 Connection of O-rings .................................................................................. 1-22
1.5 Table of Standard Tightening Torques .................................................................. 1-23
Shop Manual - April 2014 I

Table of Contents SY365(B)H-9 Crawler Hydraulic Excavator
1.6 Type of Bolts .......................................................................................................... 1-24

1.7 Tightening Sequence ............................................................................................. 1-24
1.8 Maintenance of Half Flanges ................................................................................. 1-25
1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25
1.8.2 Temperature ................................................................................................. 1-31
2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3
2.2 General Shop Safety ............................................................................................... 2-5
2.2.1 Rules and shop behavior ............................................................................... 2-6
2.2.2 Housekeeping ................................................................................................ 2-6
2.2.3 Shop Liquids Storage..................................................................................... 2-7
2.2.4 Cleaning the Parts ......................................................................................... 2-7
2.2.5 Cleaning the Machine .................................................................................... 2-8
2.2.6 Appropriate Working Apparel ......................................................................... 2-8
2.2.7 Personal Protective Equipment...................................................................... 2-8
2.2.8 Using the Correct Tools.................................................................................. 2-9
2.2.9 Fire Extinguisher and Emergency Exits ......................................................... 2-9
2.2.10 Electrical Dangers ...................................................................................... 2-10
2.2.11 Hoisting a Load .......................................................................................... 2-10
2.3 Before Repair..........................................................................................................2-11
2.3.1 Safe Work Preparations ................................................................................2-11
2.3.2 Preparing yourself ........................................................................................ 2-12
2.3.3 Lockout/Tagout............................................................................................. 2-13
2.3.4 Two people when engine running ................................................................ 2-15
2.3.5 Safety Partners ............................................................................................ 2-15
2.4 Repair Precautions ................................................................................................ 2-16
2.4.1 Running the Machine ................................................................................... 2-16
2.4.2 Mounting and Dismounting .......................................................................... 2-17
2.4.3 Removing Attachments ................................................................................ 2-18
2.4.4 Jacking Up the Machine............................................................................... 2-18
2.4.5 Adding Fluids to a System ........................................................................... 2-18
2.4.6 Aligning Parts or Components ..................................................................... 2-19
2.4.7 Driving Pins .................................................................................................. 2-19
2.4.8 When compressed air is used...................................................................... 2-19
2.4.9 Welding operation ........................................................................................ 2-20
II Shop Manual - April 2014

2.4.10 Track Recoil Springs .................................................................................. 2-20

2.4.11 High-Pressure Fluid Lines .......................................................................... 2-21
2.4.12 Air-conditioning system maintenance ........................................................ 2-22
2.4.13 High voltage precautions ........................................................................... 2-22
2.4.14 Disconnecting the System Power .............................................................. 2-23
2.4.15 Accumulator ............................................................................................... 2-23
2.4.17 Battery Hazards ......................................................................................... 2-24
2.4.18 Jump-Start Safety ...................................................................................... 2-25
2.4.19 Avoiding fire and explosion ........................................................................ 2-26
2.4.20 Chemical hazard ........................................................................................ 2-27
2.4.21 Material Safety Data Sheets (MSDS) ........................................................ 2-27
2.4.22 Proper disposal of wastes .......................................................................... 2-28
2.5 Other Precautions .................................................................................................. 2-29
2.5.1 Sling work and giving signals ....................................................................... 2-29
2.5.2 Using mobile crane ...................................................................................... 2-31
2.5.3 Using overhead hoist crane ......................................................................... 2-31
2.5.4 Selecting wire ropes..................................................................................... 2-33
3 Specifications
3.1 Specific Dimension .................................................................................................. 1-3
3.1.1 Dimension ...................................................................................................... 1-3
3.1.2 Working ranges .............................................................................................. 1-4
3.2 Technical Specifications........................................................................................... 1-5
3.3 Weight Table ............................................................................................................ 1-7
3.4 Engine oil, Fuel and Coolant.................................................................................... 1-8
3.5 Engine Performance Curves.................................................................................... 1-9
4 Structure and Functions

4.1 Engine and Cooling System ................................................................................... 4-5
4.1.1 Engine-related parts....................................................................................... 4-5
4.1.2 Radiator and intercooler................................................................................. 4-6
4.2 Power Train.............................................................................................................. 4-7
4.2.1 Overview ........................................................................................................ 4-7
4.2.2 Travel reducer AS ......................................................................................... 4-8
4.2.3 Swing reducer mechanism........................................................................... 4-10
4.2.4 Swing bearing .............................................................................................. 4-12
Shop Manual - April 2014 III

4.3 Undercarriage Travel System ............................................................................... 4-14

4.3.1 Track frame and tensioning mechanism ...................................................... 4-14
4.3.2 Idler .............................................................................................................. 4-16
4.3.3 Carrier roller ................................................................................................. 4-18
4.3.4 Track roller ................................................................................................... 4-19
4.3.5 Track ........................................................................................................... 4-20
4.3.6 Tri-grouser track shoe .................................................................................. 4-23
4.4 Hydraulic System, Part 1 ....................................................................................... 4-24
4.4.1 Deployment of hydraulic parts ..................................................................... 4-24
4.4.2 Hydraulic tank and filter ............................................................................... 4-26
4.4.3 Hydraulic pump ............................................................................................ 4-28
4.4.3.1 Outline................................................................................................. 4-29
4.4.3.2 Function .............................................................................................. 4-31
4.4.3.3 Structure ............................................................................................. 4-31
4.4.3.4 Operating principle .............................................................................. 4-32
4.4.3.5 Oil delivery control .............................................................................. 4-33
4.4.4 Pilot pump .................................................................................................... 4-34
4.4.5 Regulator .................................................................................................... 4-35
4.5 Hydraulic system, Part 2 ........................................................................................ 4-48
4.5.1 Main control valve ........................................................................................ 4-48
4.5.1.1 Overview ............................................................................................ 4-48
4.5.1.2 Main valve structure ............................................................................ 4-50
4.5.2 Hydraulic circuit (With bucket confluence function) .............................................. 4-56
4.6 Hydraulic System, Part 3 ....................................................................................... 4-79
4.6.1 Swing motor ................................................................................................. 4-79
4.6.2 Swing holding brake..................................................................................... 4-81
4.6.3 Relief valve section ...................................................................................... 4-82
4.6.4 Anti-jerk valve............................................................................................... 4-84
4.6.4.1 Operation diagram .............................................................................. 4-84
4.6.4.2 Effect illustration.................................................................................. 4-84
4.6.5 Central Swivel Joint ..................................................................................... 4-86
4.6.6 Travel motor ................................................................................................. 4-87
4.6.7 Reducer ....................................................................................................... 4-89
4.6.8 Travel motor (Nabtesco) .............................................................................. 4-91
4.6.9 Operating principle of the basic components ............................................... 4-93
4.6.9.1 Double-balanced valve ....................................................................... 4-93
IV Shop Manual - April 2014

4.6.9.2 Operation of parking brake ................................................................. 4-98

4.6.9.3 Operation of braking valve .................................................................. 4-99
4.6.10 Control system ......................................................................................... 4-108
4.6.11 Manual pilot valve .....................................................................................4-110
4.6.12 Travel pilot valve .......................................................................................4-114
4.6.12.1 Operating principle ...........................................................................4-116
4.6.13 Solenoid valve...........................................................................................4-118
4.6.14 PPC accumulator ......................................................................................4-119
4.6.15 Pilot oil filter.............................................................................................. 4-121
4.6.16 Hydraulic cylinders ................................................................................... 4-122
4.6.16.2 Lubrication at every 100 service hours ........................................... 4-123
4.6.16.1 Lubrication at every 500 service hours ........................................... 4-123
4.7 Work Equipment .................................................................................................. 4-124
4.7.1 Component dimensions ............................................................................. 4-124
4.7.2 Arm dimensions ......................................................................................... 4-126
4.7.2.1 Bucket dimensions ............................................................................ 4-128
4.8 Operator Station and Its Attachments .................................................................. 4-130
4.8.1 Air conditioner lines .................................................................................... 4-130
4.8.1.1 Layout of A/C components ................................................................ 4-132
4.8.1.2 A/C control panel............................................................................... 4-133
4.8.1.3 Diagram of electrical circuit ............................................................... 4-134
4.8.1.4 Operating principle ............................................................................ 4-136
4.8.1.5 Compressor ...................................................................................... 4-137
4.8.1.6 Clutch ................................................................................................ 4-139
4.8.1.7 Condenser ........................................................................................ 4-140
4.8.1.8 Expansion valve ................................................................................ 4-141
4.8.1.9 Evaporator ........................................................................................ 4-141
4.8.1.10 Dehydrator ..................................................................................... 4-142
4.8.1.11 Pressure switch .............................................................................. 4-143
4.8.1.12 Fresh air sensor .............................................................................. 4-144
4.8.2 Refrigerant ................................................................................................. 4-145
4.8.2.1 Compressor oil .................................................................................. 4-163
4.9 Engine Control ..................................................................................................... 4-164
4.9.1 System operation ....................................................................................... 4-165
4.9.1.1 Engine starting .................................................................................. 4-165
4.9.1.2 Engine speed control ........................................................................ 4-165
Shop Manual - April 2014 V

4.9.1.3 Engine shutdown .............................................................................. 4-165

4.9.2 System components .................................................................................. 4-166
4.9.2.1 Fuel control dial................................................................................. 4-166
4.9.2.2 Controller .......................................................................................... 4-168
4.10 Electrical Control System................................................................................... 4-170
4.10.1 Control function ........................................................................................ 4-170
4.10.2 Diagram of machine control system......................................................... 4-171
4.10.3 Engine-pump combination control ........................................................... 4-173
4.10.4 Pump control function .............................................................................. 4-177
4.10.4.1 Constant power control ................................................................... 4-180
4.10.4.2 ESS control ..................................................................................... 4-180
4.10.5 Valve control function ............................................................................... 4-181
4.10.6 Dual travel speed control ......................................................................... 4-183
4.10.7 Engine preheat/overheat alarm ............................................................... 4-185
4.10.8 Auto deceleration/acceleration control ..................................................... 4-187
4.10.9 Engine speed calibration function ............................................................ 4-188
4.10.10 System parts and components .............................................................. 4-190
4.11 Monitoring System ............................................................................................. 4-195
4.11.1 Monitor ..................................................................................................... 4-196
4.11.2 Monitor panel ........................................................................................... 4-197
4.11.2.1 Alert and signal indicators .............................................................. 4-197
4.11.2.2 Operation keys ................................................................................ 4-199
4.11.3 Monitor display and operation .................................................................. 4-201
4.11.3.1 Default page .................................................................................... 4-201
4.11.3.2 Password entry to system information ............................................ 4-202
4.11.3.3 Main menu ...................................................................................... 4-202
4.11.3.4 Engine & throttle signals ................................................................. 4-203
4.11.3.5 Pilot pressure signals ...................................................................... 4-203
4.11.3.6 Main pump & main valve signals..................................................... 4-204
4.11.3.7 Failure codes................................................................................... 4-204
4.11.3.8 Throttle help information ................................................................. 4-205
4.11.3.9 Language selection ......................................................................... 4-205
4.11.3.10 System clock setup ....................................................................... 4-206
4.11.3.11 GPS information ............................................................................ 4-207
4.11.3.12 System setup ................................................................................ 4-208
4.11.3.13 Machine configuration ................................................................... 4-208
VI Shop Manual - April 2014

4.11.3.14 Service hour setup ....................................................................... 4-209

4.11.3.15 Machine configuration setup ......................................................... 4-210
4.11.3.16 Hydraulic oil temperature ...............................................................4-211
4.11.3.17 Screen brightness setup ................................................................4-211
4.11.3.18 System lockout (level 1) ................................................................ 4-212
4.11.3.19 System lockout (level 2) ................................................................ 4-212
5 Table of Standard Values

5.1 Standard Values for Engine-Related Parts .............................................................. 5-3
5.2 Standard Values for Chassis-Related Parts ............................................................ 5-4
6 Testing and adjusting

6.1 Engine Speed - Test and Adjust............................................................................... 6-3
6.2 Exhaust Gas Color - Test ......................................................................................... 6-5
6.3 Valve Clearance - Adjust.......................................................................................... 6-7
6.3.1 Testing............................................................................................................ 6-8
6.3.2 Adjusting ........................................................................................................ 6-9
6.4 Compression force - Test ....................................................................................... 6-10
6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-13
6.5.1 Testing.......................................................................................................... 6-14
6.5.2 Adjusting ...................................................................................................... 6-18
6.6 A/C Compressor Belt Tension - Test and Adjust .................................................... 6-19
6.6.1 Testing ......................................................................................................... 6-19
6.6.2 Adjusting ...................................................................................................... 6-19
6.7 Swing Bearing Clearance - Test ............................................................................ 6-20
6.8 Track Tensioner - Test and Adjust .......................................................................... 6-21
6.8.1 Testing.......................................................................................................... 6-21
6.8.2 Adjusting ...................................................................................................... 6-22
6.9 Oil in Hydraulic Circuits - Test and Adjust .............................................................. 6-23
6.9.1 Testing.......................................................................................................... 6-23
6.9.2 Adjusting ...................................................................................................... 6-25
6.10 Control Oil Circuit Pressure - Test and Adjust...................................................... 6-28
6.10.1 Testing........................................................................................................ 6-28
6.10.2 Adjusting .................................................................................................... 6-28
6.11 Solenoid Valve Output Pressure - Test ................................................................ 6-29
6.12 Pilot Valve Output Pressure - Test ....................................................................... 6-31
Shop Manual - April 2014 VII

6.13 Work Equipment and Swing Pilot Valves - Adjust ................................................ 6-33
6.14 Hydraulic Drift of Work Equipment - Test ............................................................. 6-34
6.15 Remaining Pressure in Hydraulic Lines - Relieve................................................ 6-36
6.16 Oil Leakage Amount - Test................................................................................... 6-37
6.17 Air in Each Component - Purge ........................................................................... 6-41
7 Troubleshooting
7.1 Checks before Troubleshooting ............................................................................... 7-5
7.2 Failure Symptoms and Troubleshooting Codes ....................................................... 7-6
7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-9
7.3.1 Connector location layout ............................................................................ 7-13
7.3.2 Diagram of system electrical elements ........................................................ 7-18
7.3.3 Diagram of electrical control system ........................................................... 7-20
7.3.4 SWP connectors .......................................................................................... 7-22
7.3.5 A/AMP connectors ....................................................................................... 7-23
7.3.6 DT connectors.............................................................................................. 7-24
7.4 Troubleshooting with an Event Code ..................................................................... 7-25
7.5 Troubleshooting Electrical System (E-Mode)......................................................... 7-49
7.6 Troubleshooting Hydraulic and Mechanical Systems (H-mode) ............................ 7-81
8 Disassembly and Assembly

8.1 How to Read This Manual ....................................................................................... 8-5
8.1.1 Removing and installing an assembly............................................................ 8-5
8.2 Operating Precautions ............................................................................................. 8-6
8.3 Start Motor AS ........................................................................................................ 8-9
8.3.1 Removal ......................................................................................................... 8-9
8.3.2 Installation ...................................................................................................... 8-9
8.4 Fuel Injection Pump AS ........................................................................................ 8-10
8.4.1 Removal ....................................................................................................... 8-10
8.4.2 Installation .................................................................................................... 8-12
8.5 Engine Front Oil Seal ............................................................................................ 8-13
8.5.1 Removal ....................................................................................................... 8-13
8.5.2 Installation .................................................................................................... 8-13
8.6 Engine Rear Oil Seal ............................................................................................ 8-14
8.6.1 Removal ....................................................................................................... 8-14
8.6.2 Installation .................................................................................................... 8-14
VIII Shop Manual - April 2014

8.7 Cylinder Head AS .................................................................................................. 8-15

8.7.1 Removal ....................................................................................................... 8-15
8.7.2 Installation .................................................................................................... 8-19
8.8 Radiator AS ........................................................................................................... 8-20
8.8.1 Removal ....................................................................................................... 8-20
8.8.2 Installation .................................................................................................... 8-23
8.9 Engine and Hydraulic Pump AS ............................................................................ 8-24
8.9.1 Removal ....................................................................................................... 8-24
8.9.2 Installation .................................................................................................... 8-30
8.10 Final Drive AS ..................................................................................................... 8-31
8.10.1 Removal ..................................................................................................... 8-31
8.10.2 Installation .................................................................................................. 8-32
8.11 Final Drive AS ...................................................................................................... 8-33
8.11.1 Disassembly ............................................................................................... 8-33
8.11.2 Assembly .................................................................................................... 8-36
8.12 Swing Motor and Swing Drive AS ....................................................................... 8-42
8.12.1 Removal ..................................................................................................... 8-42
8.12.2 Installation .................................................................................................. 8-43
8.13 Swing Motor and Swing Drive AS ....................................................................... 8-44
8.13.1 Disassembly............................................................................................... 8-44
8.13.2 Assembly.................................................................................................... 8-49
8.14 Idler AS ............................................................................................................... 8-54
8.14.1 Disassembly............................................................................................... 8-54
8.14.2 Assembly.................................................................................................... 8-55
8.15 Sprocket .............................................................................................................. 8-58
8.15.1 Removal ..................................................................................................... 8-58
8.15.2 Installation .................................................................................................. 8-58
8.16 Track AS ............................................................................................................. 8-59
8.16.1 Removal ..................................................................................................... 8-59
8.16.2 Installation .................................................................................................. 8-60
8.17 Swing Bearing AS ............................................................................................... 8-62
8.17.1 Removal ..................................................................................................... 8-62
8.17.2 Installation .................................................................................................. 8-63
8.18 Swing frame AS .................................................................................................. 8-64
8.18.1 Removal ..................................................................................................... 8-64
8.18.2 Installation .................................................................................................. 8-66
Shop Manual - April 2014 IX

8.19 Swivel Joint AS .................................................................................................... 8-67

8.19.1 Removal ..................................................................................................... 8-67
8.19.2 Installation .................................................................................................. 8-69
8.20 Central Swivel Joint AS ....................................................................................... 8-70
8.20.1 Disassembly............................................................................................... 8-70
8.20.2 Assembly.................................................................................................... 8-70
8.21 Hydraulic Tank AS ............................................................................................... 8-71
8.21.1 Removal ..................................................................................................... 8-71
8.21.2 Installation .................................................................................................. 8-73
8.22 Control Valve AS .................................................................................................. 8-74
8.22.1 Removal ..................................................................................................... 8-74
8.22.2 Installation .................................................................................................. 8-79
8.23 Hydraulic Pump AS ............................................................................................. 8-80
8.23.1 Removal ..................................................................................................... 8-80
8.23.2 Installation .................................................................................................. 8-83
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft) ..................................................... 8-84
8.24.1 Removal ..................................................................................................... 8-84
8.24.2 Installation .................................................................................................. 8-84
8.25 Pilot Valve AS (Work Equipment) ....................................................................... 8-85
8.26 Travel Pilot Valve AS ........................................................................................... 8-86
8.27 Hydraulic Cylinder AS ......................................................................................... 8-87
8.27.1 Disassembly............................................................................................... 8-88
8.27.2 Assembly.................................................................................................... 8-92
8.28 Work Equipment AS ............................................................................................ 8-97
8.28.1 Removal ..................................................................................................... 8-97
8.28.2 Installation .................................................................................................. 8-99
8.29 Air Conditioner AS ............................................................................................. 8-100
8.29.1 Removal ................................................................................................... 8-100
8.29.2 Installation ................................................................................................ 8-103
8.30 Counterweight AS ............................................................................................. 8-104
8.30.1 Removal ................................................................................................... 8-104
8.30.2 Installation ................................................................................................ 8-105
8.31 Cab AS .............................................................................................................. 8-106
8.31.1 Removal ................................................................................................... 8-106
8.31.2 Installation ................................................................................................ 8-109
8.32 Cab Window Glass ............................................................................................8-110
X Shop Manual - April 2014

8.32.1 Removal ....................................................................................................8-111

8.32.2 Installation .................................................................................................8-114
8.33 Front Window AS ............................................................................................... 8-126
8.33.1 Disassembly............................................................................................. 8-126
8.33.2 Assembly.................................................................................................. 8-129
8.34 Monitor - Remove and Install ............................................................................. 8-135
8.34.1 Removal ................................................................................................... 8-135
8.34.2 Installation ................................................................................................ 8-135
8.35 Controller AS ..................................................................................................... 8-136
8.35.1 Removal ................................................................................................... 8-136
8.35.2 Installation ................................................................................................ 8-136
8.36 Radio ................................................................................................................. 8-137
8.36.1 Structure .................................................................................................. 8-137
8.36.2 Removal and installation .......................................................................... 8-139
8.36.3 Connector model and wiring .................................................................... 8-140
8.37 Battery ............................................................................................................... 8-141
8.37.1 Structure .................................................................................................. 8-141
8.37.3 Replacement ............................................................................................ 8-143
8.38 Start Switch........................................................................................................ 8-144
8.38.1 Structure ................................................................................................. 8-144
8.38.2 Removal ................................................................................................... 8-145
8.38.3 Working principle ..................................................................................... 8-146
8.38.4 Wiring ....................................................................................................... 8-146
8.39 Fuse Box............................................................................................................ 8-147
8.40 Wiper ................................................................................................................. 8-148
8.40.1 Structure .................................................................................................. 8-148
8.40.2 Working principle ..................................................................................... 8-149
8.40.3 Removal ................................................................................................... 8-150
8.40.4 Installation ................................................................................................ 8-150
8.40.5 Angle adjustment of wiper arm................................................................. 8-151
8.41 Relays ................................................................................................................ 8-152
8.41.1 Engine relays ........................................................................................... 8-152
8.41.2 Other relays ............................................................................................. 8-153
8.41.4 Relay connector and wiring...................................................................... 8-154
Shop Manual - April 2014 XI

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

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

SY365(B)H-9 Crawler Hydraulic Excavator Introduction
Introduction
1 Introduction
1.1 How to Read the Manual ......................................................................................... 1-3
1.1.1 Shop manual organization ............................................................................. 1-3
1.1.2 Revision and distribution ................................................................................ 1-4
1.1.3 Symbols ......................................................................................................... 1-5
1.1.4 Units ............................................................................................................... 1-5
1.2 Technical Terms ....................................................................................................... 1-6
营
销
公
司
1.2.1 Standard size and tolerance .......................................................................... 1-6

1.2.2 Standard clearance and value ....................................................................... 1-7
1.2.3 Standard interference .................................................................................... 1-7
1.2.4 Repair limit and allowable value .................................................................... 1-8
1.2.5 Clearance limit ............................................................................................... 1-8
1.2.6 Interference limit ............................................................................................ 1-8
1.3 Handling Electrical and Hydraulic Components....................................................... 1-9
1.3.1 Points to remember when handling electric components .............................. 1-9
1.3.1.1 Handling wiring harnesses and connectors .......................................... 1-9
1.3.1.2 Main failures occurring in wiring harness ............................................ 1-10
1.3.1.3 Removing, installing, and drying connectors and wiring harnesses ... 1-12
1.3.1.4 Handling the integrated control monitor .............................................. 1-16
1.3.1.5 Electric circuits troubleshooting precautions ....................................... 1-17
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18
1.3.2.1 Be careful of the operating environment ............................................. 1-18
1.3.2.2 Disassembly and maintenance work in the field ................................. 1-18
1.3.2.3 Sealing openings ................................................................................ 1-18
1.3.2.4 Do not let any dirt or dust get in during refilling operations ................. 1-19
1.3.2.5 Change hydraulic oil when the temperature is high ............................ 1-19
Shop Manual - April 2014 1-1
Introduction SY365(B)H-9 Crawler Hydraulic Excavator
1.3.2.6 Flushing operations............................................................................. 1-19

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

1 INTRODUCTION
1.1 How to Read the Manual
● Some attachments and optional parts in
this shop manual may not be delivered to
certain areas. If one of them is required,
consult Sany distributors.
● Materials and specifications are subject to
change without notice.
1.1.1 Shop manual organization

This shop manual contains the necessary
technical information for services performed
in a workshop. For ease of understanding, the
manual is divided into the following sections.
Introduction
This section provides an overview of what is
covered in the rest of this manual and how to
use this manual,. 营
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Shop Safety
This section covers basic shop safety infor-
mation relating to this equipment. It also de-
scribes what the hazard alerts mean that are
used throughout the manual.
Specifications
Technical specification of work equipment and
optional parts are given in this section.
Structure and functions

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

Standard Values
This section explains the standard values for
a new machine and judgement criteria for test-
ing, adjusting, and troubleshooting. This stan-
dard value table is used to check the standard
values in testing and adjusting and to judge
parts in troubleshooting.
Testing and adjusting

This section details the inspection before and
after repair work as well as the adjustment
during inspection and repair work. Trouble-
shooting table that involves “Fault”and
“Cause”are also included in this section.
Troubleshooting
This section explains the way to detect faulty
parts and the method to repair them. This sec-
tion is divided into the following parts: Electri-
cal system, Engine, Hydraulic and mechanical
system and Monitoring system. 营
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Disassembly and assembly

This section explains the procedures as well
as precautions for removing, installing, disas-
sembling and assembling of each component.
Engine
This section provides information the cooling
system, lubricating system, electrical system
and alternator in addition to disassembly and
reassembly of the engine.
System Schematics
This section provides hydraulic circuit dia-
grams and electrical circuit diagrams.
1.1.2 Revision and distribution

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

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

Safety
work.
Special technical precautions or other precautions for pre-

★ Caution
serving standards are necessary when performing work.
Weight of parts of component or parts. Caution necessary
Weight when selecting hoisting wire, or when working posture is
important, etc.
Tightening Places that require special attention for tightening torque
torque during assembly.
Coat Places to be coated with adhesives, etc. during assembly.
Oil, Coolant Places where oil, etc. must be added, and capacity.
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Places where oil, etc. must be drained, and quantity to be

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

1.2 Technical Terms

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

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

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

Tolerance of shaft
● Usually, the size of a hole and the size (lower):-0.076
of the shaft to be fitted to that hole are Tolerance of shaft
(upper):-0.030
indicated by the same standard size
and different tolerances of the hole and
shaft. The tightness of fit is decided by
the tolerance.
● Indication of size of rotating shaft and
ZX215-1000003
hole and relationship drawing of them.
Fig. 1-1

Example
Tolerance
Standard size
Shaft Hole
-0.030 +0.046
φ60
-0.076 0
1.2.2 Standard clearance and value
● The clearance made when new parts are

assembled is called the "standard clear-
ance", which is indicated by the range from
the minimum clearance to the maximum
clearance.
● When some parts are repaired, the clear-

ance is generally adjusted to the standard
clearance.
● A value of performance and function of

new products or equivalent is called the
"standard value", which is indicated by a 营
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range or a target value.
● When some parts are repaired, the value

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

size of a shaft because of the standard
size and tolerance, the difference between
these sizes is called the "interference".
● The range (A – B) from the difference (A)

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

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

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

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

replaced or repaired.
● The performance and function of a product

lowers while it is used. A value below which
the product can be used without causing a
problem is called the "allowable value".
● If a product is worn to the allowable value,

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

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● Parts can be used until the clearance be-

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

the clearance limit, they must be replaced
or repaired.
1.2.6 Interference limit
● The allowable maximum interference be-

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

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

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

1.3 Handling Electrical and Hy-

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

dling electric components
1.3.1.1 Handling wiring harnesses and

connectors 营
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Wiring harnesses consist of wiring con-

necting one component to another compo-
nent, connectors used for connecting and
disconnecting one wire from another wire,
and protectors or tubes used for protecting
the wiring.
Compared with other electrical compo-
nents fitted in boxes or cases, wiring har-
nesses are more likely to be affected by
the direct effects of rain, water, heat, or
vibration. Furthermore, during inspection ZX215-1000004
and repair operations, they are frequently Fig. 1-2
removed and installed again, so they are
likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.

1.3.1.2 Main failures occurring in wiring

harness
1. Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely Improper insertion
to occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors
is deformed or the position is not correctly
aligned, or because there is corrosion or
oxidation of the contact surfaces.
ZX215-1000005
Fig. 1-3
2. Defective crimping or soldering of connec-

tors
The pins of the male and female connec- Crimped portion
tors are in contact at the crimped terminal

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

the plating at the joint will peel and cause
improper connection or breakage.
ZX215-1000006
Fig. 1-4
3. Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
ZX215-1000007
Fig. 1-5

4. High-pressure water entering connector

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

there will be defective contact. If there is
oil or grease stuck to the connector, wipe
it off with a dry cloth or blow it dry with
compressed air and spray it with a contact
restorer.
★ When wiping the mating portion of the
connector, be careful not to use exces- ZX215-1000009
sive force or deform the pins. Fig. 1-7

★ If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and wa-
ter from the compressed air completely
before cleaning with compressed air.

1.3.1.3 Removing, installing, and drying

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

pull the connector in a parallel direction
to the clip for removing stoppers.
★ If the connector is twisted up and
down or to the left or right, the hous-
ing may break.
ZX215-1000012
Fig. 1-10

C. Action to take after removing connec-

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

Check that there is no damage or ZX215-1000022
breakage to the outside of the connec-
tor. Fig. 1-12
★ If there is any oil, water, or dirt stuck

to the connector, wipe it off with a
dry cloth. If any water has got inside
the connector, warm the inside of
the wiring with a dryer, but be care-
ful not to make it too hot as this will
cause short circuits.
★ If there is any damage or breakage,
replace the connector.
B. Fix the connector securely.
Align the position of the connector cor-

rectly, and then insert it securely. For

connectors with lock stopper, push in
the connector until the stopper clicks
into position.
C. Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct
any protrusion of the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its ZX215-1000014
correct position.
Fig. 1-13
★ If the connector cannot be corrected
easily, remove the clamp and adjust
the position.
● If the connector clamp has been
removed, be sure to return it to its
original position. Check also that
there are no loose clamps.
3. Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty 营
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wire connectors have 2 latches respective-

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

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

4. Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high-pressure water or steam directly
on the wiring harness. If water gets directly
on the connector, do as follows.
A. Disconnect the connector and wipe off
the water with a dry cloth. ZX215-1000009
★ If the connector is blown dry with Fig. 1-16

compressed air, there is the risk that
oil in the air may cause defective
contact, so remove all oil and wa-
ter from the compressed air before
blowing with air.
B. Dry the connector with a dryer.
If water gets inside the connector, use
a dryer to dry the connector.
★ Hot air from the dryer can be used, 营
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but regulate the time that the hot air

is used in order not to make the con-
ZX215-1000017
nector or related parts too hot, as
this will cause deformation or dam- Fig. 1-17
age to the connector.
C. Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits be-
tween pins caused by water.
★ After completely drying the connec- T adapter
tor, blow it with contact restorer and
reassemble.
ZX215-1000018
Fig. 1-18

1.3.1.4 Handling the integrated control

monitor
1. The integrated control monitor contains
a microcomputer, an electronic control
circuits, an LCD monitor and GPS position-
ing circuit. They control all of the electronic
circuits on the machine, so be extremely
careful when handling the integrated
control monitor.
2. Do not place objects on the integrated
control monitor. ZX135-1000001
3. Cover the control connectors with tape or Fig. 1-19

a vinyl bag. Never touch the connector
contacts with your hand.
4. Do not leave it where it may be exposed to
rain.
Tool
5. Do not place the integrated control monitor Box
on oil, water, or soil, or in any hot place,

even for a short time.
6. Precautions for arc welding
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When welding on the controller, disconnect

all wiring harness connectors connected
to the controller. Fit an arc welding ground ZX215-1000020
close to the welding point.
Fig. 1-20
ZX215-1000021
Fig. 1-21

1.3.1.5 Electric circuits troubleshooting

precautions
1. Always turn the power OFF before discon-
necting or connecting connectors.
2. Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
★ Disconnect and connect the related
connectors several times to check.
3. Always connect any disconnected connec-
tors before going on to the next step.
★ If the power is turned ON with the con-
nectors still disconnected, unnecessary
abnormality displays will be generated.
4. When carrying out troubleshooting of
circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
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★ If there is any change, there is probably

defective contact in that circuit.

1.3.2 Points to remember when handling hydraulic equipment
With the increase in pressure and precision

of hydraulic equipment, the most common
cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil, or
when disassembling or assembling hydraulic
equipment, it is necessary to be particularly
careful.
1.3.2.1 Be careful of the operating environ-

ment
Avoid adding hydraulic oil, replacing filters,
or repairing the machine in rain or high
winds, or places where there is a lot of
dust.
1.3.2.2 Disassembly and maintenance work

in the field
If disassembly or maintenance work is 司
ZX215-1000023
carried out on hydraulic equipment in the

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Fig. 1-22
field, there is danger of dust entering the
equipment. It is also difficult to check the
performance after repairs, so it is desir-
able to use unit exchange. Disassembly
and maintenance of hydraulic equipment
should be carried out in a specially pre-
pared dust-proof workshop, and the perfor-
mance should be checked with special test
equipment.
1.3.2.3 Sealing openings

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

1.3.2.4 Do not let any dirt or dust get in

during refilling operations
Be careful not to let any dirt or dust get
in when refilling with hydraulic oil. Always
keep the oil filler and the area around it
clean, and also use clean pumps and oil
containers. If an oil cleaning device is
used, it is possible to filter out the dirt that
has collected during storage, so this is an
even more effective method.
ZX215-1000025
Fig. 1-24
1.3.2.5 Change hydraulic oil when the

temperature is high
When hydraulic oil or other oil is warm, it
flows easily. In addition, the sludge can
also be drained out easily from the circuit
together with the oil, so it is best to change
the oil when it is still warm. When changing
the oil, as much as possible of the old hy-
draulic oil must be drained out. (Drain the
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oil from the hydraulic tank; also drain the

oil from the filter and from the drain plug in
the circuit.) If any old oil is left, the contam-
inants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic
oil.
1.3.2.6 Flushing operations

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

1.3.2.7 Cleaning operations

After repairing the hydraulic equipment
(pump, control valve, etc.) or when run-
ning the machine, carry out oil cleaning to
remove the sludge or contaminants in the
hydraulic oil circuit. The oil cleaning equip-
ment is used to remove the ultra fine (about
3 μ) particles that the filter built in the hy-
draulic equipment cannot remove, so it is
an extremely effective device.
ZX215-1000027
Fig. 1-26
1.4 Hose Connector

Hose connector is used to connect hoses with
a small diameter. The metal sealing surface (4)
of the joint (1) must be in close contact with 1 4 3 5 2
the metal sealing surface (5) of the hose (2) to
seal pressurized oil.
NOTICE 营
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● Do not over-tighten the nut (3). Exces- Connector

sive force applied on the metal sealing
ZX215-1000028
surface (4) and (5) may cause the joint
(1) to break. Be sure to tighten nut (3) Fig. 1-27
according to technical specifications.
● Scratches or other damages on seal-
ing surface (4) and (5) may cause leaks
at the joint. Be extremely careful not
to damage the sealing surfaces during
connecting and disconnecting work.

1.4.1 Type of hose connector
24°
24°
Male Female
ZX215-1000029
Fig. 1-28
1.4.2 Hose connector tightening torque table
Wrench size mm Wrench size mm Tightening torque

Type
Connecting nut Hose joint N·m(kgf·m,Ibf·ft)
19 19 59(6,44)
22 22 98(10,72)
27 27 118(12,87)
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36 36 235(24,173)
24° Male
41 41 295(30,218)
50 50 490(50,361)
60 60 670(68,494)
70 70 980(100,723)
19 17 44(4.5,32)
22 19 59(6,44)
27 22 118(12,87)
24° Female
36 30, 32 235(24,173)
41 36 295(30,218)
50 46 490(50,361)
NOTICE
● The torque values listed in the table are

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

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

surface of the joint (7) to seal the pressurized
7 6 9
oil.
NOTICE
● Replace o-rings (6) with new ones

Hose connector
when re-connecting hoses. 8 10
● Before tightening nut (9), make sure the

o-ring (6) has been placed into the o- ZX215-1000030
ring seat (8).Displacement of the o-ring Fig. 1-29

may have it damaged and cause leaks.
● Be careful not to damage the o-ring
seat (8) or the sealing surface (10).
Damaged o-ring (6) may cause oil leak-
age.
● If oil leakage due to loosened nut (9) is
detected, do not try to stop the leakage 营
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by tightening nut (9). Instead, replace

o-ring (6) with a new one and make
sure it is well positioned, and tighten
nut (9).
Wrench size mm Wrench size mm Tightening torque

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

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

★ Unless specified otherwise, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
Bolt di- Bolt Wrench Hex wrench Hexagonal bolt Hexagonal socket head bolt
ameter grade size size N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6 10.9 10 4 13.2 1.37 9.74 13.2 1.37 9.74
M8 10.9 13 6 31 3.16 22.87 31 3.16 22.87
M10 10.9 17 8 66 6.73 48.7 66 6.73 48.7
M12 10.9 19 10 113 11.53 83.39 113 11.53 83.39
M14 10.9 22 12 177 18.06 130.6 177 18.06 130.6
M16 10.9 24 14 279 28.47 205.9 279 28.47 205.9
M18 10.9 27 14 382 38.98 281.9 382 38.98 281.9
M20 10.9 30 17 549 56.02 405.16 549 56.02 405.16
M27 10.9 41 19 1320 134.7 974.16 1320 134.7 974.16
M10 12.9 17 6 78销
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7.96 57.76 78 7.96 57.76
营
M12 12.9 19 8 137 13.98 101.1 137 13.98 101.1

M16 12.9 24 14 339 34.6 250.18 339 34.6 250.18
M20 12.9 30 17 664 67.75 490 664 67.75 490
NOTICE
The following items apply to fine thread and coarse thread.

● Apply grease (zinc white B dissolved in spindle oil) onto the nuts and bolts to reduce
the friction coefficient. Thrust bolts do not require greasing.
● Torque tolerance is ±10%.
● Always use bolts of correct length. The tip of bolts with excessive length may contact
the bottom of the bolt hole, resulting in under-tightening. Bolts with inadequate length
may result in insufficient fastening.
● The torque values listed in the table are intended for general application. If different
torque values are specified for a special purpose, the torque values in this table are
not applicable any more.
● Make sure the threads are free of dirt or rusts before installation of nuts and bolts.

1.6 Type of Bolts
Tighten nuts and bolts properly to specified

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

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

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

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

check it carefully. Scratches and coarse-
ness cause leaks or abrasion of seals.
Uneven surface may squeeze the seal out.
If these faults are not corrected properly,
parts may have to be replaced.
2. Always use specified O-rings. Check that ZX215-1000034

the O-rings are not damaged. Do not file
Fig. 1-33
the surface of the O-ring. Apply grease
onto the O-ring to locate it.
3. Tighten the half flanges carefully. Locate

the opening at the center so that it is
perpendicular to the oil opening. Tighten Improper
the bolt manually to maintain the location
of the components.
司
公
销
营
ZX215-1000035
Fig. 1-34
1.8.1 Table of tightening torques for half flange bolts

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

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

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www.sanygroup.

com Quality Changes the World

Crawler Hydraulic Excavator

SANY HEAVY MACHINERY LIMITED

Tel: (86) 21 5700 8518

Documentation No.: B06T03ENAN1-SY365(B)H-9

Shop Manual - April 2014

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Tel: 0086-21-57008518 Fax: 0086-21-58596210

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Shop Manual - April 2014 I

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1.6 Type of Bolts .......................................................................................................... 1-24

II Shop Manual - April 2014

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2.4.10 Track Recoil Springs .................................................................................. 2-20

4 Structure and Functions

Shop Manual - April 2014 III

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4.3 Undercarriage Travel System ............................................................................... 4-14

IV Shop Manual - April 2014

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4.6.9.2 Operation of parking brake ................................................................. 4-98

Shop Manual - April 2014 V

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4.9.1.3 Engine shutdown .............................................................................. 4-165

VI Shop Manual - April 2014

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4.11.3.14 Service hour setup ....................................................................... 4-209

5 Table of Standard Values

6 Testing and adjusting

Shop Manual - April 2014 VII

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8 Disassembly and Assembly

VIII Shop Manual - April 2014

8.7 Cylinder Head AS .................................................................................................. 8-15

Shop Manual - April 2014 IX

8.19 Swivel Joint AS .................................................................................................... 8-67

X Shop Manual - April 2014

8.32.1 Removal ....................................................................................................8-111

Shop Manual - April 2014 XI

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

XII Shop Manual - April 2014

1.2.1 Standard size and tolerance .......................................................................... 1-6

1.3.2.6 Flushing operations............................................................................. 1-19

1-2 Shop Manual - April 2014

1.1.1 Shop manual organization

Structure and functions

Shop Manual - April 2014 1-3

Testing and adjusting

Disassembly and assembly

1.1.2 Revision and distribution

1-4 Shop Manual - April 2014

Symbol Item Remarks

Special safety precautions are necessary when performing

Special technical precautions or other precautions for pre-

Coat Places to be coated with adhesives, etc. during assembly.

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