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

6-36

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

6.15 Remaining Pressure in Hydraulic Lines - Relieve

Before disconnecting the lines between the hydraulic cylinders or between the hydraulic motor
and the control valve, perform the following steps in order to release the remaining pressure in
the hydraulic lines.

Even if there is no pressure remaining in the swing motor line and the travel motor line, they will
be in

uenced by the internal pressure of hydraulic tank. The breather valve must therefore be

opened to release pressure prior to operation.

1. Stop the engine, loosen the butter

y nut on the breather valve, and press the release button

to release the pressure in hydraulic tank.

2. Turn the engine start switch to the ON position and operate the control levers for several

times.

●

The pilot lock valve must be energized. Operate the control levers with the engine start
switch in the ON position.

●

Operate the control levers 2 or 3 times to release the pressure in the accumulator.

3. Start the engine and keep the engine running at low idle for about 10 seconds in order to

increase the pressure in accumulator. And then stop the engine.

4. Repeat the above step 2 through step 3 several times.

6-37

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

6.16 Oil Leakage Amount - Test

ZXT335-1004039

1. Testing the oil leakage amount of boom

cylinder

A. Start the engine and keep the engine

running until the hydraulic oil tempera-
ture reaches the operational range. And
then fully extend the boom cylinder.

To release the pressure remaining in
the lines see

“Remaining Pressure in

Hydraulic Lines - Relieve” on page 6-36.

B. Disconnect the hose (1) on the cylinder

rod end and plug the hose opening.

Take care not to disconnect the hose
on the cylinder head end.

C. Start the engine and apply relief pres-

sure to the head end of the cylinder
while the engine is running at high idle.

D. Hold this state for 30 seconds and then

test the amount of oil leakage for one
minute.

E. Make sure that the machine returns to

its normal condition after testing.

ZXT335-1004040

2. Testing the oil leakage amount of arm

cylinder

A. Start the engine and keep the engine

running until the hydraulic oil tempera-
ture reaches the operational range. And
then fully extend the arm cylinder.

To release the pressure remaining in
the lines,

See: Chapter 4 Testing and

Adjusting, “Remaining Pressure in
Hydraulic Lines - Relieve” on page 6-36

B. Disconnect the hose (2) on the cylinder

rod end and plug the hose opening.

Take care not to disconnect the hose
on the cylinder head end.

Fig. 6-36

Fig. 6-37

6-38

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1004041

3. Testing the oil leakage amount of bucket

cylinder

A. Start the engine and keep the engine

running until the hydraulic oil tempera-
ture reaches the operational range. And
then fully extend the bucket cylinder.

To release the pressure remaining in
the circuits see

“Remaining Pressure

in Hydraulic Lines - Relieve” on page
6-36

B. Disconnect the hose (3) on the cylinder

rod end and plug the hose opening.

Take care not to disconnect the hose
on the cylinder head end.

C. Start the engine and apply relief pres-

sure to the head end of the cylinder
while the engine is running at high idle.

D. Hold this state for 30 seconds and then

test the amount of oil leakage for one
minute.

E. Make sure that the machine returns to

its normal condition after testing.

C. Start the engine and apply relief pres-

sure to the head end of the cylinder
while the engine is running at high idle.

D. Hold this state for 30 seconds. Test the

amount of oil leakage for one minute.

E. Make sure that the machine returns to

its normal condition after testing.

Fig. 6-38

6-39

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1004042

4. Testing the oil leakage amount of swing

motor

A. Fully extend the work equipment. Lower

the bucket on the ground and raise the
machine slightly. Stop the engine.

B. Disconnect the drain hoses (4) and (5).

Blind the hose ends with caps.

C. Start the engine and apply swing relief

pressure while the engine is running
at high idle. Measure the amount of oil
leakage under this condition.

●

Hold the state described in step
3) for 30 seconds. Measure the
amount of oil leakage for one min-
ute.

●

After the first measurement, swing
the upper structure 180º and mea-
sure the leakage again in the same
way.

D. Make sure that the machine returns to

its normal condition after testing.

ZXT335-1004031

5. Testing the oil leakage amount of the travel

motor

A. Remove the cover of the travel motor.

B. Start the engine and lock the travel.

Insert the pin

①

between the sprocket

and the track frame in order to prevent
traveling.

Fig. 6-39

Fig. 6-40

6-41

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

6.17 Air in Each Component - Purge

Purging Steps

Hydraulic

Pump

Engine

Starting

Oil Cylin-

der

Swing

Motor

Travel

Motor

Operation

Starting

●

Changing the hydraulic oil

○

(Note)

○

(Note)

○

●

Cleaning the

lter element

●

Replacing the return

lter element

○

●

Repairing/replacing the hydraulic
pump

○

●

Disassembling the suction hose

●

Repairing/replacing the control valve

○

●

Replacing the oil cylinder

●

Disassembling the cylinder piping

○

●

Replacing the swing motor

○

●

Disassembling the swing motor

●

Replacing the travel motor

○

●

Disassembling the travel motor

Item to Be Purged

Job Description

1. Purging air from hydraulic pump

Note:

Purge air from the swing motor and travel motor only when the oil in the motor cases is drained.

Loosen the plug (1) and make sure that
oil leaks through the plug.

If you are sure of the leak, tighten the
plug (1).

Plug: 7.8~9.8 N·m{0.8~1.0 kgf·m}

●

Engine starting precaution:

When engine is started after bleeding the air
as described above, run the engine at low
idle for 10 minutes.

ZXT335-1004500

Fig. 6-42

6-42

Testing and Adjusting

SY365(B)H-9 Crawler Hydraulic Excavator

Bleeding air from hydraulic cylinder

Start the engine and keep the engine running at low idle.

Raise and lower the boom 4-5 times with the engine running at low idle.

●

Do not apply relief pressure and stop the piston at about 100 mm to stroke end.

Repeat step 2) with the engine running at high idle.

Apply relief pressure when the piston comes to stroke end with the engine running at low idle.

Purge air from arm cylinder and bucket cylinder. Repeat step 2) through step 4).

●

When a new cylinder is used for replacement, it is recommended to purge air from new cylinder
before it is installed to work equipment. Especially the boom cylinder, It must be purged prior to
installation because its piston is unable to reach the boom-down side stroke end after installa-
tion.

●

For an excavator whose hydraulic oil has been changed or which has been in storage for a long
period of time, slowly operate the boom, arm and bucket cylinders in full stroke at low engine
speed under zero load in order to purge the air. Immediate pressurization and loaded operation
after change of oil should be avoided.

Bleeding air from swing motor

Start the engine and run it at low idle.

Bleed air from swing motor by slowly turning the upper structure.

4. Bleeding air from travel motor

Start the engine and run the engine at low idle.

Loosen the bleeder plug (1) and make sure that oil oozes through the plug.

If you are sure of the leak, tighten the plug (1).

Bleeder plug: 27.5 - 35.3 Nm {2.8 - 3.6 kgm}

7-3

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

7 TROUBLESHOOTING

WARNING

●

Stop the machine on a level ground, and check that lock pins, blocks, and parking
brake are effective.

●

When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.

●

If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, so wait for the engine to cool down before starting troubleshooting.

●

Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

●

When disconnecting wiring, always disconnect the negative (–) terminal of the battery
first.

●

When removing the plug or cap from a location which is under pressure from oil, water,
or air, always release the internal pressure fi rst. When installing measuring equipment,
be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the fault, to carry out repairs swiftly,
and to prevent reoccurrence of the fault.

When carrying out troubleshooting, important point is to understand the structure and function.

However, a short cut to effective troubleshooting is to ask the operator various questions to form
some idea of possible causes of the fault that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry to disassemble the components. If compo-

nents are disassembled immediately any fault occurs:

●

Parts that have no connection with the fault or other unnecessary parts will be disassembled.

●

It will become impossible to find the cause of the fault.

It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also
lose the confidence of the user or operator.

For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fi xed procedure.

2. Points to ask user or operator:

A. Have any other problems occurred apart from the problem that has been reported?

B. Was there anything strange about the machine before the fault occurred?

C. Did the fault occur suddenly, or were there problems with the machine condition before

this?

D. Under what conditions did the fault occur?

E. Had any repairs been carried out before the fault? When were these repairs carried out?

7-4

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

F. Has the same kind of fault occurred before?

3. Check before troubleshooting

A. Check the oil level.

B. Check for any external leakage of oil from the piping or hydraulic equipment.

C. Check the travel of the control levers.

D. Check the stroke of the control valve spool.

E. Other maintenance items can be checked externally, so check any item that is considered

to be necessary.

4. Confirming fault

Confirm the extent of the fault yourself, and judge whether to handle it as a real fault or as a
problem with the method of operation, etc.

When operating the machine to reenact the troubleshooting symptoms, do not carry out any
investigation or measurement that may make the problem worse.

5. Troubleshooting

Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes
of fault, then use the troubleshooting flowchart to locate the position of the fault exactly.

●

The basic procedure for troubleshooting is as follows.

A. Start from the simple points.

B. Start from the most likely points.

C. Investigate other related parts or information.

6. Measures to remove root cause of fault

Even if the fault is repaired, if the root cause of the fault is not repaired, the same fault will oc-
cur again. To prevent this, always investigate why the problem occurred. Then, remove the
root cause.

7-5

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

Item

Criterion

Remedy

Lubricating oil, coolant

1. Check fuel level and type of fuel

2. Check for impurities in fuel

3. Check hydraulic oil level

4. Check hydraulic oil strainer

5. Check swing drive oil level

6. Check engine oil level (in oil pan)

7. Check coolant level

8. Check dust indicator for clogging

9. Check hydraulic

lter

10. Check

nal drive oil level

—

Add fuel

Clean, drain

Add oil

Clean, drain

Add oil

Add water

Clean or replace

Replace

Add oil

Electrical equipment

1. Check for looseness, corrosion of battery terminal and

wiring

2. Check for looseness, corrosion of alternator terminal

and wiring

3. Check for looseness, corrosion of start motor terminal

and wiring

—

Tighten or replace

Hydraulic,

mechanical

equipment

1. Check for abnormal noise and smell

2. Check for oil leakage

3. Bleeding air

—

Repair

Bleed air

Electrics, electrical equipment

1. Check battery voltage (with engine stopped)

2. Check electrolyte level

3. Check for discolored, burnt, exposed wiring

4. Check for missing wiring clips and hanging wiring

5. Check for wet wires (esp. wet connectors or terminals)

6. Check for blown or corroded fuses

7. Check alternator voltage (with engine speed at middle

or higher)

8. Check operating sound of battery relay (when start

switch is turned ON or OFF)

20-30V

—

After running for
several minutes:

27.5~ 29.5V

—

Replace

Add or replace

Replace

Repair

Disconnect con-
nector and dry

Replace

7.1 Checks before Troubleshooting

7-6

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

7.2 Failure Symptoms and Troubleshooting Codes

No.

Symptom

Troubleshooting

Code dis-

played

E mode

H mode

(Engine)

Action to be taken concerning Service Code, Failure code and Failure Code

Display Failure code in monitor panel

Accord-

ing to

displayed

code

Display Service Code in electrical system after
checking failure history

Display Failure Code in mechanical system after
checking failure history

Engine-related failure

Engine does not start up easily. (It always takes
some time to start up the engine)

Engine mis

res.

E-1

Color of exhaust gas is too dark.(Incomplete com-
bustion)

Engine pickup is poor.

Engine runs rough or is unstable.

E-2

Engine is short of output, or lacks power

H-2

10 Auto Idle fails.

E-5

H-5

Excessive engine oil consumption, or color of ex-
haust gas is blue

12 Premature engine oil contamination

13 Excessive fuel consumption

Engine cooling water is mixed with engine oil, spurts
out or decreases

15 Engine oil amount increases. (Water or fuel gets in)

16 Abnormal noises are heard

17 Excessive vibrations are caused

Failure related to work equipment, swing and travel

18 Power supply of machine cannot be cut off.

E-3

There are abnormal noises from around hydraulic
pump

H-4

20 All work equipment, travel and swing do not move

H-3

Speeds of all work equipment, travel and swing are
slow

H-1

When Machine Swings and Travels Simultaneously,
Travel Speed Lowers Largely

H-13

7-7

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

No.

Symptom

Troubleshooting

Code dis-

played

E mode

H mode

(Engine)

Work equipment-related failure

23 All the equipment do not work

E-7

24 Cylinder do not work singly

H-9

25 Drift of cylinder is too large

H-10

26 Work equipment time lag is too big

H-11

Other work equipment moves, when specific
work equipment is relieved

H-12

28 Boom-up speed or power is low.

E-8

H-6

29 Arm speed or power is low.

E-9

H-7

30 Bucket speed or power is low.

E-10

H-8

Travel-related failure

31 Travel speed or power is low.

E-11

H-15

32 Dual Speed Travel Not Functioning

E-14

33 Machine tends to swerve while in travel

H-14

34 Machine is dif

cult to steer, or lacks power

H-16

35 Travel speed cannot be shifted

H-17

36 Track shoe does not move (only on one side)

H-18

Swing-related failure

37 Machine does not swing

H-19

Swing acceleration is poor, or swing speed is
slow

H-20

Upper structure overruns remarkably when
stopping swinging

H-21

40 Large shock is made when stopping swinging

H-22

41 Large sound is made when stopping swinging

H-23

42 Hydraulic drift of swing is large

H-24

7-8

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

No.

Symptom

Troubleshooting

Code dis-

played

E mode

H mode

(Engine)

Monitor panel-related failure

43 Monitor display is blank.

E-12

44 Monitor displays nothing.

E-13

Engine coolant temperature reading is incor-
rect.

E-15

46 Fuel level reading is incorrect.

E-16

47 Arm-in pilot pressure reading is incorrect.

E-18

48 Arm-out pilot pressure reading is incorrect.

E-19

49 Boom-up pilot pressure reading is incorrect.

E-20

Boom-down pilot pressure reading is incor-
rect.

E-21

Bucket-close pilot pressure reading is incor-
rect.

E-22

Bucket-open pilot pressure reading is incor-
rect.

E-23

53 Swing pilot pressure reading is incorrect.

E-24

54 Left travel pilot pressure reading is incorrect.

E-25

Right travel pilot pressure reading is incor-
rect.

E-26

Other failure

56 Preheat function fails.

E-6

57 Wiper does not work.

E-17

7-9

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

7.3 Connector Location and Electrical Circuit Diagram

Connector No.

Type

Num-

ber of

pins

Component

Stereo-

gram

CN-101M

Platform lamp

E-5

CN-102M

Fuel level sensor

F-6

CN-104M

Boom lamp (L)

E-7

CN-105M

Boom lamp (R)

E-7

T-117

Terminal

High-temp switch

K-7

T-101

Terminal

Battery relay coil (+)

M-2

T-102

Terminal

Battery relay coil (-)

M-2

T-103

Terminal

Battery relay contact (output)

M-2

T-104

Terminal

Battery relay contact (input)

M-2

T-105

Terminal

Preheater fuse line 21#

M-2

T-106

Terminal

Preheater fuse line 16#

M-2

T-118

Terminal

Battery ground

M-2

T-500

Terminal

Battery ground

M-2

T-107

Terminal

Compressor clutch

K-7

T-109

Terminal

Engine oil pressure switch

J-7

T-110

Terminal

Preheater resistance wire terminal

J-7

T-111

Terminal

Start motor terminal B

K-7

T-112

Terminal

Alternator terminal B

K-6

T-135

Terminal

Start motor terminal S

K-7

T-202

Terminal

Chassis ground

W-6

Horn relay

X-6

Head lamp relay

X-6

Work lamp relay

X-6

Pilot valve relay

X-6

—

Battery relay

M-2

Start relay

X-6

—

Preheater relay

Y-6

Lockout relay

X-6

Shutdown delay relay

X-6

CN-201F

Joint connector

W-6

CN-302F

Intermediate connector

R-6

F-501

Terminal

Intermediate connector

R-6

F-502

Terminal

Intermediate connector

R-6

7-10

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

Connector No.

Type

Num-

ber of

pins

Component

Stereo-

gram

F-503

Terminal

Intermediate connector

R-6

F-504

Terminal

Intermediate connector

R-6

F-505

Terminal

Intermediate connector

R-6

F-506

Terminal

Intermediate connector

R-6

F-507

Terminal

Intermediate connector

R-6

F-508

Terminal

Intermediate connector

R-6

F-509

Terminal

Intermediate connector

R-6

CN-502F

Intermediate connector

R-5

CN-1-110

Intermediate connector

AD-6

CN-1-112F

Intermediate connector

W-6

CN-1-111M

Intermediate connector

W-6

CN-142M

Monitor

P-5

CN-182P

Intermediate connector

I-7

CN-155M

Intermediate connector

J-7

CN-503F

Intermediate connector

W-6

CN-504F

Intermediate connector

X-6

CN-505F

Intermediate connector

X-6

CN-507F

Intermediate connector

X-6

CN-106M

Hyd oil temp sensor

I-7

CN-502F

Intermediate connector

W-6

CN-181M

Preheater controller

X-6

CN-506F

Intermediate connector

W-6

CN-180M

Parking relay

Y-6

CN-140M

Front principal pressure sensor

I-7

CN-141M

Rear principal pressure sensor

I-7

CN-129M

Arm-in pilot sensor

I-6

CN-122M

Arm-out pilot sensor

I-6

CN-126M

Boom-up pilot sensor

I-6

CN-125M

Boom-down pilot sensor

I-6

CN-124M

Bucket-dig pilot sensor

I-6

CN-128M

Bucket-dump pilot sensor

I-6

CN-123M

Swing pilot sensor

I-6

CN-120M

Left travel pilot sensor

I-6

CN-121M

Right travel pilot sensor

I-6

CN-307M

Head lamp switch

R-5

SANY Crawler Hydraulic Excavator SY365H-9, SY365BH-9. Shop Manual (2014) - page 22