SANY Crawler Hydraulic Excavator SY365H-9, SY365BH-9. Shop Manual (2014)

1-4

Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

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.

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.

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

Symbol

Item

Remarks

Safety

Special safety precautions are necessary when performing
work.

★

Caution

Special technical precautions or other precautions for pre-
serving standards are necessary when performing work.

Weight

Weight of parts of component or parts. Caution necessary
when selecting hoisting wire, or when working posture is
important, etc.

Tightening

torque

Places that require special attention for tightening torque
during assembly.

Coat

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

Oil, Coolant

Places where oil, etc. must be added, and capacity.

Drain

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

1.1.3 Symbols

Important safety and quality portions are marked with the following symbols so that the shop
manual will be used practically.

1.1.4 Units

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

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

1.2 Technical Terms

★

The tolerance may be indicated in the text
and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)]. Ex-
ample) 120 (–0.022/–0.126)

●

Usually, the size of a hole and the size
of the shaft to be

tted to that hole are

indicated by the same standard size
and different tolerances of the hole and
shaft. The tightness of

t is decided by

the tolerance.

●

Indication of size of rotating shaft and
hole and relationship drawing of them.

Example

Standard size

Tolerance

120

–0.022

–0.126

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

nishing 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.

ZX215-1000003

Tolerance of hole
(upper):+0.046

Std.clearance (max.):0.122

Std.clearance (min.):0.030

Tolerance of shaft
(lower):-0.076
Tolerance of shaft
(upper):-0.030

Std.size

Fig. 1-1

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

Example

Standard size

Tolerance

Shaft

Hole

-0.030

-0.076

+0.046

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
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.

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

1.2.4 Repair limit and allowable value

●

The size of a part changes due to wear
and deformation while it is used. The limit
of changed size is called the "repair limit".

●

If a part is worn to the repair limit must be
replaced or repaired.

●

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

●

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.

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

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

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

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

ZX215-1000004

Fig. 1-2

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

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.

1.3.1.2 Main failures occurring in wiring

harness

1. Defective contact of connectors (defective

contact between male and female)

Problems with defective contact are likely
to occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors
is deformed or the position is not correctly
aligned, or because there is corrosion or
oxidation of the contact surfaces.

2. Defective crimping or soldering of connec-

tors

The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.

Improper insertion

ZX215-1000005

Fig. 1-3

Fig. 1-4

Fig. 1-5

ZX215-1000006

Crimped portion

ZX215-1000007

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

4. High-pressure water entering connector

The connector is designed to make it 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 dif

cult for it to be drained.

Therefore, if water should get into the con-
nector, the pins will be short-circuited by
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

lm is formed on the mating

surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe
it off with a dry cloth or blow it dry with
compressed air and spray it with a contact
restorer.

★

When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.

★

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.

ZX215-1000008

Fig. 1-6

ZX215-1000009

Fig. 1-7

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

1.3.1.3 Removing, installing, and drying

connectors and wiring harnesses

1. Disconnecting connectors

A. Hold the connectors when disconnect-

ing.

When disconnecting the connectors,
hold the connectors. For connectors
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
thumb and pull the connectors apart.

★

Never pull with one hand.

B. When removing from clips

●

Both of the connector and clip have
stoppers, which are engaged with each
other when the connector is installed.

●

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.

ZX215-1000010

Press lightly

when removing

Lock stopper

Fig. 1-8

ZX215-1000011

Both stoppers

Fig. 1-9

ZX215-1000012

Fig. 1-10

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

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.

2. Connecting connectors

A. Check the connector visually

Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).

Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.

Check that there is no damage or
breakage to the outside of the connec-
tor.

★

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-

ZX215-1000013

Fig. 1-11

ZX215-1000022

Clicks into position

Fig. 1-12

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

rectly, and then insert it securely. For
connectors with lock stopper, push in
the connector until the stopper clicks
into position.

C. Correct any protrusion of the boot and

any misalignment of the wiring harness.

For connectors

tted with boots, correct

any protrusion of the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its
correct position.

★

If the connector cannot be corrected
easily, remove the clamp and adjust
the position.

●

If the connector clamp has been
removed, be sure to return it to its
original position. Check also that
there are no loose clamps.

3. Connecting DT connectors

Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respective-
ly, push them in until they click 2 times.

●

Male connector: 1

●

Female connector: 2

●

Normal locking state (Horizontal): a, b,
d

●

Incomplete locking state (Diagonal): c

ZX215-1000014

Fig. 1-13

ZX215-1000015

Fig. 1-14

ZX215-1000016

Fig. 1-15

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

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.

★

If the connector is blown dry with
compressed air, there is the risk that
oil in the air may cause defective
contact, so remove all oil and 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,
but regulate the time that the hot air
is used in order not to make the con-
nector or related parts too hot, as
this will cause deformation or dam-
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-
tor, blow it with contact restorer and
reassemble.

ZX215-1000009

Fig. 1-16

Fig. 1-17

ZX215-1000017

ZX215-1000018

T adapter

Fig. 1-18

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

1.3.1.4 Handling the integrated control

monitor

1. The integrated control monitor contains

a microcomputer, an electronic control
circuits, an LCD monitor and GPS 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.

3. Cover the control connectors with tape or

a vinyl bag. Never touch the connector
contacts with your hand.

4. Do not leave it where it may be exposed to

rain.

5. Do not place the integrated control monitor

on oil, water, or soil, or in any hot place,
even for a short time.

6. Precautions for arc welding

When welding on the controller, disconnect
all wiring harness connectors connected
to the controller. Fit an arc welding ground
close to the welding point.

ZX135-1000001

Fig. 1-19

ZX215-1000020

Tool Box

Fig. 1-20

ZX215-1000021

Fig. 1-21

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

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.

★

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

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

1.3.2 Points to remember when handling hydraulic equipment

With the increase in pressure and precision
of hydraulic equipment, the most common
cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil, or
when disassembling or assembling hydraulic
equipment, it is necessary to be particularly
careful.

1.3.2.1 Be careful of the operating environ-

ment

Avoid adding hydraulic oil, replacing

lters,

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

eld

If disassembly or maintenance work is
carried out on hydraulic equipment in the
field, there is danger of dust entering the
equipment. It is also difficult to check the
performance after repairs, so it is 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.

ZX215-1000023

Fig. 1-22

ZX215-1000024

Fig. 1-23

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Introduction

SY365(B)H-9 Crawler Hydraulic Excavator

1.3.2.4 Do not let any dirt or dust get in

during re

lling 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

lter out the dirt that

has collected during storage, so this is an
even more effective method.

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
oil from the hydraulic tank; also drain the
oil from the

lter 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

ush-

ing oil to remove the contaminants, sludge,
and old oil from the hydraulic circuit. Nor-
mally,

ushing is carried out twice: primary

ushing is carried out with

ushing oil, and

secondary flushing is carried out with the
speci

ed hydraulic oil.

ZX215-1000025

Fig. 1-24

ZX215-1000026

Flushing oil

Fig. 1-25

SANY Crawler Hydraulic Excavator SY365H-9, SY365BH-9. Shop Manual (2014) - page 2