SANY Crawler Hydraulic Excavator SY365H-9, SY365BH-9. Shop Manual (2014) - page 29

 

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SANY Crawler Hydraulic Excavator SY365H-9, SY365BH-9. Shop Manual (2014) - page 29

 

 

7-107

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

H-21 Upper structure overrunning remarkably 

Failure information (1)

Upper structure overruns remarkably when it stops swinging in
both directions.

Related information

Set working mode to S and fuel control dial at position 10 to carry
out troubleshooting.

Possible causes and standard values

Cause

Standard values and troubleshooting references

1

Improper adjust-
ment or malfunc-
tion of swing motor 
(relief valve)

Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.

Swing control lever

Swing relief pressure

Swing relief 

25.5~28.5 MPa 

{260~291 kg/cm

2

If oil pressure does not become normal after adjustment, swing motor 
relief valve may have malfunction or internal defect. Check the relief 
valve directly.

2

Failure of swing 
motor

Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.

Control lever

Leakage from swing motor

Swing relief 

10 ml/min

Failure information (2)

Swing acceleration is only poor on one side, or swing speed is
low.

Related information

Set the working mode at gear (10) of power mode (S) to perform
troubleshooting.

Possible causes and standard values

Cause

Standard values and troubleshooting references

1

Malfunction of pilot 
valve

Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.

Swing control lever

Pilot valve output pressure

NEUTRAL

0 {0} 

Left swing

Right swing

3.5MPa {

36 kg/cm

2

}

2

Malfunction of swing 
control valve (spool)

Spool of swing control valve may have malfunction. Check it directly.

3

Defective seal of 
swing motor (make-
up valve)

Seal of makeup valve in swing motor may be defective. Check it di-
rectly.

Swap the left and right makeup valves and observe the result to
determine whether the seal fails.

7-108

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

H-22 Large shock produced upon swing stoppage

Failure information

 

Large shock is produced when upper structure stops swinging.

Related information

 

Set working mode to S and fuel control dial at position 10 to carry 
out troubleshooting. 

Possible causes and standard values

Cause

Standard values and troubleshooting references

1

Malfunction of swing 
pilot valve

 

Stop the engine before troubleshooting. Perform troubleshooting 
while the engine is running at high idle.

Swing control lever

Pilot valve output pressure

NEUTRAL

0 {0}

Left swing

Right swing

3.5MPa {

36 kg/cm

2

}

2

Malfunction of swing 
reverse prevention 
valve

Reverse prevention valve of swing motor may have malfunction. 
Check it directly.

 

Replace the valve with a new on to determine whether the valve 
fails. 

3

Malfunction of swing 
relief valve

Swing relief valve may be worn or sluggish. 

7-109

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

Failure information

 

High noise is produced when upper structure stops swinging.

Related information

 

Set working mode to S and fuel control dial at position 10 to carry 
out troubleshooting. 

Possible causes and standard values

Cause

Standard values and troubleshooting references

1

Malfunction of 
back pressure 
valve

Back pressure valve may have malfunction. Check it directly.

2

Malfunction of 
swing motor 
(relief valve)

Relief valve of swing motor may have malfunction. Check it directly.

3

Malfunction of 
swing motor 
(makeup valve)

Seal of makeup valve in swing motor may have malfunction. Check it di-
rectly.

 

Swap the left and right makeup valves and observe the result to deter-
mine whether the seal fails. .

4

Failure of swing 
mechanism

The swing mechanism is suspected of an internal failure. Check the inside 
of the machinery itself. 

 

Internal defect of swing mechanism can be determined with abnor-
mal noise, overheat, and metal powder or debris contained in the oil 
drained. 

H-23 High noise produced upon swing stoppage

7-110

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

H-24 Swing drift excessive

Failure information (1)

Hydraulic drift of swing is large (when swing holding brake is ap-
plied).

Related information

When swing lock switch is turned ON or when swing holding
brake release switch is in normal position, swing holding brake
operates and upper structure is 

fi

 xed with disc brake.

Possible causes and standard values

Cause

Standard values and troubleshooting references

1

Failure of swing 
holding brake 
control lines

Swing holding brake control lines and holding brake pilot valve may be 
defective. Check them directly.

2

Malfunction of 
swing motor 
(parking brake)

Parking brake of swing motor may have malfunction. Check it directly.

Failure information (2)

Hydraulic drift of swing is large (when swing holding brake is re-
leased).

Related information

When swing holding brake release switch is in release position,
swing holding brake is released and upper structure is secured
by only hydraulic pressure.

Possible causes and standard values

Cause

Standard values and troubleshooting references

1

Malfunction or de-
fective seal of swing 
control valve (spool)

Swing control valve spool may have malfunction or defective seal.

Check it directly.

2

Failure of swing mo-
tor (relief valve)

Seal of relief valve in swing motor may be defective. Check it directly.

3

Failure of swing mo-
tor (makeup valve)

Seal of makeup valve in swing motor may be defective. Check it di-
rectly.

Disassembly and Assembly

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

8-1

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

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

Disassembly and Assembly

8-2

SY365(B)H-9 Crawler Hydraulic Excavator

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

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

8-3

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

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

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

8-4

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

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
8.37.2  Removal and installation .......................................................................... 8-142
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
8.41.3  Removal and installation .......................................................................... 8-154
8.41.4  Relay connector and wiring...................................................................... 8-154

8.42 Sensors.............................................................................................................. 8-155
8.43 Connector Terminals  ......................................................................................... 8-157

8.43.1 Insertion ................................................................................................... 8-157
8.43.2 Removal ................................................................................................... 8-158

8-5

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

8  DISASSEMBLY AND ASSEMBLY

8.1  How to Read This Manual

8.1.1  Removing and installing an assembly

Special tools

 

Special tools for parts removal and installation are listed. 

 

Necessary characteristics of the tools are noted in the list of special tools. 

: Special tools that cannot be substituted and must be used. 

: Very important tools, which can be substituted with commercially available ones. 

Removal of parts

 

The "Removal" section contains procedure, precautions and the amount of oil or coolant to be 
discharged. 

 

The symbols used the in the "Removal" section are described below: 

This symbol indicates that safety-related precautions must be observed when doing the 
job.

This symbol is followed by instructions or precautions when performing a procedure. 

 

This symbol indicates related rules and precautions that must be obeyed when installing 
the pats.

 

This symbol indicates the amount of oil or coolant to be discharged. 

Installation of parts

 

Unless speci

fi

 ed otherwise, installation of a part is to be performed in a reverse order of re-

moving the part. 

 

The mark 

 used in the "Installation" section indicates the rules and precautions related to 

parts installation. 

 

Symbols used in the "Installation" sections are shown below: 

This symbol indicates that safety-related precautions must be observed when doing the job.

This symbol is followed by instructions or precautions when performing a procedure. 
This symbol indicates that speci

fi

 c coating agent must be used. 

This symbol indicates the lubricant required.
This symbol indicates a torque speci

fi

 ed. 

                 This symbol indicates the amount of oil or coolant to be added.

8-6

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

8.2 Operating Precautions

Observe the following precautions before removing or installing (disassembling or assembling) a 
component. 

1. Precautions to be observed prior to removal operation

Dispose the engine coolant properly if antifreeze is used in the engine coolant.

After disconnecting a hose or tube, seal the openings to prevent invasion of dirt or dust.

Use a suitable container to contain oil drained.

Matching mark must be made at where is necessary before removing a part in order to
avoid mistake during reinstallation.

Do not pull the wire and avoid the wire coming off its contact. To avoid excessive force im-
posing on the wire, hold the connector when disconnecting a wire.

Tag the wires and the hoses in order to ensure their connecting positions. By doing so,
mistakes can be avoided during reinstallation.

Count and check the number and thickness of the shims, and keep them in a safe place.

When raising or lifting a component, be sure to use a proper lifting equipment of ample
strength.

When forcing screws are used to remove any components, tighten the screws evenly in
turn.

The surrounding area must be cleaned before removing a component. Cover the compo-
nent after removal in order to prevent invasion of dirt or dust.

8-7

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

Precautions to be observed when disassembling the lines

The lines disassembled must be blinded with plugs.

A. Thread-connected hoses

Inner Diameter (mm)

Code

Description

Light Thread Connection

6

B210780001189

Plug

8

B210780001190

Plug

10

B210780000077

Plug

12

B210780000078

Plug

15

B210780000883

Plug

20

B210780000079

Plug

22

60056667

Plug

Heavy Thread Connection

12

B210780001142

Plug

16

60002397

Plug

20

B210780000080

Plug

25

B210780000081

Plug

B. Thread-connected adaptors (plug and nut used in combination)

Inner Dia.(mm)

Code

Description

Code

Description

Light Thread Connection

6

B210780000903

Cone Plug

23002925

Nut

8

B210780001146

Plug

B210770000011

Nut

10

B210780000088

Plug

B210334000011

Nut

12

B210780000089

Plug

B210334000012

Nut

15

B210780000882

Plug

B210334000004

Nut

20

B210780000090

Plug

B210334000010

Nut

22

B210780000091

Plug

B210780000112

Nut

Heavy Thread Connection

12

B210780001143

Plug

B210780000406

Nut

16

A820205001523

Plug

B210780000405

Nut

20

B210780000902

Plug

B210780000904

Nut

25

B210780001172

Plug

B210334000006

Nut

8-8

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

2.  Precautions to be observed prior to instal-

lation 

 

Tighten all the screws and nuts (sleeve 
nuts) to speci

fi

 ed torques. 

 

Install the hoses without twisting or in-
terference.

 

Replace the gaskets, O-rings, cotter 
pins and lock plates with new ones. 

 

Bend the cotter pin or lock plate se-
curely.

 

Before applying the adhesive, clean the 
parts of oil and dust. Apply 2 or 3 drops 
of adhesive to the threaded portion. 

 

Before applying the sealant to the gas-
ket, clean the gasket surface of oil and 
dust. Check the gasket for contamina-
tion or damage. Apply the gasket seal-
ant evenly. 

 

Clean all parts, and correct any dam-
age, dents, burrs, or rust.

 

Apply engine oil to the moving parts. 

 

Before installing a snap ring, make sure 
that the snap ring is mounted properly 
in the circular groove. 

 

Before connecting the wiring connector, 
clean the wiring connector of oil, dirt or 
water. Make sure that the wiring con-
nector is connected securely. 

 

Before using an eyebolt, check the 
eyebolt for deformation or deterioration. 
Screw on the eyebolt as far as possible 
and align it to the direction of the hook. 

 

Before tightening the half 

fl

 anges, tight-

en it evenly in turn in order to prevent 
over tightening on one side. 

 

After reassembling the hydraulic cylinder, 
main pump or other hydraulic equipment 
that has been disassembled and repaired, 
it is necessary to purge the air from the 
hydraulic cylinder prior to initial operation 
of the cylinder. The purging procedure is 

performed as the following: 

(1)  Start the engine and run the engine at 
low idle. 
(2)  Operate the work equipment control 
lever in order to cycle the movement of the 
hydraulic cylinder 4 or 5 times. Hold the cyl-
inder at where it is 100 mm from its stroke 
end. 
(3) Go on operating the hydraulic cylinder 
3 or 4 times to its stroke end. 
(4) You can run the engine at normal 
speed after this operation. 

 

This procedure is to be performed be-
fore using your machine for the first 
time after repair or long storage. 

3.  Precautions to be observed upon comple-

tion of the operations

 

Completely discharge the engine cool-
ant, tighten the drain valve, and add 
coolant to the specified level. Run the 
engine to circulate the coolant through 
the system. Check the coolant level 
again. 

 

Add hydraulic oil to the specified level 
after disassembly and reinstallation of 
a hydraulic unit. Run the engine to cir-
culate the hydraulic oil through the sys-
tem. Check the oil level again. 

 

Purge the air from the system after 
removing and repairing the lines or hy-
draulic unit and reassembling the parts. 

 

To purge the air,  see related informa-
tion in 

Testing and Adjusting

 

Add the specified amount of grease 
(MoS

2

) to the work equipment related 

parts.

8-9

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1006001

1

2

3

4

8.3 Start Motor AS 

8.3.1 Removal

1.  Open the engine hood. 

2.  Disconnect the Cables (2), (3) and (4). 

3.  Remove the start motor fixing bolt (1) in 

order to remove the start motor. 

8.3.2 Installation

 

Installation is performed in the reverse pro-
cedure of removal.

NOTICE

 

Before removing the start motor assem-
bly, disconnect the cable from the nega-
tive post (-) of the battery. Insulate the 
cable and negative post (-) with tape. 

Fig. 8-1 

8-10

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

ZXT335-1006002

ZXT335-1006003

2

1

ZXT335-1006004

5

4

3

6

7

8.4  Fuel Injection Pump AS 

8.4.1 Removal

2.  Disconnect the air hoses (1) and (2) of the 

crankcase.

3.  Remove the fuel return line (3), fuel 

delivery line (4), fuel supply line (5) and 
lubrication line (7). 

 

After disconnecting the hoses, cork 
them to prevent fuel leak. 

NOTICE

 

Disconnect the negative (-) post of bat-
tery.  

1.  Open the engine hood. 

Fig. 8-2 

Fig. 8-3 

Fig. 8-4 

8-11

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

4.  Remove the six (6) fuel delivery lines (8)

5.  Remove the air hose (9).

6.  Remove the bolt (10) fixing the electronic 

shutdown device and the bolt (11) of gov-
ernor motor.

7.  Remove the fuel injection pump mounting 

nut in order to remove the fuel injection 
pump assembly. 

ZXT335-1006005

8

 

 

ZXT335-1006006

9

10

11

Fig. 8-5 

Fig. 8-6 

8-12

Disassembly and Assembly

SY365(B)H-9 Crawler Hydraulic Excavator

8.4.2 Installation

 

Installation is performed in the reverse procedure of removal.

Torques for: 

Fuel supply line connector bolt: 28-46 N•m

Fuel return line nut: 28-46N•m

Fuel delivery line nut: 28-32N•m

Engine oil line nut: 16-25N•m

 

Install the fuel injection pump as the following:

A.  Check the fuel injection timing.

See

 “Fuel Injection Timing - Test and Adjust” on page 6-13

.

B.  Assemble the fuel injection pump assembly and tighten the nuts.

 Nut: 9.8

±

2 Nm {10

±

0.2 kgm}

 

Purge the air. 

Purge the air from the fuel injection system.

 

 

 

 

 

 

 

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