Sany Hex Service Training

For overseas dealers

Andy Liu
 Global service web

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 Global service web
R&D center: German, USA, Japan, of course China.
Two manufactories were built in Brazil and India. It is also
scheduled to build factory in Russia, Indonesia, Thailand,
and Poland in 2011.
15 branch distributed all of the world.
More than 70 dealers abroad.
More than 700 service engineers were dispatched abroad to
do the after sale service.
Center warehouse was built in 13 countries or areas, such
as Singapore, India, United Arab Emirates, Russia,
Kazakstan, Spain, Algeria, Nigeria, South Africa, Brazil, USA,
and Australia.
Also that dealers have their own warehouse to store parts.
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 Chapter 1 – Basic structure & concept

Chapter 2 – Electronic system

Chapter 3 – Hydraulic system

Chapter 4 – Engine used on Sany hex

Chapter 5 – Zexel fuel system

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 Safety first
Falling is one of the major causes
that resulting in personal injuries.

Always keep a three-point contact

with the pedal and armrest and face
to the excavator when getting on or
off the excavator.

Do not use any levers and driving cab

doors as the armrest.

Never jumping on or off the

excavator, and do not get on or off a
moving excavator.

While operating the excavator, please

notice that the platform, pedal and
armrest are slippery.

Mud, oil and water on pedal, armrest

and shoes should be removed at any
time.
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 Product code
Model code

10 SY 005 0 0318

Serial number

Update code ( 0 is basic)

Machine weight (ton)

Sort code, SY is hex

Made in 2010
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 Model number
For example, SY235C8I2K:

SY 235 C 8 I 2 K

Kawasaki hyd system

Tie Ⅱ emission

Engine: Isuzu
Hex update time

Design code
Hex weight

Sany
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 Engine configuration

I2: Isuzu TIER-Ⅱ engine.

I3: Isuzu TIER-Ⅲ engine.

M2: Mitsubishi TIER-Ⅱ engine。

M3: Mitsubishi TIER-Ⅲ engine。

C3: Cummings TIER-Ⅲ engine.

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 Model code
SY135C8I2K ISUZU TIER2 KPM PFC
SY135C8I3K ISUZU TIER3 KPM PFC
SY205C8C3K CUMMINS TIER3 KPM PFC

SY205C8M2K MITSUBISHI TIER2 KPM PFC

SY215C8C3K CUMMINS TIER3 KPM PFC

SY215C8M2K MITSUBISHI TIER2 KPM PFC

SY215C8I3K ISUZU TIER3 KPM PFC

SY235C8C3K CUMMINS TIER3 KPM PFC
SY235C8I2K ISUZU TIER2 KPM PFC
SY240C8I3K ISUZU TIER3 KPM PFC
Andy Liu KPM --- 川崎精机 8
 Delivery Service

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 Delivery Service

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 Hex structure
1 - Bucket 30 - Idler wheel
2 - Linkage 31 - Air Cleaner
3 - Rocker Arm 32 - Control Lever
4 - Bucket Cylinder 33 - Side Teeth
5 - Stick 34 - Bucket Teeth
6 - Stick Cylinder 35 - Driving Cab
7 - Boom 36 - Boom Cylinder
8 - Swivel Joint 37 - Working Light
9 - Battery Box
10 - Swing Bearing
11 - Swing Unit
12 - Control Valve
13 - Fuel Tank
14 - Hyd Oil Tank
15 - Pilot Filter
16 - Muffler
17 - Pump
18 - Engine
19 - Counterweight
20 - Radiator, Oil
25 - Track Roller
Cooler
26 - Sprocket Wheel
21 - Detergent Box
27 - Water Tank
22 - Tool Box
28 - Track Frame
23 - Track
29 - Track Tensioning Mechanism
24 - Tracking Unit
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 Hex structure

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 Undercarriage
Carrier roller X - frame track

Final drive Track roller Idler wheel

 X – frame: major structure of the undercarriage. Track rollers,
carrier rollers, idler wheel, sprocket were all installed on it.
 Track roller: hex weight was average taken by the track rollers.
 Carrier roller: carry and guide the upper part of the track.
 Track: track was used to increase the contact surface of the hex,
reduce the contact pressure, it also made the hex can be traveled
on the ground. Wider track should be selected on the soft ground.
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 Undercarriage
 Idler wheel: connected with the track tension cylinder
and the spring. Make the track tensioned properly.
Spring will absorb the shock load the track suffered to
prevent solid damage.
 Final drive: sprocket and travel motor were connected to
the final drive. Final drive reduces the motor speed and
drive the track moved forward or backward. As the motor
rotate speed was reduced, the torque was increased to
overcome the travel resistance.

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 Travel direction

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 Track tension mechanism

1 - Yoke
2 - Spring
3 - Cylinder
4 - Bolt/Washer
5 - Keeper
6 - Nut
7 - Oil Port
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 Joystick
t Fr
Le on on t
Fr t h
f t R ig

Re
a r Ri ft ar
gh e
Re t L

Left hand lever Right hand lever

Front Stick out Front Boom down
Rear Stick in Rear Boom up
Left Swing left Left Bucket in
Right Swing right Right Bucket out
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 Main hyd pump
Main hyd pump: K3V112DT piston pump made by
Kawasaki. Front pump, rear pump and pilot pump were
series connected and driven by engine flywheel.

Main pump is a tandem swash plate structure axial piston

pump. And worked under constant horsepower control.

Currently, major hydraulic

components are supplied
by manufacturer Kawasaki.

Kawasaki hyd system is

PFC controlled and the two
pump total power constant
during the variation.

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 Main hyd pump

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 Hyd pump coupling

tl y.
c
rre
g co
li n
up
c o
t h e
all
s t
In

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 Swivel joint

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 Swivel joint

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 Auxiliary function

Secondary boost
pressure sw

Horn
Double S
Joystick
Double B
Joystick
Hydraulic
ctrl lever

Travel ctrl lever

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 Hex stop pattern
Stop hex on a solid
and flat ground for
safety.
Stop engine.
Check the hyd oil
level.
Release pressure
 Operating all the
joysticks.
 Release hyd oil
tank residual
pressure.

Release hyd oil

pressure before
maintenance and
repair.
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 Specification

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 Adjustment

Bucket in was failed, how to troubleshooting?

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 Component location review

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 Measurement unit
The following table, given for reference, can be used
to convert the metric system into other systems. For
example: 24.5 MPa (3560 psi, 250 kgf/cm2)

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 Hex selection

Note: 4-6 buckets full load a truck is the best match.

hex bucket
capacity
material
weight
times a hex needs to full
load a truck

m3 Density is
1.8t/m3
5T 8T 10T 15T 20T

SY205 0.8 1.5T 3.3 5.3 6.6 9.9 13.3

SY215 0.9 1.6T 3.1 5 6.3 9.4 12.5

SY235 1.2 2.0T 2.5 4 5 7.5 10

SY335 1.5 2.5T 2 3.2 4 6 8

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 Hex selection
How to compare and assess a hex performance?
 Engine: rated power, fuel consumption / economic, and emission
/ environment protection.
 Hydraulic system: pressure, flow and internal parts wear.
 Excavate ability: cycle time and excavate force.
 Reliability and duration: service life of the implements and main
structure.
 Safety: protect facility, such as the pedal, armrest, safety belt,
slippery and so on.
 Maintenance: interval, convenience and the cost.
 Comfort: wide visibility in the cab, comfortable seat and easy
operation.
 Sany hex has enough power, low fuel consumption, wide visibility
of the cab, perfect safety facility, low maintenance cost and easy
to access.
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 Monitor

1 - Warning Indicator 2 - Function Indicators (Optional) 3 - Interface Display Area

4 - Function Display. 5 - Function Keys 6 - Encode Knob 7 - Combination Keys
8 - Working Mode 9 - Accelerator Gear 10 - Water Temperature 11 - Fuel Volume
12 - Local Time 13 - Trouble Code 14 – Accumulated Working Time
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 Monitor
1. Warning indicator: When controller detects any trouble and submits, this lamp
turns red, it turns off in normal condition.

2. Function indicators (Optional)

A. Priority from left: swing left.
B. Second from left: lamp.
C. Third from left: swing brake.
D. Fourth from left: emergency stop.
E. Priority from right: swing right.

3. Interface display area. As the left illustration shows:

A. The upper meter is coolant thermometer.
B. Lower is fuel gauge meter;
C. On the top left corner is working modes. They are H, S, L, B respectively. B is breaker
mode. S is default mode. Press F1 to switch the modes.
D. On the top right corner is accelerator gear display which shifts between 1 and 11 with
accelerator knob.
E. On the lower left corner is accumulated working time.
F. On the lower right corner is local standard time.
G. In the middle of the lower row is trouble display area where the trouble code blinks when
abnormal situation occurs.

4. Function display: When in different working conditions or performing function

shifting, this area displays the function of corresponding key (F1 to F5) below of it.
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 Monitor
5. Function switch keys
F1: working modes switch. Pressing this key can circularly switch between H,
S, L and B mode. B is breaker mode and S is start default mode.
F2: automatic idle switch. Pressing this key can switch between automatic
idle and non-automatic idle. Tortoise picture indicates automatic idle while
rabbit picture indicates non-automatic idle.
F3: tracking high/low speed switch. Pressing this key can perform tracking
high/low speed switch. Lo is low speed tracking while Hi is high speed
tracking.
F4: alarm release. Pressing this key can display alarm code and release
alarm.
F5 relative information inquiry. Pressing this key can enter relative
information inquiry and system information setup.
 Above are the functions of five keys in normal condition. As per different
working conditions, functions differ.

6. Encode knob: This knob can adjust value by switching LH and RH. It
serves as affirmation (enter) key by pressing in some pages. According
to different pages, functions differ.

7. Combination function keys:

1. Up, down, left, right, ESC, Enter keys are used to set password.
2. Select item and switch screen. According to different pages, functions differ.
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 Normal working condition
When in normal working condition,
it shows as the left illustration:
 F1: working modes switch. Pressing this
key can circularly switch between H, S, L
and B mode. B is breaker mode and S is
start default mode.
 F2: automatic idle switch. Pressing this
key can switch between automatic idle
and non-automatic idle. Tortoise picture
indicates automatic idle while rabbit
picture indicates non-automatic idle.
 F3: tracking high/low speed switch.
Pressing this key can perform tracking
high/low speed switch. Lo is displayed as
low speed tracking while Hi as high
speed tracking.
 F4: alarm release. Pressing this key can
display alarm code and release alarm.

 F5: enter display or setup condition.

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 Display or setup condition
Turn on the power switch, press F5
and enter display or setup condition.
Password was needed after F5 key
was pressed.
Input password:
 Circularly change the current value by
key F1, or change the current value by
up / down arrow key.
 Press key F2 (or by key ) to select the left
or right position of the value which you
want to change.
 After entering the 5 bits password,
confirmed by key F3 (or enter key), enter
information inquiry list.
 When the password is not correct,
system will hint automatically and stay
on the current page, requiring correct
password re-entered.
 Return to the previous page by F5 (or ESC
key).
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 Display or setup condition
Information inquiry list: Display
enters information inquiry list
after entering correct password
and confirming by pressing F3
(or ENTER key).

This interface includes following

5 items, through which different
inquiries can be entered:
 Running information inquiry

 Machine configuration inquiry

 Trouble information inquiry

 Accelerator installation assist

 System language selection

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 Display or setup condition
How to enter the next interface
from the current interface:
 Circling move down the blue cursor to
select the item to inquiry by key F1, then
confirm by key F2.
 Or move the blue cursor up and down by
arrow key up / down to select the item to
inquiry, then confirm by key ENTER.
 Or move the blue cursor up and down by
turning knob to select the item to inquiry,
then confirm by pressing the knob after
selection.
 Below the display, the inquiry content
selected under the current blue cursor is
introduced briefly by green words.
 Enter system setup and item setup
condition by key F4.
 Return to the previous interface by key
F5 or key ESC.

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 Display or setup condition
1. Running information inquiry:
A.Engine information:
 Coolant temperature °C ; Fuel volume % ; Oil pressure kPa ; Hydraulic
oil temperature °C.

B.Accelerator mechanism information:

 Accelerator gear n; Engine speed rpm; Gear position V; Accelerator
position V.

C.Hydraulic system pressure information (kg/cm2):

 Boom lifting; Boom lower; Arm digging; Arm dumping; Bucket digging;
Bucket dumping; Swing pressure; Left tracking pressure; Right tracking
pressure.

D.Main hydraulic pump information:

 Pump 1 pressure (kg/cm2); Pump 2 pressure (kg/cm2); Proportioning
solenoid valve 1 current mA; Proportioning solenoid valve 2 current mA.

E.Main control valve information:

 Bucket confluence valve; Swing priority valve; Boom priority valve;
Tracking high/low speed switch.

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 Display or setup condition
2. Machine configuration inquiry: The interface displays the
following information and return to the previous interface by
F5 or ESC key.
A. Complete vehicle model.
B. Complete vehicle number.
C. Engine model.
D. Hydraulic system model.
E. Controller model.

3. Trouble information inquiry: When system is abnormal, enter

this inquiry and the display shows all the current trouble
information according to which you can handle the machine.
For trouble information, see "Trouble code chart" for details.
4. System language selection: select the required language by
F2(Chinese) or F3(English) and return to the previous
interface by F5 key.
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 Display or setup condition
5. Accelerator installation assist:
Different from the "Accelerator
mechanism information" in
"Running information inquiry
list".
 Operating F1, F2, F3 can monitor
over the following parameters
under different conditions of
H, S, L, B, automatic idle, non-
automatic idle, high speed
tracking and low speed tracking,
etc.
(a) Accelerator gear N
(b) Engine speed rpm
(c) Gear position V
(d) Accelerator position V
 Return to the previous interface
by F5 or ESC key.

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 System setup
Enter system setup and item setup
condition by pressing F4 in
"Information Inquiry List" interface.
In such condition, the following 6
calibration setups are available:
A. System clock calibration

B. Accumulated working time edit

C. Machine configuration calibration (for

factory)

D. Protect parameter setup (not for this

machine model)

E. Protect release setup (not for this

machine model)

F. Display parameter (for factory)

After selecting the required calibration

setup, interface shift to password
input screen.
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 Troubleshoot with code
Methods and steps for code trouble
diagnosis:
 Related codes will be displayed in
sequence in the middle of the lower
display if failure occurred.
 Each code has specific meaning, so you
can analyze the reason and the failed
parts as per the diagnosis code, and
work out the solution.
If malfunction occurs when equipment
power is turned on, related codes will be
displayed successively in the left image.
 Some codes do not indicate trouble in
some specified working conditions. For
example:
 When key start switch on with engine off,
trouble code 41 indicates engine speed is
too slow will be displayed for no engine
speed.
 In some equipment, oil pressure is too
low may be displayed.
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 Troubleshoot with code
In the above monitor interface, enter
"Information Inquiry” password input
interface by pressing F5 if trouble
warning occurs.

To enter "Information Inquiry", you must

have the password the factory offered.

After entering "Information Inquiry"

password input condition, display will
show as the left. Enter password as
follows:

1. Circularly change the current value by

pressing key F1, or change the current
value by up / down key.

2. Press F2 (or , left / right key) to select the

left or right position of the value which
you want to change.

3. After entering the 5 bits password, enter

information inquiry list after confirming by
F3 (or ENTER key ).
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 Trouble code chart

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 Trouble code chart
When system detects
any abnormality,
indicator blinks as per
certain regularity,
indicate
corresponding trouble
description.

For example,
abnormal trouble 34
indicates
" repeat blink at 0.5
sec intervals for 3
times and turn off for
1.5 sec, then turn off
for 4 sec after blink
at 0.5 sec intervals
for 4 times". Repeat
that again.
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 Interchange inspection
The method of interchange inspection talked here is that two components
are interchanged which people often say. i.e. a fine component replaces a
suspected one. Judging whether there is problem about the performance of
the suspected component according to whether the problem reappears.
There are many elements which can be replaced with each other for test in
C8 model, for example:
 Front and rear proportioning solenoid in main hydraulic pump.
 Main pressure sensor of front and rear pumps in main hydraulic pump.
 9 pilot pressure sensors.
 1, 2, 7, 8 solenoid valve in solenoid valve set.
 3, 4, 5, 6 proportioning solenoid valve in solenoid valve set.
 Paddle switch in driving cab.
 Protective washer of the same current.

Besides, it can be extended to the interchange between assemblies, for

example:
 Interchange of main oil circuit of two hydraulic pumps.
 Interchange between servo valves of two hydraulic main pumps (Raiser,
adjuster).
 Interchange between two operating handles.
 Interchange between left and right tracking pilot pressure signals.
 Interchange between all kinds of pilot control pressure signals.
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 Daily maintenance & inspection
Before starting work every day:
 Check the controller and service meter.
 Check the level of coolant, fuel, engine oil, swing drive oil.
 Check the hoses and pipelines for leakage, twist or wear.
 Check for the general phenomena, noises, etc.
 Walk around to check the fasteners of the machine for
looseness or loss.
 If the machine is in trouble, repair it or contact the local
authorized dealer or Sany after sale service engineers
before operating.
 Lubricate the pins of the implement, swing gear, etc.
 Check the air cleaner for block or damage, clean up the
air cleaner or replace it.

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 Engine oil
Recommended engine oil is above API CF-4, SAE
15W/40.
 Check the engine oil level everyday.
 Engine oil initial replaced at 50 hours.
 Engine oil should be replaced every 250 hours.
 Engine oil filter should be replaced every 250 hours.
 Start the engine to warm the oil, but do not overheat the oil.
 Park the machine on the level ground.
 Lower the bucket to the ground, stop engine.
 Hang a tag “ Do Not Operate ” on the hydraulic lock in the cab.
 Drain the engine oil, remove the used engine oil filter.
 Install the new engine oil filter by hand until the seal contact the
filter base, turn the filter another ¾ to 1 turn with the belt wrench.
 Close the drain valve, fill new oil into the engine. Check the engine
oil level between the low mark and the high mark.
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 Gear oil, hydraulic oil
Gear oil maintenance interval:
 Swing drive oil
 Check the oil level every 250 hours.
 Replace the swing drive oil every 1000 hours.
 Final drive oil
 Check the oil level every 500 hours.
 Replace the final drive oil every 2000 hours.
 Hydraulic system:
 Inspect the level of hydraulic oil level daily.
 Replace the pilot oil filter every 500 hours.
 Replace the return oil filter every 500 hours.
 Replace the oil suction filter every 500 hours.
 Replace hydraulic oil every 2000 hours.
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 Hydraulic oil filters

Maintenance
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 Maintenance

For overseas dealer

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 Maintenance information
 Operation & maintenance manual: Never conduct any
inspection and maintenance work before you read and
understand the operation and maintenance manual.
 Hour Meter Reading: Record the hour meter reading daily.
Make sure whether it is time to perform the related
maintenance.
 Fuel / Oil contamination: Contamination will cause parts
damaged or system failed to work. Keeping the contaminations
away from entering the system is a key point when performing
maintenance.
 Preventing Materials Falling into the Machine: After the cover
was removed during the maintenance, make sure no nuts, bolts
or tools are left inside the machine. Failure to do so could result
in unexpected failure or damage to the machine, or accidents.
In case that any materials fall into the machine, remove it
immediately.
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 Maintenance information
 Welding Instruction
 Shut down the engine and wait for 1 minute before
disconnecting the battery negative (-) pole. If the ground
cable is connected to any electrical components (instrument,
connector, etc.), the instrument will be failed.
 Put the ground cable of the welding machine at least 1 m
(3.3 ft.) away from the place being welded.
 Choose the grounding point properly to avoid any seals or
bearings located between the grounding cable and the
welding point.
 Never use a grounding point in the vicinity of the work
equipment pin or hydraulic cylinder .
 Never apply more than 200V continuously.
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 Maintenance information
 Avoid Using Lubricants of Different Brands: Never mix
lubricants of different brands and/or grades together. If you
need to use the lubricant of another brand or grade, drain the
old lubricant completely and replace it with the new brand.
 Secure the Access Covers: When servicing the machine with
the access covers open, use a locking lever to secure the cover
to certain position. Otherwise, the cover can be swung close by
wind and cause bodily injury.
 Eliminate Air from the Hydraulic System: When any hydraulic
units have been repaired or replaced or any hydraulic lines
have been removed or installed, always bleed the air from the
system. For more information see "Eliminate Air from the
Hydraulic System.“
 Genuine Sany Parts And Lubricants: Always use the genuine
Sany parts and recommended Lubricants. Select machine oil of
suitable viscosity according to the ambient temperature.
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 Fuel system management
 To prevent the moisture in air from condensing in the fuel tank, fuel tank
must be refilled after each workday.
 Fuel injection pump is a precise component, which may not work normally if
the fuel contains water or other foreign materials.
 The sediment and water in the fuel tank and fuel water separator must be
drained before starting the engine everyday.
 Flush the fuel tank and the fuel system in case of any debris was found in
the fuel tank.
 The air in fuel system must be bled out in case that the engine runs out of
fuel or the fuel filter was replaced.
 The fuel can freeze below the specified temperature (especially lower than -
15℃ (5℉)).
 When fuel is used above the specified temperature, its viscosity and output
power will decrease .
 Preventing the foreign material from entering into the fuel when storing,
refilling the fuel, or doing the maintenance.
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 Cooling system management
 Precautions in the OMM must be followed when using antifreeze.
 Coolant is important to prevent corrosion and freezing. It is also necessary
in regions where no needs to prevent freezing.
 Sany machines are pre-filled with Shell Full-Effect Antifreeze 50/50, which
has excellent performance in anticorrosion, and anti-freezing, and can last
for one year or 2000 hours.
 Use distilled water to dilute coolant. Natural water, such as river water and
well water (hard water), contains many minerals which can easily scale in
the engine and radiator. Overheating can be occur due to the insufficient
heat exchange.
 Filled the cooling system too rapid will cause the air trapped in coolant
which can result in corrosion and also low coolant level.
 Overheating can be caused if the coolant level is low.
 If the engine is overheating, wait for the engine to cool down before refilling
coolant.

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 When required
 Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace
 Battery or Battery Cable - Inspect/Replace
 Boom Base Pins – Lubricate
 Bucket clearance - Inspect/Adjust
 Bucket Tips - Inspect/Replace
 Cab Air Filter (Fresh Air) - Clean/Replace
 Engine Air Filter Primary Element - Clean/Replace
 Engine Air Filter Secondary Element – Replace
 Fuses – Replace
 Radiator Core – Clean
 Screen (Fuel Transfer Pump) – Clean
 Track Adjustment – Adjust
 Window Washer Reservoir – Fill
 Window Wiper - Inspect/Replace
 Windows - Clean
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 Every 10 hours or daily
 Cooling System Level – Check
 Engine Oil Level – Check
 Fuel System Water Separator – Drain
 Fuel Tank Water and Sediment – Drain
 Hydraulic System Oil Level – Check
 Indicators and Gauges – Test
 Seat Belt – Inspect
 Track tension – Inspect / adjust
 Travel Alarm – Test
 Undercarriage - Check
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 Initial 50 hours
 Boom, Stick and Bucket Linkage – Lubricate
 Engine Oil - Replace
 Engine Oil Filter – Change
 Fuel System Filter – Replace
 Fuel System Priming Pump – Operate

 Every 50 hours or weekly maintenance:

 Boom, Stick and Bucket Linkage – Lubricate

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 Initial 250 H maintenance
 Fan Belt Tension- Inspect / Adjust.
 Air Compressor Belt Tension - Inspect / Adjust.
 Engine Oil And Oil Filter – Replace.
 Engine Valve Lash - Inspect / Adjust.
 Fuel Filter – Replace
 Fuel Water Separator - Clean.
 Swing Drive Oil - Change.
 Final Drive Oil – Change.
 Pilot Oil Filter – Replace.
 Hydraulic Return Oil Filter - Replace

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 Every 250 H or monthly
 Swing Bearing - Lubricate.
 Fan Belt - Inspect / Adjust / Replace.
 Air Compressor Belt - Inspect / Adjust /Replace.
 Engine Oil – Change.
 Engine Oil Filter - Change.
 Fuel Filter – Change.
 Fuel Water Separator - Clean.
 Swing Drive Oil Level - Check.
 Final Drive Oil Level - Check
 Air Filter – Inspect / Clean
 Breather – Inspect / Clean / Replace

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 Every 500 H maintenance
 Fuel Water Separator - Replace.

 Air Filter - Replace.

 Air Conditioner Fresh/Recirculation Filter – Inspect / Clean.

 Swing Pinion Grease Level - Inspect / Fill.

 Radiator, Hydraulic Oil Cooler, Air Condenser Fins - Inspect / Clean.

 Hydraulic Pilot Oil Filter - Replace.

 Hydraulic Return Oil Filter - Replace.

 Hydraulic Suction Screen – Inspect / Clean.

 Hydraulic Oil Tank Breather - Replace

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 Every 1000 H maintenance

 Battery – Clean

 Battery Hold-Down – Tighten

 Engine Valve Lash – Check

 Swing Drive Oil – Change

 Water Pump Bearing - Lubricate

 Engine Exhaust Pipe Clamps – Check

 Nitrogen Pressure in Accumulator – Check

 1000H maintenance included the 250H and 500H contents.

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 Every 2000 H maintenance
 Final Drive Oil - Change
 Hydraulic System Oil – Change
 Hydraulic Tank Screen - Clean
 Nitrogen Pressure in Accumulator - Check
 Alternator – Inspect
 Coolant – Replace
 Coolant should be replaced after one year or 2000H whichever
occurred first.

 Cooling System – Flush When Coolant Was Replaced.

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 Air cleaner
 Clean the air filter when required.
 Cleaning or replacing air cleaning after
engine was stopped.
 Clean the primary filter with compressed
air and blow from inside to outside.
 Replace the primary cleaners after cleaning
6 times or 6 months.
 Secondary air filter can not be cleaned and
should be replaced when the primary filter
was replaced.
 Inspect the clamp loosing of air hose. If
yes, tighten it timely.
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 Dusty working site
 Follow the step below when operating at the dusty
working site:
 When the air cleaner block warning siren sounds an alarm,
clean the air cleaner element in time.
 Clean the radiator core frequently and timely to avoid being
blocked, especially when the hex was used to mix the lime.
 Clean and replace the fuel filter frequently. Clean the
breather on the fuel tank cover frequently.
 Clean the electrical components, especially the starting
motor and the alternator to prevent dust from depositing.
 Move the machine to the place without dust when checking
or changing oil to avoid the dust dropping into it.
 Clean up the filter base before replacing the filter.
 Clean up the outer surface before removing cover when
doing repair or troubleshooting.
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 Replace coolant
 After engine was cooled down, remove the radiator cap slowly, drain
the coolant completely.
 Added the fresh water fully, run the engine at low idle 5 minutes and
the high idle 5 minutes. Drain water after engine was cooled.
 Added the coolant to radiator full properly, added coolant to the tank 3
properly. Run engine at low idle for 5 minutes and then high idle for 5
minutes to bleed air completely from the cooling system.
 Inspected and mark all the shrunken coolant hoses during engine
running. Replace all the shrunk hoses after engine was cooled.

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 Track tension
 Forward travel about 4 meters and
then stop the machine on the hard
ground.
 Measure the max distance between
the track top surface and the straight
ruler.
 Maximum distance “a” should be
between 10-30 mm.
 Pump grease into the fitting ② to
tighten the track.
 Loosen the nut ① to drain the grease
and loose the track.
 After the adjustment was done, move
the machine back and forth to check
if the tension was proper or not.
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 Before start inspection
 Inspect the coolant level, added coolant to the coolant
tank if required.
 Inspect the engine oil level, added the engine oil to the oil
pan if required.
 Drain water and deposit from the fuel water separator.
 Drain water and deposit from the fuel tank.
 Check the fuel level, added if required.
 Check the hydraulic oil level, added if required.
 Inspect for the loosed fasteners, such as bolts, clamps
and nuts.
 Check the electric function, such as lamp, horn, etc.
 Lubricate pins of implement.
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 Coolant level
 Coolant level should be between the
upper and lower mark of the coolant
tank when engine is working.
 Coolant tank is located in the rear of
the radiator service door.
 If the coolant is lower than the lower
mark, added coolant to the tank.
 If the coolant tank is empty, added
coolant to the radiator first, and then
add it into the coolant tank.
 Coolant should be changed every year
or 2000 hours whichever occurred
first.
 Flush the cooling system with fresh
water when the coolant was replaced.
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 Engine oil level
 Check the oil level before work everyday.
 Stop machine on a level ground.
 Check the oil level as soon as turn off the engine
will get a wrong reading. Stop the machine at
lease 10 minutes before checking.

 Take out the dipstick and clear up the oil on it

with a clean cloth, then insert it back.

 Take out the dipstick again and check that the

oil level should be between the marks.

 Refill oil through the oil filler if necessary.

 Be sure to use the recommended oil only. CG-4
SAE 15W-40 is recommended.
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 Electric circuit inspection
 Fuses were damaged or not? If yes, replace the failed fuse.

 Short or open phenomena existed? If yes, repair the failed circuit.

 Wire connectors loosed or not? If yes, tighten the connector properly.

 Inspect the starting and charging circuit for abnormal phenomena.

 Cleaning deposit on the connector of battery, starting motor and

alternator.

 Water should be avoid used to clean

the dust or other deposit on the
starting motor and / or alternator.
 Turn on the start key switch to check
whether the accessory electric circuit
worked normally, such as the lamp,
wiper, horn, lighter, and so on.
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 Fuel water separator
 Water could be formed in the storage tank, and then entered into the fuel
system together with fuel when the tank was filled.
 Water can also formed in the fuel system. For example, after one days work,
fuel in the tank was almost run out. Fuel tank was hot. If the tank was not
filled timely, moisture in air will condensed along the inner surface of the
tank .

 Drain water is a job which can not be avoided.

 Loose the drain valve to drain the water and
deposit. After draining, valve should be finger
tighten properly.
 Drain the water and deposit from the fuel
water separator before work everyday, or
anytime as required.
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 Drain from fuel tank
 Drain water and deposits from the
fuel tank before work everyday.

 Loose the drain valve, which located

on the bottom of the fuel tank, to
drain the water and deposits.

 After all the water and deposit were

drained, close the drain valve
properly.

 Fuel tank should be cleaned with the

clean fuel if excessive deposit was
found in the fuel system after a long
time using.

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 Check the hyd oil level
 Stop the machine on a hard level ground, retract all the cylinders’
rod as below image indicated.
 With the hydraulic control lever in unlock position, operated all the
pilot control levers to release the residual pressure in the hyd
system.
 Hyd oil level should be between the mark “H” and “L”. Hyd oil level
gauge is located in the main hyd pump room just beside the
hydraulic oil tank.
 If the hyd oil level is lower than the low mark, added hyd oil to the
hydraulic oil tank through the port F.
 If the oil level is above the high mark, drain the excessive hyd oil
from the tank.

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 Replace engine oil
 Start engine to warm up oil. And
then stop machine on a level ground.
 Hang a forbid tag of “Do Not
Operate” on the hydraulic control
lever in the cab.
 Using a basin or a barrel to collect
the used engine oil.
 Open the cock valve or drain plug,
drain oil thoroughly.
 Inspect for metal powder or
chipping in the used oil and deposit
on the magnet part of the drain plug.

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 Replace engine oil filter
 Oil filter located on the right side of engine or
the hydraulic pump room.
 Remove the oil filter when draining oil.
 Clean the parting face of the filter base,
lubricate the new filter seal with clean oil and
spin on the filter tightly by hand.
 Turn ¾ to 1 turn by the belt wrench.
 Close the drain valve or the plug. Added
proper amount of new oil into engine.
 Crank engine without start to feed the main
gallery and oil filter. Run the engine at low idle.
Stop it for 5 minutes.
 Check the engine oil level which should be
between the low and high mark of the dipstick.
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 Replace fuel filter
 Clean the fuel water separator properly.
 Clean the filter base to prevent dust or debris
dropped into fuel system.
 Remove the used fuel filter with the belt wrench.
 Clean the parting face of the fuel filter base.
 Lubricate the new filter seal and spin on by hand.
until it contact with the filter base. Turn ¾ to 1
turn by belt wrench.
 Loose the air bleed plug, operate the priming
pump to feed the fuel system and bleed air from
fuel system.
 Tighten the air bleed plug properly, lock the
priming pump. Start the engine and run it at low
idle for 1 minutes.
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 Swing drive oil level-Check
 Stop the machine on a hard level
ground.
 After the machine was cooled down,
pull out the dipstick G.
 Clean the oil on the dipstick G with a
clean cloth or paper.
 Put back the dipstick.
 Take out the dipstick again to check
the oil level which should be between
the low mark and the high mark. Oil level range
 If oil level is lower than the low mark,
add oil through the F.

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 Replace fuel water separator
 Remove the used separator with belt wrench and discard it.
 Replace the seal and install the new fuel water separator.
 After replace the fuel filter, operate the priming pump to
feed the fuel system and bleed air out.
 Tighten the air bleed plug, lock the priming pump, start the
engine to check for the fuel leakage.

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 Swing gear grease - Check
 Below two images indicated the position which to add the
grease to the swing gear.
 Remove the bolts and cover, insert a ruler vertically to check
the grease height which should be 14 mm above.
 If the grease height is lower than 14 mm, add grease to the
swing gear.
 If the grease is emulsified, remove and clean all the failed
grease, find out the root cause and repair it, add the proper
amount of new grease to the swing gear.

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 Debris on the radiator core
 Loose bolt ③, remove the screen ②,

loose bolt ⑤, remove the screen ⑥.

 Using pressure air or water to clean the

mud, dust, or the fade straw sucked on

the cores.

 If the machine is used in a dusty jobsite,

clean the machine timely.

 If the radiator is partially blocked by the

debris, such as mud, leaf, or fade straw,

overheating failure will be resulted.

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 Air conditioner filters
 Loose the wing nut ①, take out the
recirculation cycle air filter of the A/C.

 Open the side cover of the cab to take out

the fresh air filter of the A/C.

 Clean the A/C air filter with the pressure air

or replace with a new one if the filters was
failed or can not be cleaned.

 If the air conditioner was used when the

machine worked in a dusty jobsite, A/C air
filters should be cleaned timely as required
to ensure the A/C worked normally.

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 Swing Bearing - Lubricate

1. Stop the machine on the hard level ground

and lower the bucket on the ground.

2. Using a grease gun to fill grease into the

fittings.

3. Start engine, rotate the upper frame 30o

degree, lower the bucket on the ground.

4. Insert grease into the fittings.

5. Repeat step 3 and step 4 until the machine

rotates for 180o from the initial position.

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 Hyd Tank Breather
 The max service interval must not exceed 500 H.
 Use a brush to remove the contaminants and
then flush it with kerosene.
 Using pressure air to blow the element [2] from
inside to outside.
 If the element [2] is aging or damaged, replace
the breather valve.
 After cleaning, place it at where there is good
ventilation. Restore it after drying.
 When installing the hexagonal nut [5], tighten it
to the torque (10 - 14 N·m).
1. Valve body 2. Filter element 3. Filter element cover 4. Washer seal
5. Hexagonal nut 6. Washer seal 7. Butterfly nut
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 Replace the pilot filter
 Stop the hex on the flat ground, and lower the bucket
to the ground.
 Release the residual pressure in the hydraulic system
 Loose the hydraulic tank filler cap slowly to release
the pressure in the hydraulic tank.
 Turn the filter shell ④ counterclockwise with wrench
and remove it.
 Screw down the pilot filter element ③.
 Clean up the parting face of filter base ①
 Clean the filter shell ④ and screw, then install
the new pilot filter element on filter base.
 Turn the filter shell ④ clockwise until it contact with
the filter base, then tighten filter shell to 39 N·m
(28.8lb·ft) .
 Clean up the oil dropped around.
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 Replace hyd return oil filter
 Stop the hex on the flat ground, and lower
the bucket to the ground.
 Release the residual pressure in the hydraulic
system.
 Loose the hydraulic tank filler cap slowly to
release the pressure in the hydraulic tank.
 Loose the filter cover bolts gradually, When
moving away the last two bolts ①, press the
filter cover ② to overcome the spring force.
 Open the filter cover ③ and remove the
spring ④ and filter element ⑥.
 Discard the used filter element, install a new
filter element and spring ⑥.
 Install the return oil filter cover and tighten
the bolt ① to 49 N·m (36lb·ft) .
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 Change the swing drive oil
 Loosen the drain valve [P] to drain the used oil to a container.
 Close the drain valve [P], remove the filler cap [F] and fill with
new oil.
 Pull out the dipstick [G] and wipe off the oil.
 Insert the dipstick [G] completely into the filter tube.
 Take out the dipstick [G] and check whether the oil level is
between the H and L marks.
 After checking the oil level or refilling the oil, insert the
dipstick [G] into the hole and restore the filler cap [F].

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 Change the final drive oil
1. Stop the machine on a flat ground to
let both sides final drive have the
position as the illustration indicated.
2. Clean up mud around the plugs.
3. Use a inner hexagon spanner to
remove all the three plugs, and
drain the used oil into a container.
4. Replace the drain plug seal and
install the plug.
5. Add new oil from the filler plug hole
until the oil flows out from the level
plug hole.
6. Replace seals of the filler plug and
the level plug and install the plugs.
7. Tighten three plugs correctly.
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 Long term storage
 Clean all parts of your machine, and then store your machine
indoors. If you have to store your machine in the open air,
choose a level ground and cover your machine with canvas.
 Lubricate your machine and change its oil before storing it.
 Disconnect the battery's negative terminal and reinstall its
cover, or remove the battery from the machine.
 Use Sany genuine, efficient 50/50 coolant to prevent rusting
during the long term storage.
 Operate your machine and drive it for a short distance once a
month. This can help re-apply oil film on parts and components.
Meanwhile, charge the battery of your machine.
 Oils maybe deteriorated after a long time storage, Perform the
proper maintenance before starting.
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 Failure cases
Serial
Report by Model SMU User name
Failure case number
SY200 90h Huai Yuan
Problem Root cause Failure date Report date
Low power Fuel filter plugged 05-06-23 05-06-24
Conclusion：
1. User should pay attention to fuel quality.
Phenomena：Engine stalled, low power.
2. Operator should do the maintenance timely and
properly.

Facts found：
Fuel quality is poor, excessive debris
was found in the fuel filter.

Solution：
Replace the fuel filter, clean up the
fuel supply circuit, replace with the
certified fuel. Problem solved.

Andy Liu 92
 Failure cases
Failure case Model Serial SMU User
number

SY220 1144H

Topic Root cause Failure Inspect Repair Dealer

date date date
Heavy black Fuel quality 2005.10. 2005.10.1 2005.10.1
smoke poor 16 6 7
Phenomena: heavy black smoke emitted out Experience: failure facts was the best
under rated load. proof to convince the customer. Fuel in
the tank of normal excavator was
Troubleshooting process: added to this machine and problem
(1). No trouble code. solved this time.
(2). Fuel filter was not plugged.
(3). Air cleaner and turbocharger normal.
(4). Fuel quality was poor with dim color.

Solution: Replace with the certified fuel.

Tested and proved problem solved.
Andy Liu 93
 Failure cases
 Failure phenomena: heavy black smoke, and lack of power.
 Root cause of the failure: air filter was heavy blocked,
insufficient air can be supplied to the engine.

 Conclusion: user should be trained how to maintain the air

filter properly during the new machine delivery service.

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 Electrical system

Andy Liu
 Electronic ctrl system

Andy Liu 96
 Engine ctrl system

ENG

Andy Liu 97
 Electrical schematic
Major feature of the electrical schematic:
 Schematic is the major form of the electric
drawing.
 Electric parts or components were represented by
symbol, shape or the structure of the electric
components was not reflected on the schematic.
 Word and number code was marked aside the related
symbol.
 Electrical components were arranged as the function
and current sequence on the schematic.
 No size was needed to be marked on the schematic.

Andy Liu 98
 Electrical schematic
 Electric components and wires were the major
contents to be expressed on the schematic.

 Symbols such as graph symbol and word symbol

were the major element consist of a electrical
schematic.

 Electric components were drawn as it was in

normal status. Normal status means that
components were not in working status or
position.

 Schematic had a tighten relationship with the

major projects or the auxiliary projects.
Andy Liu 99
 how to read electric schematic
First of all, read the title of the schematic. make clear the
components name, the schematic name, contents, function,
and so on.
Then, read and understand the technical notes and
requirements carefully.
At last, research the schematic in detail:
 How many components consist of this schematic.

 Functions of all the components.

 Relationship among the components

 Read and understand the main circuit first and then the

auxiliary circuit with the sequence from left to right and

from top to bottom.
 Understand the logic sequence of the components

operation.
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 Electrical system
Electrical circuit is generally divided into main
circuit, monitor circuit and control circuit.

 Main circuit: The operation circuit of engine and

auxiliary equipments.

 Monitor circuit: The monitor circuit includes display,

sensor and pressure switch, which is used to
display the operating condition of the machine.

 Control circuit: The control circuit includes main

controller, relay, solenoid valve, etc, which is
mainly used to control the engine, main pump and
other equipments, etc.
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 Main circuit
The main functions and circuits are as follows:
 Power source circuit --- Provide power to all the electrical
systems of the machine. [Key switch, battery, fuse (fuse
box), battery relay]
 Accessory circuit --- It starts to work when the key switch
turns to ON position.
 Pre-heating circuit --- Help the engine start in cold day.
[Key switch, pre-heating control switch, pre-heating relay,
pre-heater]
 Starting circuit --- Start the engine. [Key switch, starting
motor, starting relay]
 Charging circuit --- Charge the battery. [Alternator,
adjuster]
 Engine shutdown circuit --- Stop the engine by shut-down
motor. [Key switch, stopping relay, shut-down motor]
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 Key switch: off

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 Key switch: off

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 Accessory circuit

When the key switch is turned to ON position, terminals #30

and #15 are connected.
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 Accessory circuit

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 Armrest box operating panel RH
When working
light switch is
turned on, #33
energized, boom
light and platform
light come on.

When the wiper

switch is turned
on,
 #35L energized,
wiper is working
in the low range,
 #35H energized,
wiper is working
in high range.

When sprinkler switch is turned on, #37 is energized, washing motor operates,
water pump pumps and sprays water on the windshield. This is an automatic reset
switch, the duration of spraying water is controlled by the time length of pushing
switch.

When dome light switch is turned on, #71 is energized dome light comes on.
Andy Liu 107
 Preheating circuit

ion
s it
po
A T
H E
to
ed
n
tur
a s
h w
itc
sw
e y
k
the
en
Wh

Pre-heating lasts 10S is enough, then turn off the pre-heating switch.
Andy Liu 108
 Starting circuit
When the key
switch is turned
to START
position, the
terminals of key
switch #30, #15,
#17 are
connected.
The battery relay
is turned on by
the current from
terminal #15.

Battery current
flows to starting
motor terminal B
& starting relay
terminal B
battery relay.

Based on the premise that pilot handle is locked, key switch terminal #17 connects
to starting relay terminal SW, so that the current flows through the starting relay coil.
Starting relay is turned on, current flows from starting relay terminal S to starting
motor terminal S. Starting motor is energized and start to crank engine.
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 Starting circuit

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 Shutdown circuit

Turn the key switch from ON to OFF, the current between the terminals #30 and #15 is cut
off, the stopping relay loses power. The stopping motor cuts fuel circuit to stop the eng.
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 Charging circuit
After the
engine
was
started,
release
the key
switch
and it
turns
back to
the ON
position
automati
cally.

The alternator starts to generate electricity, the current from

alternator terminal B flows to the battery and charges it
through the battery relay. The voltage of alternator terminal L
increases, and the indicator goes off.
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 Monitor circuit
Main functions of monitor
circuit are as follows:
 Display circuit: display the
machine working parameter
collected by main controller.
 Pressure sensor circuit:
1. Voltage type sensor.
2. Sensors change the
output voltage according
to the hydraulic pilot
pressure.
3. Outputs voltage signal (0
~ 5 V) of voltage to main
controller.
4. Controller converts the
voltage value to kilogram
value and transmits it to
display through CAN bus.

Andy Liu 113

 Monitor circuit
Engine sensor circuit
 Engine speed sensor: Hall type
sensor, which counts the pulse
of the flywheel teeth number.
 Coolant temperature sensor:
Resistance type sensor, it
changes resistance value with
the variation of coolant temp.
 Oil pressure sensor: Switch type
sensor, it is disconnected when
engine oil pressure reaches a
certain value.
 Fuel level sensor: Resistance
type sensor, resistance changes
as per fuel level varied.
 High water temperature sensor:
Switch type sensor, it is turned
on if the water temperature is
too high.
 Feedback sensor: Voltage type
sensor, it is changed when
controller drives accelerator
motor rotate.
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 Control circuit
Control circuits and
functions are as follows:
 Engine control circuit:
1. Choose the working
mode by the accelerator
gear knob and the
button on the display
to control the engine
speed.
2. The engine working
condition can be
monitored by water
temperature sensor,
fuel position sensor and
speed sensor.

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 Control circuit
 Pump and valve control circuit:
1. When machine is working,
main controller controls the
pump output power as per
the pilot pressure parameter
of each circuit.
2. Front and rear pump
proportional solenoid valve:
controller outputs PWM
signal to control the opening
of solenoid valve and adjust
the output hydraulic oil
amount.
3. Boom priority solenoid valve,
bucket confluence solenoid
valve, high speed driving
solenoid valve, swing
priority solenoid valve: it
operated as per its signal to
achieve the purpose of control.
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 Electric components
1. Battery Breaker Wire
2. Battery Ground Wire
3. Battery
4. Battery Connecting Wire
5. Working Light
6. Battery Relay
7. Hyd Oil Temp Sensor
8. EC Motor & EC Sensor
9. Engine Speed Sensor
10. Rear Pump Proportion
Valve
11. Front Pump Proportion
Valve
12. Engine High Temp
Switch
13. Coolant Temp sensor
14. Engine Frame
Connecting Wire
15. Portable Working Light
16. Solenoid Valve
17. Cab Wire Harness
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 Safety relay

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 Battery
1. Connect the multi-meter negative probe to the ground, and
check the voltage between the battery positive terminal
and the frame. The normal voltage is not below 24 V.
Otherwise, the battery needs to be charged or replaced.

2. Start the engine.

Check the voltage between battery positive terminal and the frame.
The normal voltage is 26 ~ 28 V.
Check the charging system if the voltage is abnormal.

 Voltage is not below 24 V. However,

sometimes it can be manifested as
the so-called "virtual current" for the
internal resistance is too high. At
this time, measure the voltage
during starting and it indicates that
the battery is lack of electricity when
it is below 18 V.

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 Alternator
Operating principle:
In the rotor winding, the
changeable magnetic field
generated by the engine
rotator driven by a belt can
generate an alternating
current which outputs the
power of about 24 V under
the control of the adjuster
and rectification system.

Quality identification: If the power is lack of electricity during

normal use. Check if the engine functions normally:
 Dismantle the connection on the post "B", start the engine, measure
the voltage at this post.
 Alternator should be failed when there is no 24 V voltage.

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 Shut down motor
Operating principle:
When the power supply is turned off by the starting
switch, the shut-down motor (Solenoid valve) drives
the shut-down handle on the main diesel oil pump by
the pull cable to cut off the fuel so that the engine
can be shut down.

Quality identification:
As for the electrical
equipment, it can be
judged by the method
of the solenoid coil.
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 Accelerator motor
Operating principle: According to the signals coming from
the controller, the accelerator motor pulls the accelerator lever
on the fuel pump by the accelerator cable so that the fuel
supply amount (Speed) can be changed.

Quality identification: It can be considered that there is no

malfunction in the motor if:

 There is no short/open circuit

inside the coil.
 No short circuit between the
coil and the housing.
 Meanwhile, the coil resistance
value is within the specified
range.
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 Relays
Operating principle: Control the
"strong current" with the "light
current" :

 When ctrl power is energized,

the magnetic field is generated
in the coil.

 Contacts were attracted to be

in touch state so that the
"strong current" can be
energized.

Quality identification:

1. Check the coil when the control signal is energized but the relay has no motion.
Generally, wire 1 and 2 are the winding union. There is resistance at the
positive direction of wire 1 and 2, diode conduction at the negative direction.

2. Check the contacts when the control signal is energized and the relay has
motion but no output. Generally, union 3, 5 are normally closed, and union 3,
4 are normally open.

3. Replace with the trouble-free relay for test.

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 Troubleshooting

Familiar with the electric system operation, work

out a solution when a failure occurred:

 Do not dismantle blindly everywhere. Grasp the failure

phenomena, the process, and the root cause first.

 Familiar with electrical system operation of the

equipment. Analysis the specific circuit, make clear the
relationship between each components.

 Combine with your working experience, troubleshoot

carefully and work out a repair solution.

 No more failure occurred due to your repair.

Andy Liu 124
 Troubleshooting
Check the mechanical failure first, and then
electrical circuit.

 Most of today’s electrical equipment, mechanical and

electronic are melted deeply. Mechanical failure will
affect the electronic usually. Which result in the
electric components failed to work accordingly.

 Do not be confused by the surface phenomena when

a failure occurred. Excluded the possibility of a
mechanical failure first, and then do the failure
analysis of the electric circuit.

Andy Liu 125

 Troubleshooting

Troubleshooting process: complex solution

should always be arranged later than the
easy one:

 Easy methods first, and then the complex accurate

way followed. Your experiences way should be
used first in the troubleshooting.

 Simple problem first, and then the hard one. The

intuitive, obvious, simple and common problem
should be solved first. And then concentrated on
the rough problems.

Andy Liu 126

 Troubleshooting

Frequent problem first, and then the seldom problem .

Frequent problem was easy to solved since it occurred
frequently and many experience was accumulated.

Concentrated time and spirits on the difficult problems.

After the simple and frequent problem was solved
quickly.

When doing the electrical troubleshooting for the hex,

hex should be power off to the repair.

When doing the welding on a hex, battery cable should

be disconnected.

Andy Liu 127

 Troubleshooting
External first, and internal then.
 Switches, sensors, and indicators which exposed or
unsealed should be checked first before the internal
components sealed or under the cover of the
equipment to avoid unnecessary dismantle.

Power off test first, and power on test later.

 When an electrical failure occurred, immediate
electrified test may cause further damage or short of
components.

 Before the power on test was carried out, resistance

should be measured, make sure no more damage will
be occurred.
Andy Liu 128
 Troubleshooting

Communal circuit first, then the specific circuit.

 If the communal circuit failed, voltage, current, and

signal can not be transferred normally. The specific
circuit will be failed to work accordingly.

 For example: if there is a problem existed in the power

supply, electrical system can not be operated normally.
specific circuits will be failed to work accordingly.

 Troubleshoot the communal circuit first will help you get

rid of fault accurately and rapidly.

Andy Liu 129

 Troubleshooting
Summarize experience after problem was solved.

 Electrical problems were always varied from one to one.

After troubleshooting successful, experience should
always be summarized.

 Write down the whole story of the problem:

 Failure phenomena.
 Root cause of the failure.
 Process you solve the problem.
 Skills you used.
 Knowledge you got from the repair.

 Study the system operation, review the whole process

of troubleshooting, and enhance your skill.
Andy Liu 130
 Hex electric control system

History of hex control system:

 Mechanic lever control.

 Hydraulic control

 Electric control

 Hydraulic servo control

 Wireless remote control

 Electric-hyd proportional control

 Computerized control system.

Andy Liu 131

 Hex electric control system
Hex electrical control system consist of:
 Input components: temperature sensors,
pressure sensors, speed sensors, switches and
so on. Signals were pick up and send to
controller.
 Controller: electronic power system EPS. Accept
and treat the input signal and then send
signals to the output components.
 Output components: injectors, gauges,
solenoids, governor actuator, servo valves, and
so on. All these components are all the actuator
just like the cylinder, motors, hyd pump.

Andy Liu 132

 Electronic system

Key function of the electronic system:

1、Engine speed control

2、Main hydraulic pump power control.
3、Electric energy save control.
4、Auxiliary electric system.

Andy Liu 133

 Engine speed ctrl
1、Dial switch located on the right console in the cab.

Andy Liu 134

 Engine speed ctrl
2、EPS controller located in the cab behind the seat.

Andy Liu 135

 Engine speed ctrl
3, Governor actuator is installed in the main
hydraulic pump compartment.

Andy Liu 136

 Engine speed ctrl
Engine speed control system operation:
 Dial switch changed, the electrical potential changed.

 The changed potential was inputted into the

controller EPS.

 EPS controller output a pulse signal to the governor

actuator.

 Governor actuator was driven to change the engine

speed.

Dial
Dialswitch
switch EPS
EPScontroller
controller Governor
Governoractuator
actuator Engine
Engine
Andy Liu 137
 Pump power ctrl

1. There are two pressure sensors on the main

hydraulic pump:
A. Front pump delivery pressure sensor

B. Rear pump delivery pressure sensor.

Delivery
Deliverypressure
pressuresensor
sensor

Andy Liu 138

 Pump power ctrl

Pressure sensor was used to pick up oil pressure

signal. The picked up oil pressure signal was then
transformed into electric signal and sent to the
controller.
Andy Liu 139
 Pump power ctrl
2、EPS controller located in the cab behind the seat.

Andy Liu 140

 Pump power ctrl
3. There are two proportional solenoid valves on
the main hyd pump:
 Front pump PRV.
 Rear pump PRV.

Front Rear
Rearpump
pumpPRV
Frontpump
pumpPRV
PRV PRV

Andy Liu 141

 Pump power ctrl
System operation – pump power control
 Oil pressure signal picked up by pressure sensor, reflect
the working load and pilot valve’s travel distance from
neutral, was transformed into electric signal and send to
the machine controller.

 Controller calculated out the power that pump should

output and sent proper current to the proportional
solenoid valve of the pump.

 Pump servo valve changed the angle of the pump

swashplate. Pump power changed as requirement.

Andy Liu 142

 Electrical energy save ctrl
1、Sany hex has AEC function:
a. Pilot valve return to neutral position for more than 5 seconds.
b. Pressure switch detected the pressure signal and sent an
electric signal to controller EPS.
c. Controller sent a signal to governor actuator and drop engine
speed to 1400 rpm. Energy was saved and noise was reduced.
d. Any of the pilot valves were moved from neutral position.
Engine speed will be restored rapidly.

Pilot valve Pressure sw Controller Governor actuator Engine

Andy Liu 143
 Electrical energy save ctrl

2、Sany hex has four kind of working modes:

Working mode
a. Standard mode. 90% rated hp.

b. Light mode. 80% rated hp.

c. Break mode. 90% rated hp.

d. Heavy mode. 100% rated hp.

Andy Liu 144

 Electrical energy save ctrl

3、Engine overheating protection:

a. If coolant temperature up to
warning range, working
mode shifted down one
level automatically.

b. If the coolant temperature

up to second level alarm,
engine speed dropped to
1400 rpm to protect engine.
Andy Liu 145
 Auxiliary function

1. Circuit breaker is located in the storage box where

the battery was installed. If it failed, the whole
machine will have no electric power supplied.

Andy Liu 146

 Auxiliary function

2. Four solenoids are installed on the pilot manifold:

a. hyd lock solenoid.

b. pilot boost solenoid.

c. travel solenoid.

d. backup solenoid.

Andy Liu 147

 Auxiliary function

3. Battery is located in the storage box. Refer to below

photos. Two batteries are series connected.

Andy Liu 148

 Auxiliary function
4. Hydraulic lock switch is located at the bottom of the
hydraulic control level. When this switch was closed,
electric power was sent to the hydraulic lock solenoid
located on the pilot manifold.

Andy Liu 149

 Monitor

Andy Liu 150

 Monitor

Old type monitor New type monitor

Andy Liu 151

 Auxiliary function

• Pre-heat: preheat the inlet air before starting in cold days.

• Off: power off.
• On: machine was powered on. Engine can be started or not.
• Start: starting engine.
Andy Liu 152
 Engine & pump ctrl system

• H mode: 2200 rpm

• L mode: 1950 rpm

• S mode (B mode control, 2150 rpm)

• Automatic idle control (1400 rpm)

Andy Liu 153
 Electric sys operation
Electronic system has following functions:

 Carry out dyno modulation to hydraulic pump

automatically as per the working load.
 Pump and engine co-operated properly. Engine had
suited power output for hydraulic pump.
 Travel speed can be selected.
 Four kind of working modes can be selected.
 AEC function: automatic engine speed control.

 Fuel was saved with the same productivity compare

with the competitor.

Andy Liu 154

 Engine speed calibration
 Three methods are used to calibrate engine speed
according to different controllers:
1. SEHC by Sany: calibrate by operating monitor.

2. KCM controller: calibrate by using a setter.

3. EC-7 controller: calibrate by using a short plug.

SEHC KCM

EC-7

Andy Liu 155

 Engine speed calibration: SEHC
 This calibration method can be used for the Sany hyd
excavators with following configurations:

1. Sany controller SEHC + Sany GPS + Germany Monitor. Such

as SY135C8、SY235C8、SY230C8、SY420C、SY460C、SY425C、

SY465C、SY700C、SY850C、SY230R、SY310R、SY420R、SY460R

and so on.

2. Sany 5I monitor + Sany controller SEHC. Such as SY135C8、

SY335C8、SY365C8、SY235C8、SY465C, and so on.

3. Sany 3I monitor. Such as SY55C、SY65C、SY75C、SY95C, etc.

Andy Liu 156

 Monitors
 Identification: There is an Encoder button at the right lower
of the Germany monitor while Sany monitors have not.

Andy Liu 157

 General method
 General method of throttle position calibration:
1. Set the working modes as H. (Note: SY55C/SY65C/SY75C/SY95C set as S.)

2. Rotate the throttle switch counterclockwise to the end to get the position “0”.

3. Push the calibration button to enter the calibration status.

4. Rotate the throttle to position 1, the displayed throttle position will be changed
to position 1 two seconds later. The position 1 calibration finished.

5. Calibrate 2→3→4→5→6→7→8→9→10→11 throttle position one by one as

above step described. A red √will be displayed after all the positions were
calibrated successful.

6. Push again the calibration button to exit the calibration status.

 For SY335C8/SY365C8 hex, the backgrtound color of the calibration

button will change from red to blue after the calibration complete
successfully, and existed the calibration automatically.
Andy Liu 158
 General method
 General method of engine speed calibration:
1. Select the H working mode, and shut off the AEC function.
2. Set throttle at position 1. ( The minimum throttle position is 0)
3. Start the engine.
4. Press the engine speed calibration button to enter the engine
speed calibration status.
5. When the displayed speed is stable and within ±10rpm of the
specification, push the ENTER button. Position 1 completed.
6. Increase one step of the throttle switch to next position.
(SY335C8/SY365C8: system auto complete the calibration.)
7. Repeat step 5 and step 6. Complete the speed calibration for all the
throttle positions.
8. Push down the stop button after all the throttle positions are
calibrated to exist this engine speed calibration. SEHC
Andy Liu 159
 Engine speed calibration: KCM

Auto idle

Andy Liu 160

 Engine speed calibration: KCM
Note: Input the maximum speed of the engine in various
work modes as the standard data for the engine speed
control.
1. Calibrating steps for the positive flow excavator speed:
A. Choice for fixed point of accelerator motor flexible shaft.
B. The maximum speed calibration of H, S, L and the A/I speed calibration.
C. Turn the dial on the setter counterclockwise to the end.
D. Turn the power off.
E. Set the setter as "MONITOR MODE", and then power up to inspect the
calibration results.
a) Pull up the memory SW: calibration mode
b) Pull down the memory SW: monitor mode

2. Instructions for accelerator motor flexible shaft fixed point selection

A. Loosen the accelerator motor flexible shaft retaining nut.
B. Connect the setter with the vehicle body wire plug well.
C. Set the setter as "CALIBRATION MODE", and turn the dial on the setter
counterclockwise to the end.
D. Power up.
Andy Liu 161
 Engine speed calibration: KCM
E. Switch the monitor to the "ACCELERATOR CALIBRATION ASSIST" screen.
F. Adjust the dial slowly to make sure that the display of the accelerator
position is 3.70 V; And pull the accelerator rocker to the high speed position
and fix the accelerator flexible shaft.
G. Adjust the knob on the upper right of the setter counterclockwise to the end,
the accelerator motor flexible shaft is released at the moment and starts the
engine.
H. Adjust the dial slowly and examine the accelerator feedback position by the
display. When the engine speed is 2230 rpm, the accelerator motor
feedback position should be 3.70 V.
I. If the accelerator motor feedback position is 3.70 V and the speed is below
2230 rpm at the time, tighten the accelerator motor flexible shaft fixed
position; If the accelerator motor feedback position is 3.70 V and the speed
is more than 2230 rpm at this time, loosen the accelerator motor flexible
shaft fixed position.
J. Adjust the engine speed to the lowest, turn the power off. Position of the
accelerator motor flexible shaft is now suitable. (Finished till this step)

3. Instructions for each speed calibration:

A. Connect the setter with vehicle body wire plug well.
B. Set the setter as "CALIBRATION MODE", and turn the adjusting dial on the
setter counterclockwise to the end.
Andy Liu 162
 Engine speed calibration: KCM
C. Start the engine.
D. Adjust the dial and adjust the speed to the maximum in the current
mode such as the maximum speed in H mode is 2200 rpm.
E. When the key in H mode is pressed, LED digit tube and LED indicator
will flash which means controller is storing data and will be finished after
5 seconds, and do not do any operations while storing data; The current
data is considered as the maximum speed in this mode.
F. Adjust the speed to the maximum speed of 2150 rpm in S mode. When
the key in S mode is pressed, LED tube and indicator will flash which
means controller is storing data and will be finished after 5 seconds, and
do not do any operations while storing data; The current data is
considered as the maximum speed in this mode.
G. Complete the speed calibration for L = 1950 rpm, A/I = 1400 rpm in
order according to the description of steps 5, 6.
H. Adjust the speed to the lowest.
I. Turn the power off.
J. Set the setter as "MONITOR MODE" and power up to start the engine;
confirm that the maximum speed calibration is correct in each mode.
(Finished till this step)
Andy Liu 163
 Engine speed calibration: KCM
The accelerator motor flexible shaft position must be selected well firstly,
and then the speed calibration can be done. Otherwise discrepancy will
occur between the complete vehicle performance and the design target.

When the speed of H11 is 2200 rpm, the accelerator motor feedback
position is about 3.50 V. When the excavator has problems such as slow
action, examine whether there is much deviation of this corresponding
relationship.

Be sure to perform the engine speed calibration if the following repair

was done:

After removing or replacing the engine.

Engine control steel cable or EC motor.

After replacing MC.

The engine speed calibration system is not included in the complete

vehicle system, please contact your supplier if necessary.
Andy Liu 164
 Governor calibration: EC-7
When to do the calibration of governor
actuator?
 Governor actuator was replaced.
 EC-7 controller was replaced.
 Engine speed was incorrect or instable.
If engine speed tolerance was within ±30
rpm at each dial position, no needs to do
calibration. Otherwise, calibrated it.
Governor actuator can be calibrated by EC-
7 controller automatically. Refer to the
following steps:
Andy Liu 165
 Governor calibration: EC-7
1. Open the box cover behind the driver seat.

2. Put the dial switch at No.1 position and start engine.

Select the working mode as H.

3. Click the “system” on the monitor, enter to check engine

speed. If the speed was out of the range 900 – 1100 rpm,
governor lever needs the manual adjustment.

4. Insert the shorted plug into the socket, or short the wire
809 and 810 directly with a wire.

5. Increase dial position gradually to 11, 2 seconds stayed

for each dial position. Engine speed should be 2200 rpm
stable at position 11.
Andy Liu 166
 Governor calibration: EC-7
6. Decrease dial position gradually to 1, more than 1 second
should be stayed for each dial position.
7. Remove the calibration plug installed in step 4.
8. Check engine speed was within specification at each dial
position.
9. Click on the monitor and return to primary screen.
10. Make sure engine speed at each dial position was normal.
11. If engine speed was abnormal in the above step, repeat
the calibration started from step 4.
12. Close the cover behind the seat and stop engine.
 Electronic controlled engine and SY310C1 can not be
calibrated.
Andy Liu 167
 Governor calibration: EC-7

Calibration plug

Andy Liu 168

 Hydraulic system

Andy Liu 169

 Hydraulic system

NFC hyd system:

PFC hyd system:
 Front pump delivery pressure
sensor and control pressure  Front pump delivery pressure
sensor. sensor.
 Rear pump delivery pressure  Rear pump delivery pressure
sensor and control pressure sensor.
sensor.  Nine pilot pressure sensors.
 NFC pressure sensor.
Controller sent a signal to PRV which adjusted pump displacement.
Andy Liu 170
 Major components

Andy Liu 171

 Hydraulic system

Hydraulic system features:

 Two pumps, two circuits.
 Constant horsepower control.
 Four working modes.
 NFC: Neutral Flow Control system.(C8 before)
 Two pumps varied their displacement under the
constant total output horsepower.

Constant output hp control means total output hp

of two pump keeps constant.

Andy Liu 172

 SY205C/SY215C Hyd schematic

Andy Liu 173

 1 - Overload Valve (Arm)
2 - Arm Regeneration Valve
3 - Arm Holding Valve
4 - Bucket Confluence Check V
5 - Load Check Valve (Arm)
6 - Orifice Loaded Check Valve
7 - Overload Valve (Bucket)
8 - Boom Holding Valve
9 - Overload Valve (Boom)
10 - Overload Valve (Spare)
11 - Load Check Valve (Boom 1)
12 - Load Check Valve
13 - Load Check Valve
14 - Check Valve C2
15 - Check Valve C1
16 - Check Valve CMR2
17 - Check Valve CMR1
18 - Main Spill Valve
19 - Straight Tracking Valve
20 - Swing Priority Valve
21 - Load Check Valve (Swing)
22 - Swing Priority Valve
23 - Check Valve
24 - Boom2 Confluence Check V
Andy Liu 174
 Pilot circuit
Pilot valve controls the pilot
pump pressure oil and outputs
certain amount of pressure oil
in proportion to control the
opening of the main valve
spool as per the operating
force of the operator.

The pilot transition block is

installed between pilot valve
and control valve.

The pressure sensor installed

on pilot transition block
detects the secondary
pressure of each pilot valve
and sent back to controller.
Andy Liu 175
 Circuit logic
1- Boom up
2- Boom down
3- Stick out
4- Stick in
5- Left Swing
6- Right Swing
7- Bucket in
8- Bucket out
9- Left Forward travel

10- Left Reversing

11- Right Forward travel

12- Right Reversing

Andy Liu 176
 Pump circuit
Secondary pressure signal collected by the pressure sensor is
sent to the controller.
Controller controls electro-magnetic proportioning valve on
hydraulic pump through electric signal. And adjusts hydraulic
pump adjuster.

Adjuster fork adjusts the swash

plate angle of hyd pump, thereby
the aim of controlling the pump
displacement can be achieved.
Pump 1 participate in work during
following operation:
 boom up
 Stick (arm) in/out
 Bucket in /out
 Swing left/right
 Travel left

Pump 2 participate in work When

operating:
 Boom up/down
 Stick (arm) in/out
 Bucket in/out
 Spare valve or tracking right
Andy Liu 177
 Valve ctrl oil circuit
Pressure oil from pilot valve flows
through pilot transition block, and
achieves the following functions
together with pressure oil flowing
through solenoid valve.
Boom lower pilot pressure: boom
holding valve
Arm retraction pilot pressure: arm
holding valve
Arm retraction: arm regeneration
valve
Boom lifting:
boom priority valve 1 (Priority to the
bucket)
boom priority valve 2 (Priority to the
swing)

Solenoid valve A4: swing priority

valve
Solenoid valve A5: bucket confluence
valve
Andy Liu 178
 Valve ctrl oil circuit
Boom lower pilot pressure: boom holding valve
Arm retraction pilot pressure: arm holding valve
Arm retraction: regeneration valve
Boom lifting:
boom priority valve 1 (priority to bucket)
boom priority valve 2 (priority to swing)

Andy Liu 179

 Swing brake release oil circuit
Swing brake is a parking
brake, which is locked by
the spring and released by
the hydraulic oil.
 When implement or
swing joystick was
removed from the
neutral position.
 Pressure signal oil Px
push down the swing
brake valve spool, and
cuts off return oil circuit
of swing brake.
 Pressure pilot oil entered
into the swing motor and
opens the brake.
 Refer to next slide.

Andy Liu 180

 Swing brake release oil circuit
Swing brake release
oil comes from pilot
pump, and divided
into two circuits:
 Standby at the
swing ctrl valve.
 Signal pressure oil
used to control the
swing ctrl valve.

After the orifice in

the main ctrl valve,
swing brake control
oil flows through the
valve spools of:
 Swing
 Boom 2
 Arm 1
 Bucket
 Boom 1
 Spare
Andy Liu 181
 Single task oil circuit
Pressure oil from
main pump 1 flows
into valve core of:
 Left travel
 Swing
 Boom 2
 Stick 1

Pressure oil from

main pump 2 flows
into valve core of:
 Right travel
 Spare
 Boom 1
 Bucket
 Stick 2

Pressure oil from

two pumps joins
together to provide
oil for:
 boom (Up)
 Stick (In and out)
 Bucket (In & out)
Andy Liu 182
 Boom up operation
Pilot oil moves the valve
spool of
 Boom 1
 Boom 2.

Pressure oil in pump 2

flows into boom cyl
through the parallel
passage and boom 1
valve spool.

At the same time, pump

1 pressure oil flows
through boom 2 valve
spool.

Pressure oil of pump 1

and pump 2 merged,
and then entered into
the boom cylinder to lift
the boom together.
Andy Liu 183
 Boom down operation
Pilot oil moves valve
spool of:
 Boom 1
 Boom holding valve.

Pressure oil in pump 2

flows into boom
cylinder rod end to
lower the boom
through:
 Parallel passage
 Boom 1 valve spool
 Boom holding valve.

 Pressure oil in pump 1

flows through the
central passage of the
main control valve &
bucket confluence,
and then back to the
hyd tank directly.

Andy Liu 184

 Stick out operation
Pilot pressure oil moves
the valve spool of arm
1 and arm 2.

Pressure oil of pump 1

flows through the
parallel circuit and arm
1 spool to the stick
cylinder.

Pressure oil of pump 2

flows through arm 2
valve spool to the stick
cylinder.

Pressure oil of pump 1

and pump 2 merged,
and entered into the
stick cylinder rod end to
extend stick together.

 See the close view of

the schematic in next
slide.

Andy Liu 185

 Stick out operation

Close view

Andy Liu 186

 Stick in operation
Pilot oil moves valve
spool of arm 1, arm 2
and arm holding valve.

Pump 1 pressure oil

flows into the stick cyl
through parallel circuit
and arm 1 valve spool.

Pump 2 pressure oil

flows through arm 2
valve spool & merged
pump 1 pressure oil.

Arm holding valve was

opened by the pilot oil.

Cylinder return oil was

clocked by the arm
regeneration valve.
Andy Liu 187
 Stick in operation
Arm regeneration
valve was closed.

Arm 2 valve core can

not return oil.

Check valve in the

arm 1 valve core was
opened.

Hydraulic oil flows

from the rod end
chamber to the big
end chamber of the
stick cylinder via the
arm holding valve &
check valve in the
arm 1 valve core
under the action of
the own weight of
stick.
Andy Liu 188
 Stick in operation
When the action of
the arm’s own
weight decreased
gradually.

Check valve in the

arm 1 valve spool
approaches closing.

Arm regeneration
valve will be opened.

Return oil from the

stick cylinder rod end
flows back to the hyd
tank via:
 Arm holding valve.
 Arm 1 valve spool.
 Arm regeneration
valve.
Andy Liu 189
 Swing operation

Pilot oil moves the swing valve spool.

Pump 1 pressure oil flows into swing mtr.
Andy Liu 190
 Bucket in operation
Pilot oil moves bucket
valve and the spool of
the bucket confluence
valve.

Pump 2 pressure oil

flows into bucket cyl
through the bucket
valve spool.

Pump 1 pressure oil

flows through central
circuit, check valve,
and merged with the
pump 2 pressure oil
before the bucket
valve spool.

The merged two pump

oil close up the bucket
together.
Andy Liu 191
 Bucket out operation
Pilot oil moves bucket
valve and the spool of
the bucket confluence
valve.

Pump 2 pressure oil

flows into bucket cyl
through the bucket
valve spool.

Pump 1 pressure oil

flows through central
circuit, check valve,
and merged with the
pump 2 pressure oil
before the bucket
valve spool.

The merged two pump

oil dumped the bucket
together.
Andy Liu 192
 Track only operation
Pilot oil moves the valve spools of left travel and right travel.
Pump 1 pressure oil flows through the left travel valve spool
and entered into the left travel motor.
Pump 2 pressure oil flows through the right travel valve spool
and entered into the right travel motor.

Andy Liu 193

 Swing & boom up operation
Pressure pilot oil
moves the valve
spools of:
 Swing
… Boom 1
g… 

win Boom 2.
n s 

e
wh Pump 2 pressure
om oil flows into boom
bo cyl through boom
ing
t 1 valve core.
Lif
Pump 1 pressure
oil flows into swing
motor through
swing valve core.
At the same time, pump 1 pressure oil flows through parallel
circuit and merges with the pump 2 pressure oil, then flows
into boom cylinder to lift the boom together with the pump 2
pressure oil.
Andy Liu 194
 Travel & stick in operation
Pilot oil pressure
moves the valve
spools of:
 Left travel
g  Right travel
in
v el  Arm 1
t r a  Arm 2.
e n  Arm holding valve
wh
i c k Meanwhile, return
s t oil of straight travel
t he valve control circuit
c t in the control valve
t ra
Re is cut off. Straight
travel valve moves.
(see purple circuit.)

Pressure oil from

pump 1 flows into
stick cylinder via
arm 1 valve core to
retract the arm.
Andy Liu 195
 Travel & stick in operation
Therefore, stick is operated only by the pump 1 pressure oil.

Pressure oil of pump 2 evenly flows into left & right travel motors to
ensure that the machine travels straightly.

 Pressure oil of pump 2 flows through right travel valve spool to drive
right travel motor.

 Meanwhile, pressure oil of pump 2 flows through straight travel valve

and left travel valve spool, and drives the left travel motor.

Besides, the arm holding valve is opened, since arm 2 valve core cannot
return oil and arm regeneration valve is closed, hydraulic oil of arm
cylinder small chamber flows through arm holding valve and check valve
in arm 1 valve core into arm cylinder main chamber under the action of
arm's own weight. ( Refer to stick in single operation.)

When the action of arm's own weight decreases gradually, the check
valve in the arm 1 valve core will approach closing. At this time, the arm
regeneration valve will open. Return oil from the small chamber of the
stick cylinder flows through arm holding valve, arm 1 valve core and arm
regeneration valve. ( Refer to stick in single operation.)
Andy Liu 196
 Travel & bucket in operation
Pilot oil pressure
moves the valve
spools of travel
motors & bucket.

g . Meanwhile, return

c kin oil of straight travel

valve control circuit
tr a
n in the control valve
e is cut off, straight
t wh travel valve moves.
k e (see purple circuit.)
u c
e b Bucket is operated

t th
only by the pump 1
a c pressure oil.
etr Pump 2 pressure oil
R evenly flows to left
& right travel MTRS
to ensure that the
machine travels
straightly.
Andy Liu 197
 Straight travel control circuit
Pressure oil comes
from the pilot pump
flows through the
orifice, and then
divided into three
parts:
 Pink circuit.
 Blue circuit
 Red circuit.

When hex had no

operation, all these
three circuits leads
oil to the hyd tank.

When all the three

circuits are blocked,
oil pressure will be
built up to shift the
straight travel valve.
Andy Liu 198
 Swing & stick out operation
Pilot oil pressure moves
the valve spools of:
 Swing
 Arm 1
 Arm 2
. Pressure oil of pump 2
i n g flows into stick cylinder
in g
s w and arm 2 valve spool
e n to extend the arm.
w h
m Pressure oil of pump 1
a r flows into swing motor
th e through swing valve
e n d core.
t
Ex At the same time, pump
1 pressure oil flows via
parallel circuit and stick
1 valve spool, merges
with the pressure oil of
pump 2, then flows into
stick cylinder to extend
the stick together.
Andy Liu 199
 Boom up & bucket in operation
Pilot oil pressure moves
the valve spools of:
 Boom 1
s ly  Boom 2
o u Bucket.
n e 

l t a Pressure oil of pump 1

u flows into boom cylinder
s im via boom 2 valve core to
ed lift the boom.
o rm
rf A part of pressure oil of
pe pump 2 flows via boom 1
t in
e valve core, and flows into
ck boom cylinder together
bu with the pressure oil from
n d
a pump 1 to lift the boom.
up Another part of the pump
o m
2 pressure oil flows into
Bo bucket cylinder through
bucket valve spool to
retract the bucket.

Andy Liu 200

 Boom up & bucket in operation
Meanwhile, boom
priority valve 1
functions:

 Bucket valve spool

was turned down.

 Oil flows to bucket

cylinder reduced.

 Proportioning of
pump 2 pressure oil
between boom cyl
and bucket cyl is
readjusted.

 More hydraulic oil

will flow into boom
cyl which makes
lifting boom priority
to the bucket.
Andy Liu 201
 Boom up & stick in operation
Pilot oil moves valve
spools of:
 Boom 1

sly  Boom 2
ou  Arm 1
n e
ta  Arm 2
ul Arm holding valve
sim 

e d
r m Pump 1 pressure oil
r fo divides into two parts:
pe
n  Flows to boom cyl to
i c ki lift boom.
t
ds
 Flows to stick cyl to
n retract the stick.
p a
u
o m Pump 2 pressure oil
Bo divides into two parts:
 Flows to boom cyl to
lift boom.
 Flows to stick cyl to
retract the stick.
Andy Liu 202
 Boom up & stick in operation
Stick regeneration
circuit:
 Arm 2 valve core
blocked the return oil.
 Arm regen valve is
closed.
 Return oil flows to
stick cyl big chamber
via the check valve in
arm I valve spool
under the arm's own
weight.
As the action of arm's
own weight decreases:
 Check valve in the
arm 1 valve spool
closes gradually.
 Arm regen valve will
open.
 Return oil goes to
hydraulic tank via arm
holding valve, arm 1
valve spool and arm
regen valve.
Andy Liu 203
 Boom up, swing & stick out

y
Pilot oil moves the valve

sl
ou
spools of:

ne
 Boom 1

ta
 Boom 2

ul
m
 Swing

si
 Arm 1

ed
m
 Arm 2.

or
Pump 2 oil flows to:

rf
pe
 Stick cylinder

e
tar  Boom cylinder
ou

Pump 1 oil flows to:

k

 Swing motor
ic
st

 Boom cylinder
d
an

 Stick cylinder
g

Pump 1 oil combined the

in
w

pump 2 oil together to:

,s

 Lift up the boom

up

 Extend the stick

mo
Bo

Andy Liu 204

 Boom up, swing, stick out & bucket in
Pilot oil moves the

y
sl
valve spools of:

ou
Boom 1 and boom 2

ne


ta
Arm 1 and arm 2

ul


m
Swing and bucket

si


ed
Pump 2 oil flows to:

m
Stick cylinder

or


rf
Boom cylinder

pe


e
Bucket cylinder

ar


Pump 1 oil flows to:

n
ti
e Stick cylinder
ck

bu

 Boom cylinder
t&

 Swing motor
ou

Meanwhile, boom
k
ic

priority valve 1 makes

st

the bucket valve core to

g,
in

turn down, more hyd oil

w

of pump 2 will flow into

,s
up

boom cyl which makes

m

lifting boom priority to

oo

the bucket.
B

Andy Liu 205

 Spare oil circuit

When the work devices such as hydraulic smashing hammer is working:

 Pilot pressure oil moves the spare valve spool.
 Pressure oil supplied from pump 2 flows through the spare valve core and flows
into the work device circuit, such as hydraulic hammer.
Andy Liu 206
 Hydraulic circuit

Andy Liu 207

 Main oil circuit

Andy Liu 208

 Pilot oil circuit

Andy Liu 209

 Pilot system
Major components of pilot system:
 Pilot pump – a gear pump which supplied pressure oil
to the pilot system.
 Pilot manifold – accumulator, solenoid Gp installed on it.
 Pilot valves – direct pressurized pilot oil to drive main
valve spool accordingly.
 Relief valve – to keep proper pilot system pressure.
 Accumulator – supply power to lower implements after
engine was shutoff.
 Solenoid valve Gp – hyd lock solenoid, travel speed
solenoid, and secondary booting solenoid.
 Power shift solenoid – regulate hyd pump hp.
 Pressure sw / solenoid – monitor status or reading.
Andy Liu 210
 Pilot pump
Pilot pump is a gear pump located
at the rear end of the main hyd
pump.
In Pilot pump provides pressure oil
for the pilot system and signal oil
Out to the main hyd pump.
If air was imprisoned in the pilot
system, related actuator will have
a retard performance.
Out

In
In

Out

Andy Liu 211

 Gear pump operation

Andy Liu 212

 Pilot pump location
From pilot filter Pilot pump To pilot filter

Inlet hose Relief valve

Andy Liu 213

 Pilot pump
From filter to pump To pilot manifold

Pilot filter

Andy Liu 214

 Pilot valve

Andy Liu 215

 Main control valve

Andy Liu 216

 Main control valve

Andy Liu 217

 Main control valve

Andy Liu 218

 Pilot oil moves spool

Andy Liu 219

 Hyd pump

Main pump is a tandem swash plate structure axial

piston pump. The pilot pump is a gear pump.
Andy Liu 220
 Main hyd pump

Andy Liu 221

 Hyd pump
Hyd pump main function
is to supply pressure oil
to hydraulic execute
components, such as hyd
motor or cylinder.

The main pump includes

front pump and rear
pump.

The pump drive shaft rotates the nine plungers simultaneously

by driving pump cylinder, when the cylinder rotates, plungers in
it intake and deliver hydraulic oil through plate while making
reciprocating movements.

Each main pump is equipped with an adjuster (4) to control the

delivery and power.
Andy Liu 222
 Hyd pump operation

Engine torque was transferred to the drive shaft.

Cylinder rotate and slide along the surface of the plate.
Plungers reciprocate in cylinder, intakes low pressure oil and
releases high pressure oil alternately.
Andy Liu 223
 Pump flow change
Cylinder is contacted
with the surface of
orifice plate & slides
along it.
The servo piston is
connected to the
swash plate by pin.
The inclination of
swash plate can be
changed by moving
the servo piston left
or right.
Changing inclination
of the swash plate,
the plunger stroke
increases/decreases.
Andy Liu 224
 Hyd pump servo valve
Major parts of servo valve are:
1. proportioning relief valve (1)
2. electro-hydraulic conversion valve (2)
3. variable-power adjuster (3)
4. positive flow adjuster (4)
5. servo piston (5)
6. servo reversing valve (6)

 Servo valve open or close the oil circuit

of servo piston (5) and change the angle
of swash plate based on various
command signal pressure, so as to
control the pump flow.

Andy Liu 225

 Pump flow increase
1. Joystick moved further from
the neutral position.

2. Pilot oil pressure detected on

the transition block increased
and sent to controller.
3. Increased electric signal was
sent to the PRV by controller.
4. Pump electromagnetic PRV
increases pump control
pressure Pi.
Andy Liu 226
 Pump flow increase

5. Pi increased and larger than

spring force C.

6. Valve core A in the adjuster

(4) moved rightward.

7. and pushes the valve core in

the servo reversing valve (6)
move leftward together with
spring E.

Oil returned 8. Then, the servo piston (5)

main chamber oil circuit
returns oil.

Andy Liu 227

 Pump flow increase

9. servo piston (5) was

pushed leftward by the
pressure oil.

10.Fork was driven leftward

together with the piston
(5).

11.Inclination of the pump

swash plate increased.

12.Pump discharge increased.

Andy Liu 228

 Pump flow increase

13. Servo piston(5) moves

leftward in step 9.

14. Valve bush of the servo

reversing valve (6) was
driven toward left.

As piston 5 moved leftward,

servo valve bush ( red color)
was driven toward left.

Andy Liu 229

 Pump flow increase

15.When the moving stroke of

valve bush and valve core of
the servo reversing valve (6)
are same.

16.Main chamber oil circuit of

servo piston(5) that flows to
the return oil is closed.

17.Servo piston (5) stops moving,

the flow increase operation is
completed.
Return oil blocked
New balance reached ? How about pump flow decrease?

Andy Liu 230

 Pump flow decrease

1. Joystick moved toward the

neutral position.

2. Detected pilot oil pressure on the

pilot transition block decreased.
and was sent to the controller.
3. Controller decrease the electrical
signal outputs to the pump PRV.
4. Pump PRV (electromagnetic
proportional valve) decreases the
Joystick neutral, Pi pump control pressure Pi.

Andy Liu 231

 Pump flow decrease

5. Pump ctrl pressure Pi

decreased, valve core
A of adjuster 4
moved leftward with
spring force C.

6. Force of the spring E

was overcome.

7. Valve core of the

servo reversing valve
(6) move rightward.

Andy Liu 232

 Pump flow decrease

8. Pressure oil enter into the main

chamber of the Servo piston 5.

9. Big and small chamber of the

servo piston 5 had the same
pressure oil P1.

10. As the surface of the big

chamber is larger than the
small chamber, servo piston 5
was push rightward.

11. Fork was driven to decrease

the inclination of the swash
plate in the pump body. Pump
discharge is decreased.

Andy Liu 233

 Pump flow decrease

12. Servo piston 5 moved rightward

which drives the valve bush of
the servo reversing valve 6 to
move toward right.

13. When moving stroke of valve

bush and valve core of servo
reversing valve 6 is same.

14. Main chamber oil circuit of

servo piston 5 that flows to the
pressure oil is closed.

15. Servo piston 5 stops moving,

the flow decreasing operation is
completed.
Andy Liu 234
 Prevent overloading

1. Pump pressure P1 and P2 act

on the end of variable-power
adjuster 3.

2. When the pump pressure P1

or P2 increased,

3. Spring force D was overcome,

and valve core B was pushed
rightward.

4. Meanwhile, spring force E

was overcome and core of
the servo reversing valve 6
was push rightward.

Andy Liu 235

 Prevent overloading

5. Pressure oil flows into the

servo piston 5 main chamber.

6. Servo piston moved rightward

under same pressure and
varied surface.

7. Fork was driven by piston 5 to

decrease the inclination of the
swash plate.

8. Pump discharge decreased and

overloading was prevented .

Andy Liu 236

 Prevent overloading

9. Servo piston 5 moved rightward

which drives the valve bush of
the servo reversing valve 6 to
move toward right.

10. When moving stroke of valve

bush and valve core of servo
reversing valve 6 is same.

11. Main chamber oil circuit of

servo piston 5 that flows to the
pressure oil is closed.

12. Servo piston 5 stops moving,

the operation is completed.

Andy Liu 237

 Flow reset operation
1. Pump pressure P1 / P2 decreases.
2. Valve core B in power adjuster 3
will be pushed leftward with the
spring force D and E.
3. Meanwhile, valve core of the servo
valve 6 was pushed leftward.
4. Servo piston 5 main chamber oil
circuit returns oil.
5. Small chamber pressure oil
pushes the servo piston 5 move
leftward.
6. Angle of swash plate increased,
Pump discharge is increased.
Andy Liu 238
 Flow reset operation
7. Bush of servo valve 6
moved leftward followed
the piston5.
8. When the travel stroke of
the bush and bore of
servo valve 6 are the
same.
9. Main chamber return oil
circuit was closed.
10.Servo piston 5 stops
moving, and the
operation is completed.
Andy Liu 239
 Swing motor group

Andy Liu 240

 Valves of swing units

Anti-rebound valve

1 - Compensation Valve 2 - Spill Valve 3 - Oil Port M

4 - Compensation Valve 5 - Cone Valve
Andy Liu 241
 Valves of swing units

The valve unit is consisted of compensation

valve, spill valve and anti-rebound valve.

 The compensation valve prevents that the cavity is

formed in the oil circuit and the motor become air
sucking.

 The spill valve prevents shock pressure and overload

occurring in the circuit.

 The anti-rebound valve prevents pressure shocking

and reversing during motor braking, which plays the
role of buffering.

Andy Liu 242

 Swing schematic
A, B: main oil port from
ctrl valve.

M: make up oil port.

Dr: case drain oil port

PX: swing ctrl oil port.

PG: pilot oil port.

One month used, four

times service engineers
were dispatched… …
Andy Liu 243
 Swing operation

Swing Swing stop

Andy Liu 244
 Anti swing valve operation
Swing joystick returns to the neutral position.
Return oil in port B was blocked by the control valve.
The inertia kinetic energy of the hex upper swing body
make the hex try to swing more.

Oil pressure in the blocked return circuit

increased rapidly. If this pressure can
not be released properly, upper swing
body will be rebound back and vibrates
back and forth.
Oil pressure increased up enough to
push the anti-swing valve spoon up, and
release the pressure oil to the left side
of the swing motor.
Andy Liu 245
 Boom & stick holding valve
Holding valve located at:
① bottom of boom cylinder
② oil circuit of the stick cylinder

Cut off operation

When the stick valve core is in the neutral-position, the
switch valve HV has no pilot pressure and is on the right
side under the action of the spring force.
At this time, the plug-in valve cuts off the pressure oil in
the cylinder small chamber completely under the action of
the spring, thus the cylinder can keep unmoved (Zero
leakage).
Andy Liu 246
 Boom & stick holding valve

Cylinder normal operation

When Px has pilot pressure (Namely the boom or arm starts

to act), switch valve HV is on the left side under the action of
the pilot pressure.

At this time, the plug-in valve is pushed open under the

action of the main pressure, through-flows the main valve
and the cylinder to make the cylinder operate.

Andy Liu 247

 Travel group

 A. B – main oil to / from ctrl valve

 PT – pilot oil to change travel speed
 D2 – drain oil

Andy Liu 248

 Travel operation schematic
Low speed travel High speed travel

Andy Liu 249

 High speed travel
Pilot pressure oil Fr solenoid
valve A2 controls travel MTR
high/low speed condition.

When the high-speed travel

mode is selected:
 MC activates the solenoid

valve A2.
 Solenoid valve A2 sent the

pilot oil to the tracking

motor swash plate angle
control valve.
 Swash plate angle reduce

to the smallest and motor

traveled in high speed.
Andy Liu 250
 High speed travel
When an excavator runs
into an obstacle (climbing,
etc.) at a high speed, it can
switch between high and
low speed automatically.

MC activates the solenoid

valve A2 according to the
following signals:
① Tracking pressure sensor.
② Pump 1 oil transfer pressure
sensor.
③ Pump 2 oil transfer pressure
sensor.
④ pump 1 control pressure
sensor.
⑤ pump 2 control pressure
sensor.
Andy Liu 251
 Travel unit
1 - DR Oil Port
2 - Oil Port A
3 - Oil Port B
4 - Measure Pressure
Oil Port P4
5 - Measure Pressure
Oil Port P1
6 - Measure Pressure
Oil Port P3
7 - Measure Pressure
Oil Port P2
8 - Balance Valve Core
9 - Safety Valve
10 - PT Oil Port

Andy Liu 252

 Travel sudden stop
When hex comes to a sudden
stop during tracking, the motor
may cause air sucking easily.

Right side pressure of tracking

motor damping valve increases
and the left side pressure
decreases momentarily.

Oil return in circuit 9 flows into

damping valve right side and
pushes damping valve piston
to move upward.

Right side pressure increase in

the buffering valve will open
the spin valve in the lower part.

Oil flows into the motor left

chamber to make up oil and
damping function works.

Andy Liu 253

 Direction valve ctrl circuit

A B

P T
A B

T P
Hyd pump Relieve valve

Andy Liu 254

 Direction valve ctrl circuit

A B

P T
A B

T P
Hyd pump Relieve valve

Andy Liu 255

 Hydraulic filters

Cover
Hyd oil filter Pilot filter
Spring

Tank

Screen
To pump
Return oil

Drain plug Hyd oil

Andy Liu 256

 257
Hydraulic schematic

Hydraulicschematic
Hydraulic schematic
Andy Liu
 Pilot system schematic

Andy Liu 258

 Solenoid valve gp

Andy Liu 259

 Engine training

Andy Liu
 Engine introduction
Basic components – cylinder block, cylinder head, flywheel,
crankshaft, con-rod, piston, turbocharger, damper, pulley,
front housing, flywheel housing, and so on.
Fuel system – fuel tank, water-fuel separator, fuel filter,
transfer pump, priming pump, injection pump, injector,
governor (actuator), ECM, sensors, and so on.
In & exh system – timing gear, camshaft, lifter, pushrod,
rocker arm, inlet and exh valves, air filter, turbo, aftercooler,
muffler, and so on.
Lube system – oil pan, oil pump, oil cooler, oil filter, oil jet,
relief valve, by-pass valve, and so on.
Electric system – battery, alternator, starting motor, start
switch, circuit breaker, fuse, lamps, horn, wiper, etc.
Cooling system – radiator, water pump, fan regulator, etc.
Andy Liu 261
 System schematic
Fuel tank
Air filter

Injection pump Muffler

Radiator Alternator
Starting motor

Oil pump

Oil pan
Battery

Andy Liu 262

 Basic components
Cylinder block is engine’s framework.
Most of the engine components are
installed in the cylinder clock.

Oil passages are drilled in the cylinder

Liner block in order to supply lubrication.
Cylinder block Coolant flow through cylinder block to
remove excessive heat and ensure
engine operated normally.

Main bearing bores of the cylinder

block should always be checked
carefully when overhaul was done.

In cold whether, frozen crack of the

Main bearing cap cylinder block should be prevented.
Andy Liu 263
 Basic components
Gasket Wet type and dry type liners
were used currently.

Wet type liner contact with

coolant at it’s outside surface.

Dry type sleeve do not contact

No sleeve sleeve liner
with coolant directly. Cooling
coolant effect was worse than liner.

seal Cylinder head was used to form

combustion chamber together
Dry type Wet type with the cylinder block.

Cylinder head gasket was

installed between the block and
head to prevent leakage of gas
Types of cylinder head and water.
Andy Liu 264
 Basic components
crankshaft
Piston linear movement was
Ring
transformed to the rotation
movement through the crank.

Con-rod was installed on the

crankshaft rod bearing journey.
pinion And the main bearing journey
flywheel was seated in the block bearing
bore.

Lube oil was supplied through

the block inner drilled passage
flywheel
and main bearing journey to the
Con-rod rod bearing journey.

Flywheel transport the engine

power to the hyd pump, and
crankshaft transformed to hyd energy.
Andy Liu 265
 Crankshaft endplay

Andy Liu 266

 Basic components
Con-rod
Piston transforms the heat energy of
combustion chamber into mechanical
energy and drive crankshaft to rotate.

Piston rings were installed in the

piston ring grooves to seal the
clearance between piston and liner.
Piston ring
Gas rings were used to seal the gas
in the combustion chamber.

Oil ring was used to scrape down

excessive oil splashed on the liner by
the oil jet.

Top ring
If liner was worn severely, heavy
Piston blow-by will be resulted and
excessive oil consumption will be
complained.
Andy Liu 267
 Fuel system

Andy Liu
 Diesel engine fuel system types:
Mechanical type: Injection pump + governor
+ fuel pipe + injector
MUI: governor + unit injector
PEEC engine: ECM + actuator + injection
pump +injector
EUI: ECM + unit injector
HEUI: ECM + Hep pump + unit injector
Common rail: ECM + high pressure pump +
unit injector.
Andy Liu 269
 Fuel system schematic

Fuel tank
Injector

Relief valve

Priming pump

Water separator
Governor
Fuel filter Transfer pump Filter
Andy Liu 270
 Fuel system schematic

Andy Liu 271

 Fuel system schematic

Andy Liu 272

 Fuel system
Water and debris should be
drained from the fuel tank
every morning before work.
Red line
Float Breather in the fuel tank cap
should be cleaned timely and
never be clogged.

Fuel tank should be filled

Cap
Screen everyday just after work to
Dipstick drive out hot vapor in the tank.

Fuel – water separator should

Cap be drained everyday before
work, or the time the float
was found floated up.
Drain valve
Andy Liu 273
 Fuel system

Air bleed plug

Filter
Case

Andy Liu 274

 Fuel system
Transfer pump – installed just beside the fuel injection
pump, and drove by the fuel pump camshaft.

Priming pump
 Installed on the transfer pump.
 Supply fuel and drive out air from the fuel system before starting.
 Was used when filter was replaced or engine repair.

Fuel filter – was used to filter out the debris to keep the
fuel system away from the contamination.
 A spoon of contamination will damage fuel system severely.
 Never pre-fill the fuel filter anytime replacement.
 Install fuel filter correctly as per the indication on the filter.
 Loosen the air bleed, using the priming pump to fill the fuel filter
and bleed air out before starting.
 Using the genuine not the counterfeit filters always.
Andy Liu 275
 Fuel system
To fuel injector

Valve seat
Delivery valve
Plunger

Gear
Fuel rack
Lifter
Camshaft

Zexel fuel system, the same as used

on caterpillar 320 series excavators.
Andy Liu 276
 Fuel system
Plunger

Fuel supply

End
Slot

Plunger
Max fuel

Fuel rack  plunger rotated  fuel quantity changed  Engine speed varied
Andy Liu 277
 Fuel system
Connector
setting screw To fuel tank
Spring

Check valve
From pump

pushrod Needle valve

Needle valve

When the fuel pressure was high enough to open the needle
valve against the spring inner the injector, pressure fuel
passed through the orifice on the nozzle tip, atomized, and
sprayed into combustion chamber.

Injector can be tested with the special tool if it is suspected.

Andy Liu 278
 Inlet & exh system

Excessive oil
consumption .
Aftercooler Inlet leakage.
Exh leakage at
Exh valve the manifold.
Exh leakage
after turbo.
Andy Liu 279
 Inlet & exh system

Andy Liu 280

 Inlet & exh system
Rocker arm
Rocker arm shaft
Pushrod Injector

Lifter Spring
Clearance
Bridge Water
Idler
Valve guide
Camshaft gear Insert
Cyl head
Crankshaft gear Exh Inlet
Camshaft gear
Idler Teeth of camshaft gear are
Fuel pump driving gear two times of the crankshaft
gear.
Idler
Timing marks were carved
on the timing gears.

Pulley
Idler Balance shafts were usually
installed in the 4 - cylinder
Crank
Oil pump gear Crankshaft gear
engine.
Andy Liu 281
 Inlet & Exh system
In Exh In Exh In Exh Exh
open closed closed In
closed closed closed closed
open

In In In Exh
closed Exh Exh closed In Exh
closed closed closed open closed open

Andy Liu 282

 Inlet & Exh system
Turbine wheel

Compressor
wheel

Turbocharger was used to boost the inlet air pressure. Turbine

wheel was pushed and rotated at fast speed, and much more
fresh air was compressed for combustion.
Aftercooler was used to cool the compressed pressure air and
then sent to the combustion chamber. After boosted & cooled,
high density air was sent to combustion chamber.
ATAAC was currently used to replace the water cooled
aftercooler during to its cooling capability.
Andy Liu 283
 Inlet & Exh system
Outer filter Inner filter

Dust tank

Vacuum valve

Nip the vacuum valve, closed during operation, to release

the dust in the tank.
Outer filter should be replaced after cleaning with pressure
air, lower than 0.2 MPa, up to 6 times or 6 months.
Check the filter with a flashlight to see whether it was
broken or not when doing maintenance.
Always replace the inner and outer filter at the same time.
Andy Liu 284
 Air filter indicator

Andy Liu 285

 Inlet & Exh system

Muffler was used to reduce the exhaust noise. If the

muffler was not installed and engine was started, exhaust
noise will be uncomfortable and sounded abnormal.
Andy Liu 286
 Lubrication system
Fuel pump Turbocharger
Rocker arm

Camshaft Piston

Main oil gallery

By-pass valve

Relief valve Crankshaft

Timing gear Oil cooler

Oil filter
Oil pump

Turbocharger:
1. 30K to 50K rpm.
2. Highest component
Andy Liu 287
 Lubrication system
Relief valve – protect lube
system from damage. Valve
setting is 3~6kg/cm2.
By pass valve – protect lube
system from damage when
the oil filter was blocked.
Oil filter
Oil filter should not be filled
Debris filtered out
before installation.
Cut open the oil filter after it
was replaced. Abnormal
wear material could be
found in it.
Which will cause low oil
pressure? Relief valve or by
pass valve?
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 Lubrication system
Oil outlet Oil outlet
Coolant outlet
Coolant inlet
Core Oil jet
Cover
Cooler core
By-pass
Coolant inlet
Oil inlet

Oil outlet Oil jet

Oil inlet
Oil cooler – remove oil heat
By pass filter Cover
prevent oil deterioration.
Main filter
From Oil jet – spray oil to remove
pump
the heat from piston to
avoid the seizure.

By pass filter By pass filter – filtrate oil

completely to reduce
To oil pan
contamination.
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 Lubrication system
Key function of lube system:
 Provide lubrication for the motive parts and components to prevent
the adhesive wear.
 Provide cooling for the high temperature components, such as
turbocharger, to prevent the adhesive.
 Cleaning the debris or foreign material float on the metal contact
surface to prevent the abrasive wear.
 Seal the clearance between the mating face.
 Coat metal surface to prevent metal rust.
Correct operation extended hex service life:
 Proper idle time was required for the hex. Never accelerate engine
speed rapidly just after starting.
 Do not stop engine immediately after long time full load working.
Especially, engine can not be stopped at rated speed and rated
load.
 Do the lube system maintenance timely and correctly.

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 Engine oil viscosity

Oil viscosity in cold Oil viscosity under high

weather. temperature.
Six stage: 0W, 5W, 10W, Five viscosity stage: 20,
15W, 20W, 25W. 30, 40, 50, 60.
W – first letter of winter. Oil has a larger number
The smaller the number will have higher viscosity
before W, the better the and better performance
fluidity at low temperature. at high temperature.
High speed engine should
use high viscosity lube oil.
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 Engine oil selection

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 Engine oil key function
Lubrication: provide lubrication for the moving parts.
Cooling: remove heat to prevent parts from adhesive
wear.
Neutralization: TBN (Total Base Number) is a important
parameter which indicated the oil ability to neutralize the
acid produced by the SO2 and vapor during engine
working.
Cleaning: dispersant in the oil clean dirty in the oil from
the moving parts.
 A drop of around 50% of fresh oil TBN indicates that the
oil is almost at the end of its useful life.
 Can the hydraulic oil used as engine oil?
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 Cooling system

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 Cooling system
Fuel was combusted and heat was generated:
 33% heat – useful power.

 30% heat – lost through exhaust gas.

 30% heat – removed by cooling system.

 7% heat – radiated through engine surface.

Best coolant range: 78℃~93℃

Overcooling – coolant temperature lower than
65 ℃.
Frozen should be prevented in the cold weather
by using correct coolant.
Overheating is another severe problem should
be prevented about the cooling system.
Fan belt tension – checked correctly and timely.
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 Cooling system
Regulator
Upper tank
Housing
Cap
Impeller
Seal Gp

Bottom tank From radiator

Hot coolant came from the engine flow through the radiator
core from the top tank to the bottom tank, and cooled by the
fresh air blew or suck by the fan.
Radiator cap was used to keep proper pressure in the cooling
system and increase the boiling temperature.
Inspection hole on the water pump housing:
 If coolant leaked out from the hole, water seal group was failed.
 If oil or grease was found in it, oil seal group was damaged.

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 Cooling system
To radiator To radiator
Spring Regulator Spring Regulator
Valve Valve
Port opened

From cyl head

From cyl head

Heat inductor
Heat inductor

Port opened
To water pump To water pump
When the coolant temperature was too low to open the port
to the radiator. No coolant was sent to radiator for cooling
and engine was warm up.
When the coolant was hot enough to open the port to the
radiator completely, hot coolant was sent to radiator for
cooling to keep a stable coolant temperature.
 Is it possible that two ports opened at the same time?
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 Electrical system

Starting circuit:
 Control circuit: signal current attract and hold the solenoid of
starting motor.
 Main circuit: electric power was sent to the starting motor through
the attracted solenoid.
Charging circuit: charge battery and supply electric power.
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 Electrical system

Current flow through the heat plug and make the plug tip
temperature high enough to ignite the fuel sprayed in the
pre-combustion chamber. lighted fuel then went into the
combustion chamber and burned there completely.

Band type heater was installed in the inlet circuit to warm

up the cold air before it entered into combustion chamber.
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 Electrical system
Install the battery wire correctly, negative wire can not
be connected to positive pole wrongly or vice versa.
When welding job was done on the hex, battery cable
should be disconnected. Also that the negative pole of
the welding machine should be closed to the welding
point to prevent welding current flow through hex which
will result in components damaged.
If engine was hard to start, cranking time should be
within 10 seconds for each time and cranking interval
should be more than 30 seconds to prevent starter
failure.
If engine still can not be started for three times cranking,
stop cranking to find out the root cause of failure.
Disconnect the negative cable before the positive cable,
and install the positive pole first and then connect the
negative cable to the battery.
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 Electrical system

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 Engine model number

6 B T A 5.9 - C
Application code
 A = agriculture
Displacement (L)
 C = construction
 F = fire pump
Aftercooler installed
 G = generator set
 L = locomotive
Turbocharger installed
 M = marine
 P = power module
Engine series code
 R = railway

Number of cylinder

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 Valve lash adjustment
 Crank engine to No.1 cylinder
TDC in compress stroke.
 Adjust the valves’ lash with the
mark ● in the below chart.
 Crank engine 360°in correct
direction and adjust the valves’
lash with the mark ○ in below
chart.

Cyl number

Exh valve

Inlet valve
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 Valve lash adjustment
 Find out the valve lash:
In the manual OMM.
On the engine nameplate.
On the emission plate.
 Crank engine correctly.
Correct direction.
If over cranked, then
return back 30°above
and then align to the
timing mark.
 Mark the valves adjustment
was made.
Lash

 Recheck again after all valve

lash was adjusted. Tighten
the locknut correctly.
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 Blowby test

 Test requirements:
Hyd oil temp 55~80℃.
Normal coolant temperature.
Working mode set to H.
Highest dial switch position.
Travel motor line relief valve
part number part name
test group opened.
jet  How about the testing result?
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 Oil pressure test

 Remove oil pressure sensor

and install a connector.
(10kg/cm2）

 Test the oil pressure at both

low speed and high speed
under normal oil temp.
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 Speed sensor
 If the speed sensor gap was
too small, it maybe damaged
by the flywheel.

 If the speed sensor gap was

too large, it can not pick up the
speed signal.

 Speed sensor installation:

Speed sensor Flywheel
 Remove the speed sensor
 Crank engine to one flywheel
teeth top at the center of speed
sensor hole.
 Finger install the sensor to
contact with the tooth top.
Locknut
 Return the sensor back ¾ turn.
gap
 Tighten the locknut correctly.
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 6D34-TL engine

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 Specification

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 Information plate

Nameplate on the valve cover

A: engine model
B: displacement
C: rated power
D: valve lash
E: fire order
F: fuel timing
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 Specification summary

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 Valve lash adjustment

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 Components
1. rocker arm
2. Valve spring
3. camshaft
4. liner
5. cylinder head
6. flywheel
7. crankshaft
8. Exhaust valve
9. piston
10. con-rod
11. Timing gear
12. lifter
13. Inlet valve
14. pushrod
A: rotate direction
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 Valve mechanism

The valve stem sealing ring is

installed in the valve in order
to control the amount of the
lubricant on the slippery area
between the valve and valve
guide.
Using the adjusting screw to
adjust the valve lash.
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 Timing gear group

Timing marks
("1", "2", "3")
are marked
on each gear,
in order to
install gears
correctly.

When the three couple of timing marks are aligned,

engine was set to the No.1 cylinder TDC.
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 Con-rod & piston

Piston & con-rod

Cylinder head gasket

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 Piston & con-rod

Make sure that the quality of each cylinder is equal

when replacing connecting rod.
Install the piston and con-rod follow the direction
shown in the illustration.
Make the mark near piston ring closed end upward
and set each ring closed end in the direction shown
in the illustration.
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 Piston & con-rod

Check that the piston ring closed end is in the

specified position.
 A: No.1 Compression Ring closed end
 B: No.2 Compression Ring closed end
 C: oil ring closed end
 D: oil ring support spring corresponding part
 " △ ": forward mark on the piston
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 Fuel system
Fuel system
1 Fuel inlet
2 Fuel filter
3 Injector
4 inlet hose
5 Return hose
6 tank
7 Governor
8 Suction hose
9 Transfer pump
10 injection pump
11 relief valve
12 return pipe
13 fuel tube
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 Cooling system

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 Cooling system
1 bolt
2 washer
3 fan
4 belt
5 bolt
6 adapter
7 pump pulley
8 pump group
9 seal - o- ring
* front cover
X: can’t be reused

V-belt (4) should be replaced one set a time. Even that only
one belt was failed.
Seal-o-ring (9) should be lubricated with soap liquid not oil
before installation, otherwise it will be expanded.
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 Cooling system
If the V-belt was not tensioned correctly, adjust the belt
follow the steps below:
 Loosen the bolts Q.
 Pry alternator toward outside to a correct tension.
 Hold the alternator and tighten the bolts Q.

Causing:
 Belt and or alternator bearing maybe
damaged if the belt was too tensioned.
 In order to keep the correct belt tension, V-best
should always be replaced once a set.
 V-belt should be free of oil or grease, otherwise it will
slip which result in overheating & battery
undercharged.
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 Alternator

Do not misconnect the battery terminals. Otherwise, the

diodes and regulator will be damaged.

Keep the alternator dry. The inside of the alternator will be

short or damaged if water comes in.

Do not disconnect the battery wire when engine is running.

The impulse voltage will be generated when the engine is
running, which will damage the diodes and regulator.
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 Heating plug

Pre-heating system testing:

 Turn the start switch to off position.
 Connect the checking lamp 2(24V-1,8W about)
to the heating plug.
 Turn the start switch to the heating position. If
the lamp 2 can not be lighted up, check the
heating plug or the heater relay.
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 Isuzu engine 6BG1T

6BG1T

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 Information

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 Fuel timing adjustment

1. Crank to No.1 cylinder top dead center (TDC) –

pointer aligned with the timing mark engraved
on the crankshaft pulley. And then… …
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 Fuel timing adjustment
2. Loose the four nuts.
3. Pry to rotate fuel
pump inside or outside.
1. Fuel timing advance:
rotate the pump
outward.
2. Fuel timing retard:
rotated the pump
inward.
3. Distance between two There are other two
scale is 1 mm which nuts behind the pump,
equals about crankshaft between the pump and
angle 2o. cylinder block, needs to
4. Tighten the four nuts be loosed.
correctly.
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 Inlet & exhaust
Exhaust gas push the hot
wheel of turbocharger to
rotate at high speed.
Compressor wheel rotated
A
R
at the same speed with
Fresh air

A
T D the turbine wheel.
I
T A Engine Clean fresh air is sucked
A T in by the cool wheel.
O
C R Compressed hot air was
then sent to the ATTAC.
Exhaust
Fresh air flow through the
From… … ATTAC sucked by fan.
Hot air in ATTAC is cooled
Turbocharger down, and sent to the
combustion chamber.
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 Turbocharger

Hot wheel is installed on the exhaust manifold, and driven

by the exhaust gas.
Lube oil came from the main oil gallery, flow through center
housing to lube and cool the turbo, and then back oil pan.
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 Turbocharger
Turbocharger consist of:
 Turbine housing
 Cartridge
 Compressor housing
 Turbine wheel
 Compressor wheel.
 Fasteners and so on.

Lubricated and cooled by lube

oil. For most of marine engine,
turbocharger was cooled by
coolant.
Turbine wheel and turbo shaft
was inertial welded into one
piece.
 If the balance was broken,
turbocharger will be damaged.
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 Aftercooler

Aftercooler was used in the turbocharged air inlet

and exhaust system commonly to cool down the
inlet air temperature and increase engine output
power about 15-20%.
Three types aftercooler:
Jacket water aftercooler. Gradually replaced by ATAAC.
Air to air aftercooler.
Separate water circuit aftercooler for superpower engine.
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 Cooling system
30% of heat energy generated
by fuel combustion was removed
by cooling system.
Regulator adjusted coolant temp
by directing the coolant to
different cycle circuit.
Fresh air flows through radiator
and coolant was cooled down
properly.

Coolant tank is in the rear of the radiator of the service door.

When engine is working, coolant level should be between
the upper and lower limit sign of the coolant tank.
Added coolant into the tank, not radiator, to the proper level.
If the coolant was filled excessively, it will be overflowed out
from the tank to the ground.
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 Regulator

By pass cycle circuit:

 Coolant temperature is lower than the regulator open temperature.
 Coolant is inducted to the water pump inlet from the cyl head.
 Engine will be warmed up rapidly.
Cooling cycle circuit:
 Coolant temperature is higher than the regulator max open point.
 Coolant is inducted to the radiator for cooling.
Two cycle circuit coexisted: coolant temp is between the regulator start
to open temperature and maximum open temperature.
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 Regulator

If the regulator was suspected

failed, it should be tested:
 Regulator start to open temperature.
 Regulator max opened temperature.
 Max distance that regulator opened.
A stick was used to stir water to
82oC get water temperature evenly.
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 Regulator

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 Belt tension

1. Apply 98N (10kg) force to the

middle of the belt as shown in
the illustration to measure the
belt deflection.

2. Position the small O-ring at

the point 98N of the vernier.

3. Position the big O-ring at the

point (the specified maximum
value of the belt deflection) of
the vernier.
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 Belt tension
4. Position at the middle of the belt,
press and push it until the part
indicated by the arrow touches the
O ring.

5. Measure the belt tension.

6. If the measured value is above the
standard value, adjust the belt
correctly.
7. Visually check the belt for crack
and damage. Replace the belt if
abnormal.

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 Lubrication system

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 Lubrication system – oil jet

Installed on the main oil gallery and supplied lube oil for
piston cooling and lubrication.
Can not be reused if the oil jet tube was bended.
Failure modes: bended, broken, and cracked.
If it oil jet tube was plugged by the dirty oil, … …
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 Oil pump
1、Oil strainer
2、Suction tube
3、Pump housing
4、Driven gear
5、Drive gear and shaft as
6、Driven gear shaft

Oil pump was driven by the

camshaft through the helical gear.
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 Engine rotation

From rear end view, engine rotated counterclockwise.

Standard rotation: counterclockwise from rear end view.
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 Be in the hospital

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 Engine animation

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 Information plate

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 Valve lash adjustment
No.1 compress TDC No.6 compress TDC

 Inlet valve – 0.4 mm

 Exhaust valve – 0.4 mm

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 Valve lash adjustment

Adjust the valve lash cylinder by cylinder:

 Adjust inlet and exhaust valve lash of the same cylinder each time.
 Crank engine 120o and adjust next cylinder’s valve lash as per fire order.
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 Cylinder pressure
Remove the injector of the checked
cylinder.
Install a shim and tool onto the
injector mounting hole, fix them with a
injection nozzle cap.
Install compression pressure gauge.
Start the engine and measure the
compression pressure of all cylinders.
Calculate the pressure differences
between cylinders.

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 Operation and maintenance

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 Operation and maintenance
Read and understand the OMM
manual carefully before repair or
maintenance was done.
Pay more attention to the safety
plates stamped on the hex.
Always keep a three-point contact
with the pedal & armrest and face
to hex when getting on or off the
excavator.
Hang a “Do Not Start” tag on the
joystick anytime the repair or
maintenance was done.
If water entered into combustion
chamber, never try to start engine
before the water was cleaned up.
Perform maintenance according to
the maintenance interval timely.
And so on… …
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 Oil filter replacement
Engine oil and oil filter
replace interval:
 Initial 50 hours.
 Every 250 hours.
Start and warm engine
before oil was drain.
Engine oil and oil filter
should be replaced at the
same time.
Drain oil thoroughly and
check debris in the oil.
Removed the oil filter, clean up the mating face of the filter
base, lubricate the new filter seal with clean oil, spin on and
tighten it correctly.
Cut open the used filter to check the metal debris in it.
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 Fuel filter replacement
Fuel system should be maintained
properly to get engine performed
excellently.
 Drain the tank every morning before
work.
 Drain the fuel water separator every
morning before work.
 Fill the fuel tank everyday after work
properly to drive out the vapor.
 Keep the breather of the fuel tank cap
clean and not blocked.
 Replace the fuel filter every 250 hrs
interval or as per requirement.
 Clean the fuel screens thoroughly.
 Bleed air and priming correctly.
 Prevent air leaked into fuel system.
 And so on… …
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 Before start inspection
Engine oil level:
Stop the hex on a solid flat ground.
Oil level should be between the full
and add marks on the dipstick.
Coolant lever:
Coolant level should be between the
full and add marks on the coolant
tank.
Coolant should be 10 mm above the
radiator core.
Fan belt:
Check for its tension.
Cracked or damaged?
Check for other abnormal phenomena, such as oil leakage,
coolant leakage, air hose clamp loosed, exhaust gas leakage,
temper color, fastener loosed, and so on.
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 After start inspection
Warm up engine:
 Let the engine run for 10 minutes with speed lower than
1000 rpm.
 Do not accelerate or take load before engine warm up,
especially in the cold season.
After start up inspection:
 Oil pressure: 290~590 kPa.
 Battery charge status.
 Engine operation sound and the smoke color.
 Leakage. Such as oil leakage, coolant leakage, fuel
leakage, air leakage, exhaust gas leakage, and so on.
 Coolant level and coolant temperature.
 Check other systems or components beside the engine
during the same time.
 If abnormal conditions occurred, resolve it before work.
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 Engine stop
After a long time working, engine should be cool
down stopped.
 Unload the excavator. Put the bucket on the ground.
 Return all the joysticks back to neutral position.
 Decelerated engine speed gradually. From high to low,
each dial position stayed for more than 15 seconds.
 Let engine run at low idle for five minutes to cool down
engine.
 Turn the start switch to off position to shut off engine.
 Move the joysticks in all directions to release the
pressure in the accumulator.
 Put the hydraulic activation control level to the lock
position.
 Close the window and lock the cab door.
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 Zexel fuel system

Andy Liu
 Photo view

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 System operation

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 Priming & transfer pump

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 Fuel injection pump

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 Pump operation

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 Before start

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 Start engine

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 Low idle

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 High idle

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 Full load

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 Engine shut off

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 Fuel pump workbench

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 Check endplay

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 Governor

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Andy Liu 371