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

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

6-1

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
6.13  Work Equipment and Swing Pilot Valves - Adjust ................................................ 6-33

6-3

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

6 TESTING AND ADJUSTING

6.1 Engine Speed - Test and Adjust

Testing

Start the engine and keep the engine running
until coolant temperature enters operational
range. Key in the password on the monitor
and check if the engine speed is normal in
each gear position.

Testing Items:

1. Engine speed at low idle

2. Engine speed at fuel control dial position

11 (H and S modes)

3. Engine speed at relief, with fuel control dial

in position 11 (H and S modes)

4. Engine speed at auto deceleration

Main Menu

Operating Information

Failure Information

Throttle Help Info

Language Selection

SYS Clock Setup

GPS Information

Running parameters of engine,
main pump and main valve.

XP1251203007

Fig. 6-1

6-4

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

Calibration

1. Preconditions for auto speed calibration:

A. Start the engine.

B. Check the throttle position voltage for

gear position 1 on the Throttle Help Info
page on the monitor. Normal voltage
should be 1.3

0.3V under normal

speed range of 1050

50. If the voltage

is out of the speci

ed range, manually

adjust the throttle pull rod. Otherwise
abnormality would occur in speed
calibration and a red question mark

“

”

would appear after Engine Speed on
the Throttle Help Info page on the
monitor.

2. Enter the speed calibration page.

Press F5 on the default page of monitor
and key in the password to access the
Main Menu. Choose Throttle Help Info on
the Main Menu to enter the page like the

gure on the right.

3. Speed calibration

Press F4 on the Throttle Help Info page to
execute speed calibration. The system en-
ters speed calibration (when the icon turns
red) and it automatically shifts to full speed
(when the icon turns red).

4. Successful calibration

If the calibration is done successfully, the
icon for calibration indication turns blue.
The switching to full deceleration requires
pressing F2 to switch it manually.

XP2051203013

n/min

AUTO

rpm

Throttle Help Info

Current Gear N

：

Engine Speed rpm

：

Gear Position V

：

Throttle Position V

：

Fig. 6-2

6-5

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

●

Tools used for testing exhaust gas color

No.

Part Name

Smoke meter

Opacimeter

ZX335-1004002

ZX335-1004003

1. Testing with smoke meter

A. Put the

lter paper in the smoke meter.

B. Insert the waste gas intake pipe into

the exhaust pipe.

C. Start the engine and keep the engine

running until engine coolant tempera-
ture is within the operational range.

D. When engine speed increases sud-

denly or is kept at high idle, direct
exhaust gas through smoke meter to
the

lter paper.

E. Remove the

lter paper from the smoke

meter. Read the smoke value through
the apparatus provided.

F. Remove the testing tools after testing.

Make sure the machine goes back to
its normal state.

2. Testing with opacimeter

A. Mount the opacimeter onto the exhaust

pipe by clamping it to the pipe outlet.

6.2 Exhaust Gas Color - Test

CAUTION

●

Be careful not to touch any hot part
when installing or removing a testing
equipment.

Fig. 6-3

Fig. 6-4

6-6

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

ZX335-1004004

B. Open the opacimeter and preheat it for

about 15 minutes.

C. Start the engine and keep the engine

running until engine coolant tempera-
ture is within the operational range.

D. When engine speed increases sud-

denly or is kept at high idle, use the
opacimeter to read the smoke value of
exhaust gas.

E. Remove the testing tools after testing.

Make sure the machine goes back to
its normal state.

Fig. 6-5

6-7

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

6.3 Valve Clearance - Adjust

●

Service Standard (Unit: mm)

Location

Service Item

Standard Value

Limits

Correction meth-

—

Valve clearance (with engine cold)

0.4

—

Adjust

●

Special tools

Symbol

Tool name and shape

Part Number

Application

Flat-head screwdriver

MH060008

Adjustment of valve clearance (carried

on machine)

Check and adjust the valve clearance in cold state as per the following procedure:

ZX335-1004006

6-8

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

6.3.1 Testing

In cold state, valve clearance is to be checked
and adjusted as per the following procedure:

1. Remove the rocker arm cover.

2. Turn the No.1 piston or the No.6 piston to

the top dead center (TDC) of compression
stroke by following the steps below.

●

Turn the engine until the TDC line on
the crankshaft pulley is in line with the
timing pointer.

●

Turn the No.1 piston or the No.6 piston
to the TDC of compression stroke.

Aligning point

ZX335-1004007

Note:

When the rocker arm at the intake side

and rocker arm at the exhaust side cannot be
turned by hands, it is indicated that the piston
has reached the TDC of compression stroke.
Turning the engine by one more turn, the TDC
of compression stroke of No.1 piston and No.6
piston swaps.

ZX335-1004008

3. When the No.1 piston is at the TDC, adjust

the valve clearance in a sequence marked
with a black dot (

●

Cylinder

Exhaust

●

○

●

○

●

○

Intake

●

○

●

○

A. When a feeler gauge is used for such

measurement, resistance to a moving
feeler gauge in the clearance should be
felt.

B. If the feeler gauge moves easily in the

clearance, it is impossible to obtain
accurate result.

4. If the measured value is out of specifica-

tion, readjustment shall be performed
according to the following method.

Fig. 6-6

Fig. 6-7

6-9

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

ZX335-1004009

Adjusting screw

Locknut

Valve clearance

6.3.2 Adjusting

1. In adjustment of valve clearance, loosen

the locknut before adjusting the adjusting
screw. A standard clearance is achieved
when slight resistance to the feeler gauge
is felt when pulling it out from the clear-
ance.

2. After adjustment, hold the adjusting screw

with a screwdriver to prevent it from turn-
ing, and tighten the locknut.

Locknut: 21-30 N.m{2.1- 3.1 kgf.m}

3. Go on with the next step until all valve

clearances marked with a black dot (

●

)

have been adjusted

4. Recheck the clearances with the feeler

gauge. Readjustment should be made if
deviation from the standard valve is found.

5. When the engine is carried in vehicle,

using

to turn the adjusting screw will

make the job easy.

Fig. 6-8

6-10

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

6.4 Compression force - Test

●

Service standard

Location

Service Item

Standard value

Limits

Correction

method

—

Compression

force

Every cylinder (200

rpm/h)

3.0MPa {30.6kgf/cm

}

2.5MPa {25.5kgf/cm

}

Check

Inter-cylinder pres-

sure difference

—

390 kPa {

≤

4kgf/cm

}

Check

●

Special tool

Symbol

Tool name and shape

Part number

Application

Pressure gauge connector

5-85317-001-0 (JKM-

1015)

Checking the compres-

sion force

ZX335-1004010

Pressure gauge connector

1. Reduction of compression force can be an

indication for engine overhaul.

2. Check the compression force regularly

and pay attention to its variation from time
to time. Understanding the variation of
compression force is helpful for trouble-
shooting. In addition, in a new vehicle or
when new parts are installed for replace-
ment, the pressure may be higher due to
running-in of the piston ring, valve seat,
etc. The pressure will become normal as
the parts wear.

3. Before testing, make sure that the engine

oil, start motor and battery are in normal
condition.

4. The vehicle is to meet the following condi-

tions.

A. Preheat the engine until engine coolant

temperature reaches 75~85

℃

B. Switch off all lamps and auxiliary

devices.

C. Place the gear lever in a neutral posi-

tion.

Fig. 6-9

6-11

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

5. Remove the entire fuel injector.

6. Cover the fuel injector mounting opening

with a rag.

7. Activate the start motor in order to run the

engine. Check the cloth if it is stuck with
foreign substances.

8. According to the substances (engine oil

and/or coolant) adhering to the cloth, the
following factors might be involved.

A. When engine oil is found, it might be

improper sealing caused by piston ring.
Check the piston ring.

B. When engine oil and coolant are found,

it might be cracking of cylinder. Replace
the crankcase.

9. Mount the gasket and

to the fuel injec-

tor mounting hole and fix them with the
injector cap. Install the compression force
gauge.

10. Start the engine and measure the com-

pression force of each cylinder. Calculate
the differential pressure between the
cylinders.

11. When the compression force and the

differential pressure between cylinders
deviate from their limits, inject a small
amount of engine oil through the fuel
injector mounting hole, and measure the
compression force again.

●

If the compression force is higher, it is
probably due to worn or damaged piston
ring or cylinder inner surface.

●

If the compression force is still low, it is
probably due to stuck valve or improper
seating, or improperly mounted gasket
of cylinder head.

WARNING

●

When coolant and/or engine oil is found
attached to the rag, running the engine
may cause the hot coolant and engine
oil to squirt out through the mounting
hole of the fuel injector. This is very
dangerous. Never touch or look into the
fuel injector mounting hole when the
engine is running.

6-13

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

6.5 Fuel Injection Timing - Test and Adjust

Location

Service Item

Standard value

Limits

Correction

method

—

Fuel injection timing (BTDC)

8 degrees

7~9 degrees

Adjust

Symbol

Part tightened

Tightening torque

Remark

—

Body, fuel delivery valve

39~44

—

Nut, injection tube

28~32

—

Symbol

Tool name and shape

Part number

Application

Universal con-

necting rod with

extension

MH061099

Inspection and adjust-

ment of fuel injection

timing

●

Common tool (Unit: N·m)

●

Tightening torque (Unit: N·m)

●

Service standard

ZX335-1004011

NOTICE

●

Take care not let dust or foreign ma-
terials get into the fuel injection pump
when adjusting the injection timing.

6-14

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

6.5.1 Testing

ZX335-1004012

Aligning point

ZX335-1004007

1. Align the TDC mark on the crankshaft pul-

ley with the pointer. Remove the cap of the
inspection hole on the timing gear cover in
front of the fuel injection pump.

Check if the pointer on the nut-

xing plate

on the gear of fuel injection pump is aligned
with the outstanding mark on the gear
chamber of fuel injection pump.

In case of misalignment, turn the crankshaft
pulley one more turn and repeat the above
steps in order to obtain proper alignment.

Check if the marking lines are aligned with
each other.

(The marking lines have been aligned prop-
erly when assembling the body of fuel injec-
tion pump and

xing the

ange at factory)

Now, test the angle of crankshaft at the be-
ginning of fuel injection.

2. Turn the crankshaft pulley counterclock-

wise approximate 30 degrees.

Fig. 6-10

Fig. 6-11

6-15

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

3. Remove the injection tube from No.1

plunger. This allows you to observe the
fuel when it begins to flow out from No.1
plunger.

ZX335-1004013

4. Remove from No.1 plunger the valve body

①

, seat

②

, spring

③

and spool

④

5. Reassemble the valve body

①

and tighten

it to the speci

c torque. Do no reassemble

the spring, seat and spool now. Leave
them for later reassembly.

ZX335-1004014

ZX335-1004015

6. Secure the fuel control lever in the fully

open position.

Fig. 6-12

Fig. 6-13

Fig. 6-14

6-16

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

7. Slowly turn the crankshaft pulley clockwise

while operating the hand pump to feed the
fuel constantly.

Stop operating the pump immediately when
no fuel is seen coming out of No.1 fuel de-
livery valve.

The crankshaft angle is now the engine

’

fuel injection beginning angle.

ZX335-1004016

8. Observe and make sure that the mark

(of fuel injection beginning angle) on
crankshaft pulley is in line with the timing
pointer.

The timing mark is the engine

’

s fuel injec-

tion beginning angle. Discharge the remain-
ing fuel from the body of delivery valve.
Make sure that no fuel is delivered from the
delivery pump.

Note:

Engines of the same type may have a

fuel injection pump that is different in injec-
tion timing. To obtain an engine of required
speci

cation, please contact machine supplier

or local ISUZU engine service station. These
specifications are provided by ISUZU or en-
gine manufacturer.

TDC

ZX335-1004017

Damping pulley

Fig. 6-15

Fig. 6-16

6-17

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

9. Remove the body of fuel delivery valve

from No.1 plunger.

10. Install the internal parts (valve seat, spring

and spool) on the body.

11. Reassemble the fuel delivery valve AS on

No.1 plunger and tighten it to the speci

torque.

12. Install the injection tube to No.1 cylinder

and tighten it to the speci

c torque.

ZX335-1004018

Body

Seat

Spring

Spool

NOTICE

●

Do not tighten the fuel injection pump
body more than specified. The pump
body is aluminum and it can be de-
formed by over-tightening, resulting in
unfavorable impact on the operation of
control rack.

Fig. 6-17

SANY Crawler Hydraulic Excavator SY365H-9, SY365BH-9. Shop Manual (2014) - page 20