Quality Changes the World

Crawler Hydraulic
Excavator

SY500H

Shop Manual
SY500H Hydraulic Excavator

SY500H
Hydraulic Excavator

Shop Manual

WARNING
• Read and follow the safety precautions and instructions in this manual and on the machine
decals. Failure to do can cause serious injury, death or property damage. Keep this manual
with the machine for reading and future reference.

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 SY500H Hydraulic Excavator

2 Shop Manual-June 2016

SY500H Hydraulic Excavator

Sany Group
Sany Heavy Machinery Limited.
Sany Industrial Park, Dongcheng avenue, Kunshan Economic Development Zone,
Jiangsu, China
Zip code: 215300
Service hotline: 4008 28 2318
Inquiring and Complaint Number: 4008 87 9318
http: //www.sanygroup.com

© 2016 by Sany Group. All rights reserved. No part of this publication may be
reproduced, used, distributed or disclosed except during normal operation of the
machine as described herein. All information included within this publication was
accurate at the time of publication. Product improvements, revisions, etc., may result in
differences between your machine and what is presented here. Sany Group assumes
no liability. For more information, contact Sany Group.

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2 Shop Manual-June 2016

 SY500H Hydraulic Excavator Table of Contents

Table of Contents
1 Introduction........................................................................................................................1-1
1.1 How to Read the Manual......................................................................................................1-5
1.1.1 General ..........................................................................................................................1-5
1.1.2 Shop manual organization ..........................................................................................1-5
1.1.3 Revision and distribution .............................................................................................1-6
1.1.4 Symbols .........................................................................................................................1-6
1.1.5 Units ...............................................................................................................................1-7
1.2 Technical Terms.....................................................................................................................1-7
1.2.1 General ..........................................................................................................................1-7
1.2.2 Standard size and tolerance .......................................................................................1-7
1.2.3 Standard clearance and value....................................................................................1-8
1.2.4 Standard interference ..................................................................................................1-9
1.2.5 Repair limit and allowable value.................................................................................1-9
1.2.6 Clearance limit ........................................................................................................... 1-10
1.2.7 Interference limit ........................................................................................................ 1-10
1.3 Handling Electrical and Hydraulic Components ............................................................ 1-10
1.3.1 General ....................................................................................................................... 1-10
1.3.2 Points to remember when handling electric components.....................................1-11
1.3.2.1 Handling wiring harnesses and connectors ....................................................1-11
1.3.2.2 Main failures occurring in wiring harness ........................................................1-11
1.3.2.3 Removing, installing, and drying connectors and wiring harnesses........... 1-13
1.3.2.4 Handling the integrated control monitor.......................................................... 1-18
1.3.2.5 Electric circuits troubleshooting precautions.................................................. 1-19
1.3.3 Points to remember when handling hydraulic equipment ................................... 1-19
1.3.3.1 General ................................................................................................................ 1-19
1.3.3.2 Be careful of the operating environment......................................................... 1-20
1.3.3.3 Disassembly and maintenance work in the field............................................ 1-20
1.3.3.4 Sealing openings................................................................................................ 1-20
1.3.3.5 Do not let any dirt or dust get in during refilling operations .......................... 1-21
1.3.3.6 Change hydraulic oil when the temperature is high ...................................... 1-21
1.3.3.7 Flushing operations ........................................................................................... 1-22
1.3.3.8 Cleaning operations........................................................................................... 1-22
1.4 Hose Connector ................................................................................................................. 1-23
1.4.1 General ....................................................................................................................... 1-23
1.4.2 Type of hose connector ............................................................................................ 1-23
1.4.3 Hose connector tightening torque table ................................................................. 1-23

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1.4.4 Connection of O-rings............................................................................................... 1-24

1.5 Table of Standard Tightening Torques ............................................................................ 1-25
1.6 Type of Bolts ....................................................................................................................... 1-26
1.7 Tightening Sequence......................................................................................................... 1-27
1.8 Maintenance of Half Flanges............................................................................................ 1-28
1.8.1 General ....................................................................................................................... 1-28
1.8.2 Table of tightening torques for half flange bolts..................................................... 1-28
1.8.3 Temperature ............................................................................................................... 1-33

2 Shop Safety ........................................................................................................................2-1

2.1 Hazard Alert Information ......................................................................................................2-5
2.2 General Shop Safety ............................................................................................................2-6
2.2.1 General ..........................................................................................................................2-6
2.2.2 Rules and shop behavior.............................................................................................2-7
2.2.3 Housekeeping ...............................................................................................................2-8
2.2.4 Shop Liquids Storage...................................................................................................2-8
2.2.5 Cleaning the Parts........................................................................................................2-9
2.2.6 Cleaning the Machine ..................................................................................................2-9
2.2.7 Appropriate Working Apparel .................................................................................. 2-10
2.2.8 Personal Protective Equipment............................................................................... 2-10
2.2.9 Using the Correct Tools .............................................................................................2-11
2.2.10 Fire Extinguisher and Emergency Exits................................................................2-11
2.2.11 Electrical Dangers ................................................................................................... 2-12
2.2.12 Hoisting a Load........................................................................................................ 2-12
2.3 Before Repair...................................................................................................................... 2-13
2.3.1 Safe Work Preparations ........................................................................................... 2-13
2.3.2 Preparing yourself ..................................................................................................... 2-14
2.3.3 Lockout/Tagout .......................................................................................................... 2-14
2.3.4 Two people when engine running ........................................................................... 2-16
2.3.5 Safety Partners .......................................................................................................... 2-17
2.4 Repair Precautions ............................................................................................................ 2-18
2.4.1 Running the Machine ................................................................................................ 2-18
2.4.2 Mounting and Dismounting ...................................................................................... 2-19
2.4.3 Removing Attachments ............................................................................................ 2-20
2.4.4 Jacking Up the Machine ........................................................................................... 2-20
2.4.5 Adding Fluids to a System........................................................................................ 2-21
2.4.6 Aligning Parts or Components................................................................................. 2-21
2.4.7 Driving Pins ................................................................................................................ 2-22
2.4.8 When compressed air is used ................................................................................. 2-22
2.4.9 Welding operation ..................................................................................................... 2-22
2.4.10 Track Recoil Springs............................................................................................... 2-23

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2.4.11 High-Pressure Fluid Lines...................................................................................... 2-23

2.4.12 Air-conditioning system maintenance .................................................................. 2-24
2.4.13 High voltage precautions........................................................................................ 2-24
2.4.14 Disconnecting the System Power ......................................................................... 2-25
2.4.15 Accumulator ............................................................................................................. 2-25
2.4.16 Battery Hazards....................................................................................................... 2-26
2.4.17 Jump-Start Safety ................................................................................................... 2-27
2.4.18 Avoiding fire and explosion.................................................................................... 2-27
2.4.19 Chemical hazard ..................................................................................................... 2-28
2.4.20 Material Safety Data Sheets (MSDS)................................................................... 2-28
2.4.21 Proper disposal of wastes...................................................................................... 2-29
2.5 Other Precautions .............................................................................................................. 2-30
2.5.1 Sling work and giving signals................................................................................... 2-30
2.5.2 Using mobile crane.................................................................................................... 2-32
2.5.3 Using overhead hoist crane ..................................................................................... 2-32
2.5.4 Selecting wire ropes.................................................................................................. 2-34

3 Specifications ...................................................................................................................3-1
3.1 Dimensions ............................................................................................................................3-3
3.2 Working ranges .....................................................................................................................3-4
3.3 Technical Specifications.......................................................................................................3-5
3.4 Table of Weights....................................................................................................................3-7
3.5 Engine Oil, Fuel and Coolant...............................................................................................3-8
3.6 Engine Performance Curve .................................................................................................3-9

4 Structure and Functions .............................................................................................4-1

4.1 Engine and Cooling System ................................................................................................4-7
4.1.1 Engine-relate parts.......................................................................................................4-7
4.1.2 Radiator and intercooler ..............................................................................................4-8
4.2 Power Train............................................................................................................................4-9
4.2.1 Power train ....................................................................................................................4-9
4.2.2 Travel reducer AS...................................................................................................... 4-10
4.2.3 Swing reduction mechanism.................................................................................... 4-12
4.2.4 Swing bearing ............................................................................................................ 4-14
4.3 Undercarriage..................................................................................................................... 4-15
4.3.1 Track frame and tensioning mechanism ................................................................ 4-15
4.3.2 Idler.............................................................................................................................. 4-17
4.3.3 Carrier roller ............................................................................................................... 4-18
4.3.4 Track roller.................................................................................................................. 4-20
4.3.5 Tracks.......................................................................................................................... 4-22
4.4 Hydraulic System, Part 1................................................................................................... 4-26

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4.4.1 Deployment of hydraulic parts ................................................................................. 4-26

4.4.2 Hydraulic Pump (SY500H)....................................................................................... 4-27
4.4.3 Pilot pump................................................................................................................... 4-30
4.4.4 Regulator (KR3S-9T1L-V)........................................................................................ 4-31
4.4.4.1 General ................................................................................................................ 4-31
4.4.4.2 Oil delivery control.............................................................................................. 4-47
4.4.5 Pilot pump................................................................................................................... 4-48
4.4.6 Regulator (KR3K-9N1H-V)....................................................................................... 4-49
4.5 Hydraulic System, Part 2................................................................................................... 4-61
4.5.1 Control valve .............................................................................................................. 4-61
4.5.1.1 General ................................................................................................................ 4-61
4.5.1.2 Main valve structure........................................................................................... 4-64
4.5.2 Hydraulic circuit (With bucket confluence function).............................................. 4-70
4.6 Hydraulic System, Part 3................................................................................................... 4-92
4.6.1 Swing motor ............................................................................................................... 4-92
4.6.2 Relief valve section ................................................................................................... 4-94
4.6.3 Anti-jerk valve............................................................................................................. 4-95
4.6.4 Central swivel joint .................................................................................................... 4-98
4.6.5 Travel motor ............................................................................................................... 4-99
4.6.5.1 General ................................................................................................................ 4-99
4.6.5.2 Operation of parking brake ............................................................................. 4-105
4.6.5.3 Operation of braking valve.............................................................................. 4-106
4.6.6 Control system ..........................................................................................................4-115
4.6.7 Pilot valve ..................................................................................................................4-116
4.6.8 Travel pilot valve...................................................................................................... 4-122
4.6.9 Solenoid valves........................................................................................................ 4-126
4.6.10 Pilot accumulator................................................................................................... 4-127
4.6.11 Pilot oil filter ............................................................................................................ 4-128
4.7 Work Equipment............................................................................................................... 4-129
4.7.1 Component dimensions.......................................................................................... 4-129
4.7.2 Arm dimensions ....................................................................................................... 4-132
4.7.3 Bucket dimensions .................................................................................................. 4-134
4.8 Air Conditioning System.................................................................................................. 4-136
4.8.1 Air Conditioning System ......................................................................................... 4-136
4.8.2 Layout of A/C components..................................................................................... 4-137
4.8.3 A/C control panel ..................................................................................................... 4-138
4.8.4 Diagram of electrical circuit.................................................................................... 4-139
4.8.5 Refrigeration principle............................................................................................. 4-140
4.8.6 Compressor.............................................................................................................. 4-142
4.8.7 Clutch ........................................................................................................................ 4-144

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4.8.8 Condenser ................................................................................................................ 4-144

4.8.9 Expansion valve....................................................................................................... 4-145
4.8.10 Evaporator.............................................................................................................. 4-145
4.8.11 Dehydrator.............................................................................................................. 4-146
4.8.12 Pressure switch ..................................................................................................... 4-147
4.8.13 Refrigerant.............................................................................................................. 4-147
4.8.13.1 General............................................................................................................ 4-147
4.8.13.2 Evacuation ...................................................................................................... 4-150
4.8.13.3 Refrigerant filling operation .......................................................................... 4-152
4.8.13.4 Troubleshooting with manifold pressure gauge......................................... 4-156
4.8.14 Compressor oil....................................................................................................... 4-163
4.9 Engine Control.................................................................................................................. 4-164
4.9.1 General ..................................................................................................................... 4-164
4.9.2 System operation..................................................................................................... 4-165
4.9.3 System components ............................................................................................... 4-166
4.9.3.1 Fuel control dial ................................................................................................ 4-166
4.9.3.2 Engine control unit (ECU) ............................................................................... 4-167
4.10 Electrical Control System.............................................................................................. 4-172
4.10.1 Control function ..................................................................................................... 4-172
4.10.2 Diagram of machine control system ................................................................... 4-173
4.10.3 Engine-pump combination control ...................................................................... 4-174
4.10.4 Valve control function............................................................................................ 4-176
4.10.5 Travel control function .......................................................................................... 4-177
4.10.6 Low engine oil pressure alarm and protection .................................................. 4-179
4.10.7 High engine coolant temperature alarm and protection .................................. 4-180
4.10.8 Engine preheating control .................................................................................... 4-181
4.10.9 Engine starting and energizing delay control .................................................... 4-182
4.10.10 System parts and components ......................................................................... 4-183
4.10.10.1 Pump pressure sensor................................................................................ 4-183
4.10.10.2 Pilot pressure sensor .................................................................................. 4-184
4.10.10.3 Engine speed sensor .................................................................................. 4-185
4.10.10.4 Coolant temperature sensor ...................................................................... 4-186
4.10.10.5 Fuel level sensor.......................................................................................... 4-186
4.10.10.6 Oil pressure switch ...................................................................................... 4-187
4.11 Monitor System............................................................................................................... 4-188
4.11.1 General ................................................................................................................... 4-188
4.11.2 Monitor .................................................................................................................... 4-189
4.11.3 Monitor panel ......................................................................................................... 4-190
4.11.4 Monitor operation................................................................................................... 4-192
4.11.4.1 Default page.................................................................................................... 4-192

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4.11.4.2 Main Menu Password entry to system information ................................... 4-194

4.11.4.3 Main Menu....................................................................................................... 4-195
4.11.4.4 System Lockout .............................................................................................. 4-195
4.11.4.5 Engine & Throttle Signals ............................................................................. 4-196
4.11.4.6 Pilot Pressure Signals ................................................................................... 4-196
4.11.4.7 Main & Cooling Pump Signals...................................................................... 4-197
4.11.4.8 Input & Output Switch Signals...................................................................... 4-197
4.11.4.9 Failure information ......................................................................................... 4-198
4.11.4.10 GPS Information........................................................................................... 4-198
4.11.4.11 Language Selection ..................................................................................... 4-199
4.11.4.12 System Time Calibration............................................................................. 4-199
4.11.4.13 Maintenance Information ............................................................................ 4-200
4.11.4.14 Maintenance Confirmation ......................................................................... 4-200
4.11.4.15 System Setting ............................................................................................. 4-201
4.11.4.16 Machine Configuration Setting................................................................... 4-201
4.11.4.17 Operation Time Calibration......................................................................... 4-202
4.11.4.18 Machine Configuration Setup..................................................................... 4-202
4.11.4.19 Alarm Content Setting ................................................................................. 4-203
4.11.4.20 Screen Backlight Adjust .............................................................................. 4-203
4.11.4.21 Running Correct Setting.............................................................................. 4-204
4.11.4.22 Engine Information....................................................................................... 4-204
4.11.4.23 Engine Failure Information ......................................................................... 4-205
4.11.4.24 Engine other information............................................................................. 4-205
4.11.4.25 Daily maintenance information .................................................................. 4-206
4.11.4.26 System lockout information ........................................................................ 4-206

5 Standard Values...............................................................................................................5-1
5.1 Standard Values for Engine-Related Parts .......................................................................5-3
5.2 Standard Values for Chassis-Related Parts......................................................................5-4

6 Testing and Adjusting ..................................................................................................6-1

6.1 Exhaust Gas Color - Test .....................................................................................................6-3
6.2 Valve Clearance - Adjust......................................................................................................6-4
6.3 Compression Force - Test....................................................................................................6-6
6.4 Fuel Injection Timing - Test and Adjust ..............................................................................6-8
6.5 Engine Oil Pressure - Test ...................................................................................................6-9
6.6 Engine Speed Sensor - Adjust ..........................................................................................6-11
6.7 A/C Compressor Belt Tension - Check and Adjust.........................................................6-11
6.8 Swing Bearing Clearance - Check................................................................................... 6-12

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6.9 Track Tensioning device - Check and Adjust ................................................................. 6-14

6.10 Oil in hydraulic circuits - Test and Adjust ...................................................................... 6-15
6.11 Control Oil Circuit Pressure - Check and Adjust.......................................................... 6-19
6.12 Solenoid Valve Output Pressure - Test ......................................................................... 6-20
6.13 Pilot Valve Output Pressure - Test................................................................................. 6-22
6.14 Work Equipment and Swing PPC Valves - Adjust....................................................... 6-24
6.15 Hydraulic Drift of Work Equipment - Test...................................................................... 6-24
6.16 Remaining Pressure in Hydraulic Lines - Relieve....................................................... 6-26
6.17 Oil Leakage Amount - Test ............................................................................................. 6-27
6.18 Air in Each Component - Purge ..................................................................................... 6-31
6.19 Sensors - Test................................................................................................................... 6-33
6.19.1 Coolant temperature sensor .................................................................................. 6-33
6.19.2 Checking engine spe .............................................................................................. 6-34
6.19.3 Pressure sensor ...................................................................................................... 6-34
6.19.4 Fuel level sensor ..................................................................................................... 6-35

7 Troubleshooting ..............................................................................................................7-1
7.1 General ...................................................................................................................................7-3
7.2 Checks before Troubleshooting ..........................................................................................7-4
7.3 Troubleshooting Types and Steps ......................................................................................7-5
7.3.1 Troubleshooting types .................................................................................................7-5
7.3.2 Troubleshooting steps .................................................................................................7-5
7.4 Connectors.............................................................................................................................7-7
7.4.1 List of connectors .........................................................................................................7-7
7.4.2 Connector locations ...................................................................................................7-11
7.4.3 SWP connectors........................................................................................................ 7-13
7.4.4 A/AMP connectors..................................................................................................... 7-14
7.4.5 DT connectors ............................................................................................................ 7-14
7.5 Troubleshooting with an Event Code .............................................................................. 7-16
7.6 Troubleshooting the Electrical System (E-Mode).......................................................... 7-23
7.7 Troubleshooting the Hydraulic and Mechanical System (H-Mode) ............................ 7-47

8 Disassembly and Assembly......................................................................................8-1

8.1 Operating Precautions..........................................................................................................8-7
8.2 Start Motor AS .......................................................................................................................8-9
8.2.1 Removing sequence ....................................................................................................8-9
8.2.2 Installing sequence ................................................................................................... 8-10
8.3 Fuel Injection Pump AS..................................................................................................... 8-10
8.3.1 Removal...................................................................................................................... 8-10
8.4 Engine Rear Oil Seal ......................................................................................................... 8-16
8.4.1 Removal...................................................................................................................... 8-16

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8.4.2 Installation .................................................................................................................. 8-17

8.5 Cylinder Head AS............................................................................................................... 8-17
8.5.1 Removal...................................................................................................................... 8-17
8.5.2 Installation .................................................................................................................. 8-20
8.6 Engine Rear Oil Seal ......................................................................................................... 8-22
8.6.1 Removal...................................................................................................................... 8-22
8.6.2 Installation .................................................................................................................. 8-23
8.7 Cylinder Head AS............................................................................................................... 8-26
8.7.1 Removal...................................................................................................................... 8-26
8.7.2 Insallation.................................................................................................................... 8-28
8.8 Radiator AS......................................................................................................................... 8-40
8.9 Engine and Hydraulic Pump AS....................................................................................... 8-44
8.9.1 Removal...................................................................................................................... 8-44
8.9.2 Installation .................................................................................................................. 8-50
8.10 Radiator AS....................................................................................................................... 8-51
8.11 Engine and Hydraulic Pump AS..................................................................................... 8-56
8.11.1 Removal.................................................................................................................... 8-56
8.11.2 Installation ................................................................................................................ 8-62
8.12 Final Drive AS................................................................................................................... 8-62
8.12.1 Removal.................................................................................................................... 8-62
8.12.2 Installation ................................................................................................................ 8-63
8.13 Final Drive AS................................................................................................................... 8-64
8.13.1 Disassembly............................................................................................................. 8-64
8.13.2 Assembly .................................................................................................................. 8-67
8.14 Swing Motor and Swing Drive AS.................................................................................. 8-72
8.14.1 Removal.................................................................................................................... 8-72
8.14.2 Installation ................................................................................................................ 8-73
8.14.3 Disassembly............................................................................................................. 8-74
8.14.4 Assembly .................................................................................................................. 8-79
8.15 Idler AS.............................................................................................................................. 8-84
8.15.1 Disassembly............................................................................................................. 8-84
8.15.2 Assembly .................................................................................................................. 8-85
8.16 Sprocket ............................................................................................................................ 8-88
8.16.1 Removal.................................................................................................................... 8-88
8.16.2 Installation ................................................................................................................ 8-88
8.17 Track AS............................................................................................................................ 8-88
8.17.1 Removal.................................................................................................................... 8-88
8.17.2 Installation ................................................................................................................ 8-90
8.18 Swing Bearing AS ............................................................................................................ 8-91
8.18.1 Removal.................................................................................................................... 8-91
8.18.2 Installation ................................................................................................................ 8-91

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8.19 Swing frame AS................................................................................................................ 8-92

8.19.1 Removal.................................................................................................................... 8-92
8.19.2 Installation ................................................................................................................ 8-95
8.20 Swivel Joint AS................................................................................................................. 8-96
8.20.1 Removal.................................................................................................................... 8-96
8.20.2 Installation ................................................................................................................ 8-98
8.21 Central Swivel Joint AS................................................................................................... 8-99
8.21.1 Disassembly............................................................................................................. 8-99
8.21.2 Assembly ................................................................................................................ 8-100
8.22 Hydraulic Tank AS.......................................................................................................... 8-100
8.22.1 Removal.................................................................................................................. 8-100
8.22.2 Installation .............................................................................................................. 8-102
8.23 Control Valve AS ............................................................................................................ 8-103
8.23.1 Removal.................................................................................................................. 8-103
8.23.2 Installation .............................................................................................................. 8-106
8.24 Hydraulic Pump AS........................................................................................................ 8-107
8.24.1 Removal.................................................................................................................. 8-107
8.24.2 Installation .............................................................................................................. 8-109
8.25 Middle Oil Seal (Hydraulic Pump Input Shaft) ............................................................8-110
8.25.1 Removal...................................................................................................................8-110
8.25.2 Installation ...............................................................................................................8-111
8.26 Independent Radiator AS ..............................................................................................8-111
8.26.1 ..................................................................................................................................8-111
8.26.2 Installation ...............................................................................................................8-111
8.27 Work Equipment Pilot Valve AS....................................................................................8-111
8.27.1 Assembly .................................................................................................................8-111
8.28 Travel Pilot Valve AS ......................................................................................................8-113
8.28.1 Assembly .................................................................................................................8-113
8.29 Hydraulic Cylinder AS ....................................................................................................8-113
8.29.1 Disassembly............................................................................................................8-113
8.29.2 Assembly ................................................................................................................ 8-120
8.30 Work Equipment AS ...................................................................................................... 8-125
8.30.1 Removal.................................................................................................................. 8-125
8.30.2 Installation .............................................................................................................. 8-126
8.31 Air Conditioner AS ......................................................................................................... 8-127
8.31.1 Removal.................................................................................................................. 8-127
8.31.2 Installation .............................................................................................................. 8-131
8.32 Counterweight AS.......................................................................................................... 8-131
8.32.1 Removal.................................................................................................................. 8-131
8.32.2 Installation .............................................................................................................. 8-132
8.33 Cab AS ............................................................................................................................ 8-133

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8.33.1 Removal.................................................................................................................. 8-133

8.33.2 ................................................................................................................................. 8-136
8.34 Monitor............................................................................................................................. 8-137
8.34.1 Removal.................................................................................................................. 8-137
8.34.2 Installation .............................................................................................................. 8-137
8.35 Controller AS .................................................................................................................. 8-137
8.35.1 Removal.................................................................................................................. 8-137
8.35.2 Installation .............................................................................................................. 8-138
8.36 Radio................................................................................................................................ 8-138
8.36.1 Structure ................................................................................................................. 8-138
8.36.2 Removal.................................................................................................................. 8-139
8.36.3 Installation .............................................................................................................. 8-140
8.36.4 Connector model and wiring................................................................................ 8-141
8.37 Battery ............................................................................................................................. 8-141
8.37.1 Structure ................................................................................................................. 8-141
8.38 Battery ............................................................................................................................. 8-142
8.38.1 Installation and Removal...................................................................................... 8-142
8.38.2 Installation .............................................................................................................. 8-142
8.38.3 Replacement.......................................................................................................... 8-143
8.39 Start Switch..................................................................................................................... 8-144
8.39.1 Structure ................................................................................................................. 8-144
8.39.2 Removal.................................................................................................................. 8-145
8.39.3 Installation .............................................................................................................. 8-146
8.39.4 Working principle and wiring................................................................................ 8-146
8.40 Electrical Power Center ................................................................................................ 8-147
8.40.1 Installation and Removal...................................................................................... 8-147
8.40.2 Installation .............................................................................................................. 8-148
8.41 Wiper................................................................................................................................ 8-148
8.41.1 Structure ................................................................................................................. 8-148
8.41.2 Working principle................................................................................................... 8-149
8.41.3 Removal.................................................................................................................. 8-149
8.41.4 Installation .............................................................................................................. 8-150
8.41.5 Wiper arm angle adjustment................................................................................ 8-151
8.42 Relays.............................................................................................................................. 8-151
8.42.1 Engine relays ......................................................................................................... 8-151
8.42.2 Other load relays ................................................................................................... 8-152
8.43 Connector Terminals ..................................................................................................... 8-154
8.43.1 Insertion .................................................................................................................. 8-154
8.43.2 Removal.................................................................................................................. 8-155

9 System Schematics .......................................................................................................9-1

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9.1 Hydraulic Circuit Diagram ....................................................................................................9-3

9.2 Electrical Diagram.................................................................................................................9-4
9.3 Cab harness........................................................................................................................ 9-16
9.4 Control Switch Harness..................................................................................................... 9-17
9.5 Tool box Harness................................................................................................................ 9-18
9.6 Pump room Harness.......................................................................................................... 9-19
9.7 Vehicle Body Harness ....................................................................................................... 9-20
9.8 Boom Harness.................................................................................................................... 9-21

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 SY500H Hydraulic Excavator

XII Shop Manual-June 2016

 SY500H Hydraulic Excavator Introduction

Introduction
1 Introduction........................................................................................................................1-1
1.1 How to Read the Manual......................................................................................................1-5
1.1.1 General .........................................................................................................................1-5
1.1.2 Shop manual organization .........................................................................................1-5
1.1.3 Revision and distribution............................................................................................1-6
1.1.4 Symbols........................................................................................................................1-6
1.1.5 Units ..............................................................................................................................1-7
1.2 Technical Terms.....................................................................................................................1-7
1.2.1 General .........................................................................................................................1-7
1.2.2 Standard size and tolerance......................................................................................1-7
1.2.3 Standard clearance and value ..................................................................................1-8
1.2.4 Standard interference.................................................................................................1-9
1.2.5 Repair limit and allowable value ...............................................................................1-9
1.2.6 Clearance limit.......................................................................................................... 1-10
1.2.7 Interference limit....................................................................................................... 1-10
1.3 Handling Electrical and Hydraulic Components ............................................................ 1-10
1.3.1 General ...................................................................................................................... 1-10
1.3.2 Points to remember when handling electric components ...................................1-11
1.3.2.1 Handling wiring harnesses and connectors ...................................................1-11
1.3.2.2 Main failures occurring in wiring harness .......................................................1-11
1.3.2.3 Removing, installing, and drying connectors and wiring
harnesses .................................................................................................. 1-13
1.3.2.4 Handling the integrated control monitor ........................................................ 1-18
1.3.2.5 Electric circuits troubleshooting precautions ................................................ 1-19
1.3.3 Points to remember when handling hydraulic equipment .................................. 1-19
1.3.3.1 General............................................................................................................... 1-19
1.3.3.2 Be careful of the operating environment ....................................................... 1-20
1.3.3.3 Disassembly and maintenance work in the field .......................................... 1-20
1.3.3.4 Sealing openings .............................................................................................. 1-20

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 Introduction SY500H Hydraulic Excavator

1.3.3.5 Do not let any dirt or dust get in during refilling operations......................... 1-21
1.3.3.6 Change hydraulic oil when the temperature is high..................................... 1-21
1.3.3.7 Flushing operations .......................................................................................... 1-22
1.3.3.8 Cleaning operations ......................................................................................... 1-22
1.4 Hose Connector ................................................................................................................. 1-23
1.4.1 General ...................................................................................................................... 1-23
1.4.2 Type of hose connector ........................................................................................... 1-23
1.4.3 Hose connector tightening torque table ................................................................ 1-23
1.4.4 Connection of O-rings.............................................................................................. 1-24
1.5 Table of Standard Tightening Torques ............................................................................ 1-25
1.6 Type of Bolts ....................................................................................................................... 1-26
1.7 Tightening Sequence......................................................................................................... 1-27
1.8 Maintenance of Half Flanges............................................................................................ 1-28
1.8.1 General ...................................................................................................................... 1-28
1.8.2 Table of tightening torques for half flange bolts ................................................... 1-28
1.8.3 Temperature.............................................................................................................. 1-33

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Introduction SY500H Hydraulic Excavator

WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.

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 SY500H Hydraulic Excavator Introduction

1.Introduction

1.1 How to Read the Manual

1.1.1 General

• Some attachments and optional parts in this

shop manual may not be delivered to cer-
tain areas. If one of them is required, con-
sult Sany distributors.
• Materials and specifications are subject to
change without notice.

1.1.2 Shop manual organization

This shop manual contains the necessary

technical information for services performed
in a workshop. For ease of understanding, the
manual is divided into the following sections.

Introduction

This section provides an overview of what is

covered in the rest of this manual and how to
use this manual.

Shop Safety

This section covers basic shop safety informa-

tion relating to this equipment. It also de-
scribes what the hazard alerts mean that are
used throughout the manual.

Specifications

Technical specification of work equipment and

optional parts are given in this section.

Structure and functions

This section explains the structure and func-

tion of each component. It helps the reader to
get a better understanding of the machine
structure, and also serves as a reference for
troubleshooting.

Standard Values

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 Introduction SY500H Hydraulic Excavator

This section explains the standard values for

a new machine and judgement criteria for
testing, adjusting, and troubleshooting. This
standard value table is used to check the
standard values in testing and adjusting and
to judge parts in troubleshooting.

Testing and adjusting

This section details the inspection before and

after repair work as well as the adjustment
during inspection and repair work. Trouble-
shooting table that involves “Fault”and “Cau-
se”are also included in this section.

Troubleshooting

This section explains the way to detect faulty

parts and the method to repair them. This sec-
tion is divided into the following parts: Electri-
cal system, Engine, Hydraulic and mechanical
system and Monitoring system.

Disassembly and assembly

This section explains the procedures as well

as precautions for removing, installing, disas-
sembling and assembling of each component.

System Schematics

This section provides hydraulic circuit dia-

grams and electrical circuit diagrams.

1.1.3 Revision and distribution

Any complements, revisions, or other change

of notices will be sent to Sany distributors. Get
the most up-to-date information before you
start any work.

1.1.4 Symbols

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

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 SY500H Hydraulic Excavator Introduction

Symbol Item Remarks

Special safety precautions are necessary when
Safety
performing work.
Special technical precautions or other precautions
Caution for preserving standards are necessary when
performing work.
Weight of parts of component or parts. Caution
Weight necessary when selecting hoisting wire, or when
working posture is important, etc.
Tightening Places that require special attention for tightening
torque torque during assembly.
Places to be coated with adhesives, etc. during
Coat
assembly.
Oil, Places where oil, etc. must be added, and
Coolant capacity.
Places where oil, etc. must be drained, and
Drain
quantity to be drained.

1.1.5 Units

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

1.2 Technical Terms

1.2.1 General

The maintenance standard values necessary

for judgment of products and parts are de-
scribed by the following terms.

1.2.2 Standard size and tolerance

• To be accurate, the finishing size of parts is

a little different from one to another.
• To specify a finishing size of a part, a tem-
porary standard size is set and an allowable
difference from that size is indicated.
• The above size set temporarily is called the
"standard size" and the range of difference

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 Introduction SY500H Hydraulic Excavator

from the standard size is called the

"tolerance".
• The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.

Example

Standard size Tolerance

–0.022
120
–0.126

★ The tolerance may be indicated in the text

and a table as [standard size (upper limit of
tolerance/lower limit of tolerance)]. Example)
120 (–0.022/–0.126)

• Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and differ-
ent tolerances of the hole and shaft. The
tightness of fit is decided by the tolerance.
• Indication of size of rotating shaft and hole
and relationship drawing of them. Fig.1-1

Example

Standard Tolerance
size Shaft Hole
-0.030 +0.046
Φ60
-0.076 0

1.2.3 Standard clearance and value

• The clearance made when new parts are

assembled is called the "standard clear-
ance", which is indicated by the range from
the minimum clearance to the maximum
clearance.
• When some parts are repaired, the clear-
ance is generally adjusted to the standard
clearance.
• A value of performance and function of new
products or equivalent is called the

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SY500H Hydraulic Excavator Introduction

"standard value", which is indicated by a

range or a target value.
• When some parts are repaired, the value of
performance/function is set to the standard
value.

1.2.4 Standard interference

• When the size of a hole is smaller than the

size of a shaft because of the standard size
and tolerance, the difference between these
sizes is called the "interference".
• The range (A – B) from the difference (A)
between the minimum size of the shaft and
the maximum size of the shaft to the differ-
ence (B) between the maximum size of the
shaft and the minimum size of the hole is
the "standard interference".
• After repairing or replacing some parts,
measure the size of their hole and shaft and
check that the interference is in the stand-
ard range.

1.2.5 Repair limit and allowable value

• The size of a part changes due to wear and

deformation while it is used. The limit of
changed size is called the "repair limit".
• If a part is worn to the repair limit must be
replaced or repaired.
• The performance and function of a product
lowers while it is used. A value below which
the product can be used without causing a
problem is called the "allowable value".
• If a product is worn to the allowable value, it
must be checked or repaired. Since the per-
missible value is estimated from various
tests or experiences in most cases, how-
ever, it must be judged after considering the
operating condition and customer's
requirement.

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 Introduction SY500H Hydraulic Excavator

1.2.6 Clearance limit

• Parts can be used until the clearance be-

tween them is increased to a certain limit.
The limit at which those parts cannot be
used is called the "clearance limit".
• If the clearance between the parts exceeds
the clearance limit, they must be replaced
or repaired.

1.2.7 Interference limit

• The allowable maximum interference be-

tween the hole of a part and the shaft of an-
other part to be assembled is called the
"interference limit".
• The interference limit shows the repair limit
of the part of smaller tolerance.
• If the interference between the parts ex-
ceeds the interference limit, they must be
replaced or repaired.

1.3 Handling Electrical and Hydraulic Components

1.3.1 General

To maintain the performance of the machine

over a long period, and to prevent failures or
other troubles before they occur, correct "op-
eration", "maintenance and inspection", "trou-
bleshooting", and "repairs" must be carried
out. This section deals particularly with correct
repair procedures for mechatronics and is
aimed at improving the quality of repairs. For
this purpose, it gives sections on "Handling
electric components" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic
oil).

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 SY500H Hydraulic Excavator Introduction

1.3.2 Points to remember when handling electric components

1.3.2.1 Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting

one component to another component, con-
nectors used for connecting and disconnect-
ing one wire from another wire, and protectors
or tubes used for protecting the wiring.

Compared with other electrical components

fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, Fig.1-2
so they are likely to suffer deformation or
damage. For this reason, it is necessary to be
extremely careful when handling wiring
harnesses.

1.3.2.2 Main failures occurring in wiring harness

1. Defective contact of connectors (defective

contact between male and female)

Problems with defective contact are likely to

occur because the male connector is not
properly inserted into the female connector, or
because one or both of the connectors is de-
formed or the position is not correctly aligned,
or because there is corrosion or oxidation of
the contact surfaces.
Fig.1-3

2. Defective crimping or soldering of

connectors

The pins of the male and female connectors

are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper connec-
tion or breakage.

Fig.1-4

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 Introduction SY500H Hydraulic Excavator

3. Disconnections in wiring

If the wiring is held and the connectors are

pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the soldering
may be damaged, or the wiring may be
broken.

Fig.1-5

4. High-pressure water entering connector

The connector is designed to make it difficult

for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on the
connector, water may enter the connector, de-
pending on the direction of the water jet. Ac-
cordingly, take care not splash water over the
connector. The connector is designed to pre-
vent water from entering, but at the same
time, if water does enter, it is difficult for it to
be drained. Therefore, if water should get into
the connector, the pins will be short-circuited Fig.1-6
by the water, so if any water gets in, immedi-
ately dry the connector or take other appropri-
ate action before passing electricity through it.

5. Oil or dirt stuck to connector

If oil or grease are stuck to the connector and

an oil film is formed on the mating surface be-
tween the male and female pins, the oil will
not let the electricity pass, so there will be de-
fective contact. If there is oil or grease stuck
to the connector, wipe it off with a dry cloth or
blow it dry with compressed air and spray it
with a contact restorer.

★ When wiping the mating portion of the con-

nector, be careful not to use excessive force
Fig.1-7
or deform the pins.

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 SY500H Hydraulic Excavator Introduction

★ If there is oil or water in the compressed air,

the contacts will become even dirtier, so re-
move the oil and water from the compressed
air completely before cleaning with com-
pressed air.

1.3.2.3 Removing, installing, and drying connectors and wiring harnesses

1. Disconnecting connectors

A. Hold the connectors when disconnecting.

hold the connectors. For connectors held by a

screw, loosen the screw fully, then hold the
male and female connectors in each hand
and pull apart. For connectors which have a
lock stopper, press down the stopper with
your thumb and pull the connectors apart.

★ Never pull with one hand.

Fig.1-8

B. When removing from clips

• Both of the connector and clip have stop-

pers, which are engaged with each other
when the connector is installed.

Fig.1-9

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 Introduction SY500H Hydraulic Excavator

• When removing a connector from a clip, pull

the connector in a parallel direction to the
clip for removing stoppers.

★ If the connector is twisted up and down or

to the left or right, the housing may break.

Fig.1-10

C. Action to take after removing connectors

After removing any connector, cover it with a

vinyl bag to prevent any dust, dirt, oil, or water
from getting in the connector portion.

★ If the machine is left disassembled for a

long time, it is particularly easy for improper
contact to occur, so always cover the
connector.

Fig.1-11

2. Connecting connectors

A. Check the connector visually

Check that there is no oil, dirt, or water stuck

to the connector pins (mating portion).

Check that there is no deformation, defective

contact, corrosion, or damage to the connec-
tor pins.

Check that there is no damage or breakage to

the outside of the connector. Fig.1-12

★ If there is any oil, water, or dirt stuck to the

connector, wipe it off with a dry cloth. If any
water has got inside the connector, warm the
inside of the wiring with a dryer, but be careful

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 SY500H Hydraulic Excavator Introduction

not to make it too hot as this will cause short

circuits.

★ If there is any damage or breakage, replace

the connector.

B. Fix the connector securely.

Align the position of the connector correctly,

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

C. Correct any protrusion of the boot and any

misalignment of the wiring harness.

For connectors fitted with boots, correct any

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

★ If the connector cannot be corrected easily,

remove the clamp and adjust the position.

• If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps. Fig.1-13

Fig.1-14

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 Introduction SY500H Hydraulic Excavator

3. Connecting DT connectors

Since the DT 8-pin and 12-pin heavy duty wire

connectors have 2 latches respectively, push
them in until they click 2 times.

• Male connector: 1
• Female connector: 2
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c

Fig.1-15

4. Drying wiring harness

If there is any oil or dirt on the wiring harness,

wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must
be washed in water, do not use high-pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as
follows.

A. Disconnect the connector and wipe off the

water with a dry cloth.

★ If the connector is blown dry with com- Fig.1-16

pressed air, there is the risk that oil in the air
may cause defective contact, so remove all oil
and water from the compressed air before
blowing with air.

B. Dry the connector with a dryer.

If water gets inside the connector, use a dryer

to dry the connector.

★ Hot air from the dryer can be used, but reg-

ulate the time that the hot air is used in order
not to make the connector or related parts too
hot, as this will cause deformation or damage Fig.1-17
to the connector.

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 SY500H Hydraulic Excavator Introduction

C. Carry out a continuity test on the

connector.

After drying, leave the wiring harness discon-

nected and carry out a continuity test to check
for any short circuits between pins caused by
water.

★ After completely drying the connector, blow

it with contact restorer and reassemble.

Fig.1-18

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 Introduction SY500H Hydraulic Excavator

1.3.2.4 Handling the integrated control monitor

1. The integrated control monitor contains a

microcomputer, an electronic control circuits,
an LCD monitor and GPS positioning circuit.
They control all of the electronic circuits on
the machine, so be extremely careful when
handling the integrated control monitor.

2. Do not place objects on the integrated con-

trol monitor.

3. Cover the control connectors with tape or a

vinyl bag. Never touch the connector contacts
with your hand.
Fig.1-19
4. Do not leave it where it may be exposed to
rain.

5. Do not place the integrated control monitor

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

6. Precautions for arc welding

When welding on the controller, disconnect all

wiring harness connectors connected to the
controller. Fit an arc welding ground close to
Fig.1-20
the welding point.

Fig.1-21

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 SY500H Hydraulic Excavator Introduction

1.3.2.5 Electric circuits troubleshooting precautions

1. Always turn the power OFF before discon-

necting or connecting connectors.

2. Before carrying out troubleshooting, check

that all the related connectors are properly
inserted.
★ Disconnect and connect the related con-
nectors several times to check.

3. Always connect any disconnected connec-

tors before going on to the next step.
★ If the power is turned ON with the connec-
tors still disconnected, unnecessary abnor-
mality displays will be generated.

4. When carrying out troubleshooting of cir-

cuits (measuring the voltage, resistance, con-
tinuity, or current), move the related wiring
and connectors several times and check that
there is no change in the reading of the tester.
★ If there is any change, there is probably de-
fective contact in that circuit.

1.3.3 Points to remember when handling hydraulic equipment

1.3.3.1 General

With the increase in pressure and precision of

hydraulic equipment, the most common cause
of failure is dirt (foreign material) in the hy-
draulic circuit. When adding hydraulic oil, or
when disassembling or assembling hydraulic
equipment, it is necessary to be particularly
careful.

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 Introduction SY500H Hydraulic Excavator

1.3.3.2 Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or

repairing the machine in rain or high winds, or
places where there is a lot of dust.

Fig.1-22

1.3.3.3 Disassembly and maintenance work in the field

If disassembly or maintenance work is carried

out on hydraulic equipment in the field, there
is danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dust-proof workshop, and the per-
formance should be checked with special test
equipment.

1.3.3.4 Sealing openings

After any piping or equipment is removed, the

openings should be sealed with caps, tapes,
or vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt en-
tering or of the surrounding area being made
dirty by leaking oil so never do this. Do not
simply drain oil out onto the ground, but col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.

Fig.1-23

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 SY500H Hydraulic Excavator Introduction

1.3.3.5 Do not let any dirt or dust get in during refilling operations

Be careful not to let any dirt or dust get in

when refilling with hydraulic oil. Always keep
the oil filler and the area around it clean, and
also use clean pumps and oil containers. If an
oil cleaning device is used, it is possible to fil-
ter out the dirt that has collected during stor-
age, so this is an even more effective method.

Fig.1-24

1.3.3.6 Change hydraulic oil when the temperature is high

When hydraulic oil or other oil is warm, it flows

easily. In addition, the sludge can also be
drained out easily from the circuit together
with the oil, so it is best to change the oil when
it is still warm. When changing the oil, as
much as possible of the old hydraulic oil must
be drained out. (Drain the oil from the hydraul-
ic tank; also drain the oil from the filter and
from the drain plug in the circuit.) If any old oil
is left, the contaminants and sludge in it will
mix with the new oil and will shorten the life of
the hydraulic oil.

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 Introduction SY500H Hydraulic Excavator

1.3.3.7 Flushing operations

After disassembling and assembling the

equipment, or changing the oil, use flushing
oil to remove the contaminants, sludge, and
old oil from the hydraulic circuit. Normally,
flushing is carried out twice: primary flushing
is carried out with flushing oil, and secondary
flushing is carried out with the specified hy-
draulic oil.

Fig.1-25

1.3.3.8 Cleaning operations

After repairing the hydraulic equipment

(pump, control valve, etc.) or when running
the machine, carry out oil cleaning to remove
the sludge or contaminants in the hydraulic oil
circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 μ) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.

Fig.1-26

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1.4 Hose Connector

1.4.1 General

Hose connector is used to connect hoses with

a small diameter. The metal sealing surface
(4) of the joint (1) must be in close contact
with the metal sealing surface (5) of the hose
(2) to seal pressurized oil.

CAUTION
• Do not over-tighten the nut (3). Excessive
force applied on the metal sealing surface
(4) and (5) may cause the joint (1) to break. Fig.1-27
Be sure to tighten nut (3) according to
technical specifications.
• Scratches or other damages on sealing
surface (4) and (5) may cause leaks at the
joint. Be extremely careful not to damage
the sealing surfaces during connecting and
disconnecting work.

1.4.2 Type of hose connector

Fig.1-28

1.4.3 Hose connector tightening torque table

Wrench size mm Wrench size mm Tightening torque

Type
Connecting nut Hose joint N·m（kgf·m,lbf·ft）
19 19 59（6,44）
24° Male 22 22 98（10,72）
27 27 118（12,87）
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 Introduction SY500H Hydraulic Excavator

Wrench size mm Wrench size mm Tightening torque

Type
Connecting nut Hose joint N·m（kgf·m,lbf·ft）
36 36 235（24,173）
41 41 295（30,218）
50 50 490（50,361）
60 60 670（68,494）
70 70 980（100,723）
19 17 44（4.5,32）
22 19 59（6,44）
27 22 118（12,87）
24° Female
36 30, 32 235（24,173）
41 36 295（30,218）
50 46 490（50,361）

CAUTION
• The torque values listed in the table are intended for general application.
• Do not use torque values listed in this table when different torque values are specified for a spe-
cial purpose.

1.4.4 Connection of O-rings

Place O-ring (6) in contact with the contact

surface of the joint (7) to seal the pressurized
oil.

Fig.1-29

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 SY500H Hydraulic Excavator Introduction

CAUTION
• Replace o-rings (6) with new ones when re-connecting hoses.
• Before tightening nut (9), make sure the o-ring (6) has been placed into the o-ring seat (8).Dis-
placement of the o-ring may have it damaged and cause leaks.
• Be careful not to damage the o-ring seat (8) or the sealing surface (10). Damaged o-ring (6)
may cause oil leakage.
• If oil leakage due to loosened nut (9) is detected, do not try to stop the leakage by tightening
nut (9). Instead, replace oring (6) with a new one and make sure it is well positioned, and tight-
en nut (9).

Wrench size mm Wrench size mm Tightening torque

（Connecting nut） （Hose joint） N·m（kgf·m,lbf·ft）
19 17 44（4.5,32）
22 19 59（6,44）
27 22 118（12,87）
36 30, 32 235（24,173）
41 36 295（30,218）
50 46 490（50,361）

1.5 Table of Standard Tightening Torques

Table of tightening torques for bolts and nuts

★ Unless specified otherwise, tighten metric nuts and bolts to the torque below. (When using tor-
que wrench)

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 Introduction SY500H Hydraulic Excavator

Bolt Hex Hexagonal socket head

Bolt Wrench Hexagonal bolt
diame wrench bolt
grade size
ter size N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6 10.9 10 4 13.2 1.37 9.74 13.2 1.37 9.74
M8 10.9 13 6 31 3.16 22.87 31 3.16 22.87
M10 10.9 17 8 66 6.73 48.7 66 6.73 48.7
M12 10.9 19 10 113 11.53 83.39 113 11.53 83.39
M14 10.9 22 12 177 18.06 130.6 177 18.06 130.6
M16 10.9 24 14 279 28.47 205.9 279 28.47 205.9
M18 10.9 27 14 382 38.98 281.9 382 38.98 281.9
M20 10.9 30 17 549 56.02 405.16 549 56.02 405.16
M27 10.9 41 19 1320 134.7 974.16 1320 134.7 974.16
M10 12.9 17 6 78 7.96 57.76 78 7.96 57.76
M12 12.9 19 8 137 13.98 101.1 137 13.98 101.1
M16 12.9 24 14 339 34.6 250.18 339 34.6 250.18
M20 12.9 30 17 664 67.75 490 664 67.75 490

CAUTION
The following items apply to fine thread and coarse thread.
• Apply grease (zinc white B dissolved in spindle oil) onto the nuts and bolts to reduce the friction
coefficient. Thrust bolts do not require greasing.
• Torque tolerance is ±10%.
• Always use bolts of correct length. The tip of bolts with excessive length may contact the bottom
of the bolt hole, resulting in under-tightening. Bolts with inadequate length may result in insuffi-
cient fastening.
• The torque values listed in the table are intended for general application. If different torque val-
ues are specified for a special purpose, the torque values in this table are not applicable any
more.
• Make sure the threads are free of dirt or rusts before installation of nuts and bolts.

1.6 Type of Bolts

Tighten nuts and bolts properly to specified
torque values. The type and grade of bolts are
illustrated on the right.

Use correct bolts and tighten them properly

when assembling machines or components.

Fig.1-30
1-26 Shop Manual-June 2016
SY500H Hydraulic Excavator Introduction

1.7 Tightening Sequence

When two or more bolts are being tightened,
follow the tightening sequence shown on the
right to ensure even tightening.

CAUTION
• Always use suitable tools for specific work.
Use of improper tools and methods may
cause a hazardous situation.
• Use tools of correct sizes when loosening
or tightening the nuts or bolts. Otherwise,
the tools may slide and cause personal
injury.
Fig.1-31

Fig.1-32

Shop Manual-June 2016 1-27

 Introduction SY500H Hydraulic Excavator

1.8 Maintenance of Half Flanges

1.8.1 General

1. Clean the sealing surface of the flange and

check it carefully. Scratches and coarseness
cause leaks or abrasion of seals. Uneven sur-
face may squeeze the seal out. If these faults
are not corrected properly, parts may have to
be replaced.

2. Always use specified O-rings. Check that

the O-rings are not damaged. Do not file the
surface of the O-ring. Apply grease onto the
Fig.1-33
O-ring to locate it.

3. Tighten the half flanges carefully. Locate

the opening at the center so that it is perpen-
dicular to the oil opening. Tighten the bolt
manually to maintain the location of the
components.

Fig.1-34

1.8.2 Table of tightening torques for half flange bolts

★ Unless specified otherwise, tighten the half flange bolts to the torques below.

Thread diameter of
Width across flats Tightening torque
bolt
mm mm N·m kgf·m
10 14 59～74 6.0～7.5
12 17 98～123 10.0～12.5
16 22 235～285 23.5～29.5

Conversion Table

Method of using conversion table

1-28 Shop Manual-June 2016

 SY500H Hydraulic Excavator Introduction

The conversion table in this section is provided to enable simple conversion of figures. For details
of the method of using the conversion table, see the example given below.

Example:

Method of using the conversion table to convert from millimeters to inches

Convert 55 mm into inches

Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).

Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line
down from (B).

Take the point where the two lines cross as (C). This point (C) gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.

Convert 550 mm into inches

The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.

Carry out the same procedure as above to convert 55 mm to 2.165 inches.

The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to Inches

Shop Manual-June 2016 1-29

Introduction SY500H Hydraulic Excavator

Millimeters to Inches

1mm=0.03937in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.535
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.031 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound

1kg=2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 90.39 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 112.43 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 134.48 55.12 57.32 59.52 61.73 63.93
30 66.14 68.34 70.55 72.75 156.53 77.16 79.37 81.57 83.77 85.98
40 88.18 90.39 92.59 94.80 178.57 99.21 101.41 103.62 105.82 108.03

50 110.23 112.43 114.64 116.84 200.62 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 222.66 143.30 145.50 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 244.71 165.35 167.55 169.75 171.96 174.16
80 176.37 178.57 180.78 182.98 266.76 187.39 189.60 191.80 194.00 196.21
90 198.41 200.62 202.82 205.03 288.80 209.44 211.64 213.85 216.05 218.26

1-30 Shop Manual-June 2016

SY500H Hydraulic Excavator Introduction

Liters to U.S. Gallons

1l=0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.114 2.378
10 2.642 2.906 3.170 3.435 3.699 3.963 4.227 4.491 4.756 5.020
20 5.284 5.548 5.812 6.077 6.341 6.605 6.869 7.133 7.398 7.662
30 7.926 8.190 8.454 8.719 8.983 9.247 9.511 9.775 10.040 10.304
40 10.568 10.832 11.096 11.361 11.625 11.889 12.153 12.417 12.682 12.946

50 13.210 13.474 13.738 14.003 14.267 14.531 14.795 15.059 15.324 15.588
60 15.852 16.116 16.380 16.645 16.909 17.173 17.437 17.701 17.966 18.230
70 18.494 18.758 19.022 19.287 19.551 19.815 20.079 20.343 20.608 20.872
80 21.136 21.400 21.664 21.929 22.193 22.457 22.721 22.985 23.250 23.514
90 23.778 24.042 24.306 24.571 24.835 25.099 25.363 25.627 25.892 26.156

Liters to U.K. Gallons

1l=0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.739 3.959 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.779

50 10.999 11.218 11.438 11.658 11.878 12.098 12.318 12.538 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.038 18.258 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

Shop Manual-June 2016 1-31

 Introduction SY500H Hydraulic Excavator

kgm to ft.lb

1 kgf·m=7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7
60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
1019. 1034. 1041. 1070.
140 1012.6 1027.1 1048.8 1056.0 1063.3 1077.7
9 3 6 5

1092. 1142.
150 1085.0 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1150.0
2 8
1215.
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1222.4
1
1236. 1251. 1258. 1287.
170 1229.6 1244.1 1265.8 1273.0 1280.2 1294.7
8 3 5 5
1309. 1323. 1330. 1359.
180 1301.9 1316.4 1338.1 1345.3 1352.6 1367.0
2 6 9 8
1381. 1396. 1403. 1432.
190 1374.3 1388.7 1410.4 1417.7 1424.9 1439.4
5 0 2 1

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 SY500H Hydraulic Excavator Introduction

kg/cm2 to lb/in2

1 kgf/cm2=14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.3 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.0 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 996 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2133 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2390 2404
170 2418 2432 2446 2461 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2774 2788 2802 2816 2830

200 2845 2859 2873 2887 2902 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3342 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

1.8.3 Temperature

Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into

a Centigrade temperature reading or vice versa is to enter the accompanying table in the center
(boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centi-
grade degrees.

Shop Manual-June 2016 1-33

 Introduction SY500H Hydraulic Excavator

If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to be
a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the col-
umn at the left.

If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to be
a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

1-34 Shop Manual-June 2016

SY500H Hydraulic Excavator Introduction

℃ ℉ ℃ ℉ ℃ ℉ ℃ ℉
–40. –40 –40 –11. 11 51.8 7.8 46 114.8 27.2 81 177.
0 7 8
–37. –35 –31.0 –11. 12 53.6 8.3 47 116.6 27.8 82 179.
2 1 6
–34. –30 –22.0 –10. 13 55.4 8.9 48 118.4 28.3 83 181.
4 6 4
–31. –25 –130 –10. 14 57.2 9.4 49 120.2 28.9 84 183.
7 0 2
–28. –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.
9 0
–28. –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.
3 8
–27. –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.
8 6
–27. –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.
2 4
–26. –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.
7 2
–26. –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.
1 0
–25. –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.
6 8
–25. –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.
0 6
–24. –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.
4 4
–23. –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.
9 2
–23. –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.
3 0
–22. –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.
8 8
–22. –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.
2 6
–21. –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.
7 4
–21. –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.
1 2
–20. –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.
6 0

Shop Manual-June 2016 1-35

Introduction SY500H Hydraulic Excavator

℃ ℉ ℃ ℉ ℃ ℉ ℃ ℉
–20. –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.
0 0
–19. –3 26.6 0.0 32 89.6 19.4 67 152.6 43.3 110 230.
4 0
–18. –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.
9 0
–18. –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.
3 0
–17. 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.
8 0
–17. 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.
2 0
–16. 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.
7 0
–16. 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.
1 0
–15. 4 39.2 3.9 39 102.2 23.3 74 165.2 62.8 145 293.
6 0
–15. 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.
0 0
–14. 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.
4 0
–13. 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.
9 0
–13. 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.
3 0
–12. 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.
8 0
–12. 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.
2 0

1-36 Shop Manual-June 2016

 SY500H Hydraulic Excavator Shop Safety

Shop Safety

2 Shop Safety ........................................................................................................................2-1

2.1 Hazard Alert Information ......................................................................................................2-5
2.2 General Shop Safety ............................................................................................................2-6
2.2.1 General .........................................................................................................................2-6
2.2.2 Rules and shop behavior ...........................................................................................2-7
2.2.3 Housekeeping..............................................................................................................2-8
2.2.4 Shop Liquids Storage .................................................................................................2-8
2.2.5 Cleaning the Parts.......................................................................................................2-9
2.2.6 Cleaning the Machine.................................................................................................2-9
2.2.7 Appropriate Working Apparel ................................................................................. 2-10
2.2.8 Personal Protective Equipment.............................................................................. 2-10
2.2.9 Using the Correct Tools ............................................................................................2-11
2.2.10 Fire Extinguisher and Emergency Exits...............................................................2-11
2.2.11 Electrical Dangers .................................................................................................. 2-12
2.2.12 Hoisting a Load ...................................................................................................... 2-12
2.3 Before Repair...................................................................................................................... 2-13
2.3.1 Safe Work Preparations .......................................................................................... 2-13
2.3.2 Preparing yourself.................................................................................................... 2-14
2.3.3 Lockout/Tagout ......................................................................................................... 2-14
2.3.4 Two people when engine running .......................................................................... 2-16
2.3.5 Safety Partners......................................................................................................... 2-17
2.4 Repair Precautions ............................................................................................................ 2-18
2.4.1 Running the Machine............................................................................................... 2-18
2.4.2 Mounting and Dismounting..................................................................................... 2-19
2.4.3 Removing Attachments ........................................................................................... 2-20
2.4.4 Jacking Up the Machine.......................................................................................... 2-20
2.4.5 Adding Fluids to a System ...................................................................................... 2-21
2.4.6 Aligning Parts or Components ............................................................................... 2-21
2.4.7 Driving Pins ............................................................................................................... 2-22
Shop Manual-June 2016 2-1
 Shop Safety SY500H Hydraulic Excavator

2.4.8 When compressed air is used ................................................................................ 2-22

2.4.9 Welding operation .................................................................................................... 2-22
2.4.10 Track Recoil Springs ............................................................................................. 2-23
2.4.11 High-Pressure Fluid Lines .................................................................................... 2-23
2.4.12 Air-conditioning system maintenance................................................................. 2-24
2.4.13 High voltage precautions ...................................................................................... 2-24
2.4.14 Disconnecting the System Power........................................................................ 2-25
2.4.15 Accumulator............................................................................................................ 2-25
2.4.16 Battery Hazards ..................................................................................................... 2-26
2.4.17 Jump-Start Safety .................................................................................................. 2-27
2.4.18 Avoiding fire and explosion................................................................................... 2-27
2.4.19 Chemical hazard .................................................................................................... 2-28
2.4.20 Material Safety Data Sheets (MSDS) ................................................................. 2-28
2.4.21 Proper disposal of wastes..................................................................................... 2-29
2.5 Other Precautions .............................................................................................................. 2-30
2.5.1 Sling work and giving signals ................................................................................. 2-30
2.5.2 Using mobile crane .................................................................................................. 2-32
2.5.3 Using overhead hoist crane.................................................................................... 2-32
2.5.4 Selecting wire ropes ................................................................................................ 2-34

2-2 Shop Manual-June 2016

Shop Safety SY500H Hydraulic Excavator

2-3 Shop Manual-June 2016

Shop Safety SY500H Hydraulic Excavator

WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.

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 SY500H Hydraulic Excavator Shop Safety

2.Shop Safety
2.1 Hazard Alert Information
Most accidents are usually caused by the failure to follow fundamental repair procedures and
safety rules for the system under repair. To avoid accidents it is important to read and understand
all information outlined in this manual before performing repairs on the machine system.

The following (ANSI/ISO) signal words are used to inform you that there is a potentially hazardous
situation that may lead to damage, personal injury or even death. In this manual, on the machine,
part or component decals and different signal words are used to express the potential level of a
hazard.

DANGER WARNING
• Indicates an imminent hazard which WILL • Indicates a potentially hazardous situation
result in serious injury or death if message which COULD result in serious injury or
is ignored. death if message is ignored.

CAUTION • Indicates THE MACHINE MAY BE DAM-

AGED if improperly operated or maintained.
• Indicates a potentially hazardous situation
which COULD RESULT IN MINOR OR MA-
JOR INJURY if message is ignored.

This is to alert the user of a hazard. It is This symbol is used in a graphic to alert the
usually used in a graphic. user to not do something.

Besides the above signals words, the following words are also used to remind you of rules to be
followed or to provide you with very useful information.

Note: It is followed by measures that must be taken to prevent reduction of machine service life.

Remark: It is followed by very useful information.

Shop Manual-June 2016 2-5

 Shop Safety SY500H Hydraulic Excavator

WARNING
• Improper repair procedures on this machine can be hazardous and could result in serious injury
or even death.
• All personnel involved with the repair of this machine must read this manual thoroughly before
performing any procedures on this equipment.
• Some actions involved in the operation or repair of this machine could cause a serious accident
if they are not performed in the manner described in this manual.
• All precautions outlined in this manual apply only to intended repair procedures of the machine
or system. If you perform any repairs not specifically prohibited, you must be sure that it is safe
for you and others. In no event should you or others engage in prohibited uses or actions as de-
scribed in this manual.
• SANY delivers machines that comply with all applicable regulations and standards of the coun-
try to which the machines have been shipped. If this machine has been purchased in another
country or purchased from someone in another country, it may lack certain safety features and
specifications that are necessary for use in your country. If there is any question about whether
your product complies with the applicable standards and regulations of your country, contact
your SANY representative before performing repairs on this machine.

2.2 General Shop Safety

2.2.1 General

It's important to establish good shop safety

rules for everyone who enters or uses the
shop area. Implementing shop safety rules will
keep employees safe and provide the most
productive environment for working or learn-
ing. Post rules where they can clearly be
viewed at all times. If necessary, provide shop
personnel with a written copy of the rules and
discuss any questions or confusion with them.

Always keep in mind, shop safety is NOT

something to be studied at the start of a proj-
ect and then forgotten; most accidents are
caused by carelessness, being in a hurry or
by simply disregarding safety rules. Remem-
ber this, if you are DILIGENT and follow in-
structions outlined in this shop manual with
care, repair operations can be safe and enjoy-
able. Safe work practices, should become a
force of habit.

2-6 Shop Manual-June 2016

SY500H Hydraulic Excavator Shop Safety

WARNING
• Mistakes in operation are extremely haz-
ardous. Read the Safety, Operation &
Maintenance Manual that came with the
machine carefully before operating the ma-
chine. Failure to follow this alert could re-
sult in serious injury or death.

2.2.2 Rules and shop behavior

• Study all shop rules relating to the proce-

dure carefully and constantly apply them.
When in doubt about any task, get help! DO
NOT take chances.
• Know your job. It is foolish, and often disas-
trous, to make repairs to a machine without
first receiving proper instructions. Always
use the shop manual when performing any
repair tasks. Get additional help if you are
NOT sure what must be done or how a task
should be performed.
• The shop is a place to work, not play. It is
NOT a place for “horseplay”. A “joker” in a
repair shop is a “walking hazard” to every- Fig.2-1
one. Daydreaming or socializing on the job
also increases your chances of injury.
• If you must smoke, smoke only in the area
provided for smoking. Never smoke while
on the shop floor or work area.

Shop Manual-June 2016 2-7

Shop Safety SY500H Hydraulic Excavator

2.2.3 Housekeeping

• Oils, grease, fuel, antifreeze or any fluid

spills should be mopped up immediately.
These items pose a serious slip hazard. Re-
gardless of who was responsible for the
spill, it is your job as a shop employee to se-
cure and clean up the spill area.
• Keep the shop clean. Scrap or old parts
should be disposed of properly. Never allow
them to remain on the bench or shop floor.
• All equipment and tools must be put back in
their proper storage areas after each use.
It's imperative that you do not let a shop be- Fig.2-2
come cluttered and disorganized in order to
prevent accidents.
• Always keep in mind, proper house clean-
ing is vital for a safe and pleasant work
environment.

2.2.4 Shop Liquids Storage

• Liquids, cleaning solvents or machine fluids

should be properly stored in an area away
from work locations. These storage areas
should be ventilated to an outdoor location
to avoid any vapor accumulation in a con-
fined shop area. Follow all OSHA regula-
tions regarding fluid storage.
• Never leave open containers of liquids sit-
ting around. These could spill or catch fire.
Always read the container label for informa-
tion on storage and handling of the liquids.
• Never store liquids in containers that are Fig.2-3
not properly labeled for that liquid. Confu-
sion could result in equipment damage, fire
or an unexpected explosion.
• Never smoke or bring open flames around
liquids, doing so could result in an unex-
pected fire or explosion.

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 SY500H Hydraulic Excavator Shop Safety

• Never handle liquids without using personal

protective equipment. Treat all liquids with
caution.

2.2.5 Cleaning the Parts

Never use gasoline, diesel fuel or similar flam-

mable liquids to clean parts. Always use ap-
proved non-flammable solvents to clean
parts. Failure to do so could result in explo-
sion or fire.

Fig.2-4

2.2.6 Cleaning the Machine

• Always use high-pressure hot water and

mild, nonflammable grease-cutting soaps or
cleaning agents to clean the machine parts.
Never use flammable or caustic cleaning
agents.
• Never use high-pressure steam cleaners to
clean the machine. Steam cleaners will
damage the paint, hoses or electrical
system.
• Never pressure-wash or flood the inside of
an operator cab. This will damage sensitive
electrical components. Fig.2-5

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 Shop Safety SY500H Hydraulic Excavator

2.2.7 Appropriate Working Apparel

Improper or loose clothing, casual dress cloth-

ing, jewelry, incorrect shoes or long hair can
result in possible injury.

Make a list of the types of clothing that are not

allowed in the shop area. Go over the list with
personnel before they start a job.

Fig.2-6

2.2.8 Personal Protective Equipment

If your shop specifies the use of safety equip-

ment, OSHA requires this equipment to be
used when on the shop floor or in the area
where this equipment is required.

Never allow personnel in the shop area with-

out the proper personnel protective equipment
even for a moment.

Always keep personnel protective equipment

in good condition and replace them as
required.
Fig.2-7

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2.2.9 Using the Correct Tools

• Always use the proper authorized tools for

the job. Using tools that are not authorized,
incorrect for the job, defective or damaged
could cause serious injury.
• Keep all tools in good condition, learn the
correct way to use them.
• Before starting the work, thoroughly check
the tools, machine, forklift, crane, service
car, etc.
• Keep your tools clean, and when the job is
complete, take inventory of the tools you Fig.2-8
were using to be sure no tools were left in
the machine.
• Always put shop tools back in there proper
storage location when finished.
• If welding repairs are needed, always have
a trained, experienced or certified welder
carry out the work.

2.2.10 Fire Extinguisher and Emergency Exits

• It is important to know where all emergency

exits and fire extinguishing equipment are
located if a fire should occur in the shop.
• Before preparing for work, take time and
walk around the shop to make a mental
note of where all exits and fire equipment
are located. If you are performing repairs in
the field, always have a fire extinguisher
handy and within reach.
• If you do not know how to use a fire extin-
guisher contact someone who can instruct
you in the proper use of this equipment. Fig.2-9

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2.2.11 Electrical Dangers

• When testing electrical circuits, always be

aware of what you will be checking in these
systems. High voltage or high amp circuits
could damage your equipment or cause a
spark, explosion or possible fire.
• Before performing any repairs or testing on
an electrical system be sure of the system
voltage dangers. Always check the circuit to
be sure it is off before performing any
repairs.
• When working around flammable liquids or
explosive systems, use only approved anti-
explosion proof work lamps. Non-approved
work lamps can cause an explosion or fire.

Fig.2-10

2.2.12 Hoisting a Load

If you will be lifting parts or components that

weigh more than 35 lbs (16 kg), it is important
to follow some basic rules.

• Always use the appropriate lifting equip-

ment such as hoist, crane, forklift etc. to
handle a loads if possible.
• Be sure the lifting equipment is in good con-
dition and rated for the load you are about
to lift.
• If straps are to be used, ensure they are in
good condition and rated for the load to be
lifted with them.
• If you must lift the load by hand, keep your
Fig.2-11
back straight and parallel with the load, and
lift the load using your leg muscles to avoid
back injuries. Always ask for a lifting
assistant.

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2.3 Before Repair

2.3.1 Safe Work Preparations

Before starting any repairs, be sure the ma-

chine is sitting on a level stable surface.

Lower all the work equipment to a safe and

stable position on the ground. Turn the engine
OFF and neutralize the work equipment con-
trols by rotating them to the left and right (joy-
stick control) or moving them back and forth
(lever control). This function will relieve sys-
tem pressure.

Block the tracks (if equipped) or wheels (if

equipped) with chocks to prevent the machine
from moving. Fig.2-12

If equipped, set the hydraulic lock lever in the

LOCKED position. If equipped, set the parking
brake in the PARK position.

Be sure all personnel and equipment is clear

of your work area and you can be seen by all
working personnel especially if performing re-
pairs in the field.

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 Shop Safety SY500H Hydraulic Excavator

2.3.2 Preparing yourself

Only approved personnel can maintain or re-

pair the machine. An observer may be as-
signed if necessary.

• Wear protective clothing and shoes neces-

sary for the job.
• Wear rubber apron and rubber gloves when
handling corrosive materials. Wear heavy
gloves when handling wooden materials,
wire ropes or sharp-edged metals.
• Wear a face shield when removing spring
Fig.2-13
or elastic parts, or adding acid to battery.
Wear safety hat and goggles when you
weld or cut with a torch.
• Never carry out grinding, flame cutting or
welding without an aspirator and ventilation
equipment. If you have to weld on the ma-
chine, refer to related instructions and
understand the correct operating
procedure.

Fig.2-14

2.3.3 Lockout/Tagout

Due to the size and complexity of this ma-

chine, Lockout and Tagout procedures may
be required by your company to ensure the
safety of yourself and others involved in the
repair process of the machine. While work is
in progress, all power sources must be dis-
abled, locked and tagged with a warning label.
Lockout/Tagout procedure establishes the
minimum requirements used to isolate all
power sources from potentially hazardous en-
ergy, and to ensure that the machine is“
locked out and tagged out” before anyone
performs repairs on the machine.

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 SY500H Hydraulic Excavator Shop Safety

Sequence of procedures

Only authorized employees performing re-

pairs on the machine shall perform Lockout/
Tagout in accordance with this procedure
listed below.

If the employee performing repairs to the ma-

chine is issued a lock and key, the employee
shall not share the lock or key with other em-
ployees until all repair procedures are com-
plete and the machine is ready to put back
into service.

The following steps shall be performed in the

sequence listed when the equipment is to be
either locked-out or tagged-out for repair.

Fig.2-15

Locking out of service

1. Notify all employees who may be potentially

affected by the repair process on the
machine.

2. Secure the machine in a safe position. If

equipped, set the parking brake or hydraulic
lock lever in the PARK or LOCKED position.

3. Identify, remove or disconnect all power or

energy sources and be sure to install a Lock- Fig.2-16
out/Tagout device on them. If the machine is
equipped with a Maintenance Alert Tag, at-
tach this tag to the machine controls.

4. Be sure all employees involved in the re-

pairs have installed there lock on the power
source before performing any repairs. Once
an employee has completed there repair pro-
cedure, they must remove there lock and not
access the machine in any manor.

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 Shop Safety SY500H Hydraulic Excavator

Returning to service

1. The authorized person who performed the

Lock out/Tagout procedure shall check the
area around the machine to ensure that no
one is exposed to any hazard before startup.

2. The authorized person who performed the

Lock out/Tagout shall ensure that all guards
have been reinstalled to their proper place, all
tools and equipment have been removed and
all locks are removed.

3. The authorized person who performed the

Lock out/Tagout shall verify that all controls
are in the neutral or “off” position and all per-
sonnel are aware of the time the machine will
be back in service.

4. Remove the Lockout/Tagout equipment and

any additional alert equipment and reenergize
the machine for return to service.

2.3.4 Two people when engine running

In order to prevent injury, do not perform the

service while the engine is running. If the serv-
ice must be performed while the engine is run-
ning, operate only when two people are on
the spot and follow the regulations below:

• Always have one operator sit on the opera-

tion seat and be ready to turn off the engine
at any time. All the operators must keep in
touch with each other.
• Set the safety lock control lever to the lock
position.
• Do not touch any control lever. If some con-
trol lever must be operated, send signal to
other people and warn them to transfer to
safe place quickly.

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 SY500H Hydraulic Excavator Shop Safety

• Do not drop or insert the tools and other ob-

jects into the fan or fan belt, or the parts will
be broken or thrown out.

2.3.5 Safety Partners

No one should be allowed to perform work op-

erations in any shop alone. It should be a gen-
eral shop safety rule for a minimum of two
people in the shop area at all times when work
procedures are performed. A person alone in
the shop might not be able to get emergency
help in the event of a shop accident.

When working together always maintain clear

contact with each other at all times to avoid
the occurrence of unexpected incidents.

When carrying out any operation with two or Fig.2-17

more workers, always agree on the operating
procedures and signals before starting.

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 Shop Safety SY500H Hydraulic Excavator

2.4 Repair Precautions

2.4.1 Running the Machine

Run the machine during repair procedures

ONLY if directed to do so in this shop manual.
If the machine must be run when making re-
pairs, it is important to follow some basic
safety rules.

• Always be aware of rotating components.

• During repair operations while the engine is
running, one worker must remain in the op-
erator seat of the machine with clear con-
tact between the person performing the
repairs on the machine at all times. Fig.2-18

• If equipped, all lock levers must be in the

LOCK position or the parking brake must be
in the PARK position.
• The person in the cab must never touch
any controls. If a control lever must be oper-
ated, always maintain a clear view to the
person doing the repair and signal them
when you are about to move the control
lever.
• Be aware of hot surfaces. During running
operations, most surfaces will be hot, and Fig.2-19
some surfaces will be extremely hot. If nec-
essary, use personnel protective equipment
when working around high temperature
surfaces.
• Keep in mind that during running opera-
tions, hydraulic systems, cooling systems
and fuel systems will be under extremely
high pressure and at high temperatures.
• Always use caution when working on or
near these systems.
Fig.2-20

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2.4.2 Mounting and Dismounting

It is important to follow these procedures

when mounting or dismounting the
equipment:

• Use all hand-holds and step plates on your

equipment.
• Never jump off or onto the equipment.
• Wipe off any oil, grease, or mud from your
shoes, rails, steps or platforms before get-
ting on the equipment; always keep these
areas clean and in good condition.
• Never get on or off moving equipment. Fig.2-21
These actions may lead to serious injury. Al-
ways bring the equipment to a full stop and
turn the engine OFF.
• When getting on or off the equipment, al-
ways face the equipment and maintain a
three-point contact (both feet and one hand
or one foot and both hands) with the hand-
rails, steps and platforms to ensure that you
support yourself correctly.

• Never climb on areas of the machine that

are not designated walk areas.
• Never climb on or off the machine with
tools, parts or similar objects in your hands.
• Never use machine controls or non-speci-
fied points on the equipment to get on or off
the machine.
• Use all hand-holds when on the machine.

Fig.2-22

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Shop Safety SY500H Hydraulic Excavator

2.4.3 Removing Attachments

• If you will be removing large heavy attach-

ments from the machine, always be sure to
use the correct lifting equipment rated for
the capacity of the load you will be lifting.
• After the attachment or part has been re-
moved, store it where it cannot fall or move.
Always be sure what you are storing is sit-
ting stable on a stable surface and clear of
all walkways or fire exits.

Fig.2-23

2.4.4 Jacking Up the Machine

• If you will be working under the machine al-

ways use approved jack stands that will
support the weight of the machine you are
working on.
• Never rely on the hydraulics of the machine
or a hydraulic jack to support the machine
during repairs.
• Always lower the work equipment to the
ground and check the stability of the ma-
chine before going under the machine.
Fig.2-24

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2.4.5 Adding Fluids to a System

If it should be necessary to add fluids to a sys-

tem during running operations, always be
aware that these systems may be hot and
under high pressure.

Before adding fluids, shut the machine down

and allow the systems to cool down to outdoor
ambient temperatures before removing any
caps. Failure to do so may result in serious
burns or a sudden loss of fluid.

Fig.2-25

2.4.6 Aligning Parts or Components

• Be careful when installing or aligning parts

or components.
• Avoid using your fingers or hands to posi-
tion holes or part mating surfaces, serious
injury could result if your hand or fingers
should get ought between the surfaces.
• Always use tools to align a part or compo-
nent to avoid any finger or hand injuries.

Fig.2-26

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 Shop Safety SY500H Hydraulic Excavator

2.4.7 Driving Pins

When using a hammer to drive pins, metal

particles may fly off. This may lead to serious
eye injuries. Always do the following:

• Always wear a face shield or goggles when

striking a metal object with a metal hammer.
• Before performing any of these procedures,
be sure all personnel are clear of your work
area.
• If possible, avoid using a steel hammer to
drive a component or pins in place. Dam-
Fig.2-27
age to the component may result. Always
use a soft or non-ferrous hammer to drive a
component or a pin.

2.4.8 When compressed air is used

When compressed air is used for cleaning, fly-

ing particles may cause personal injury. In this
case, wear goggles, dust-preventive mask,
gloves and other protective gear.

2.4.9 Welding operation

There is possibility of fire or electrocution dur-

ing welding. Therefore, welding must be per-
formed by qualified personnel with suitable
equipment. Never allow other people to do the
welding.

Fig.2-28

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2.4.10 Track Recoil Springs

If you are making repairs to a machine

equipped with tracks, always be aware of the
dangers involved with track recoil springs.
This spring is under extreme pressure at all
times. If it is disassembled by mistake, the
spring may fly out and cause serious injury.

Be careful when removing or installing tracks

on track-type machines. When removing the
master track link the track system may sepa-
rate suddenly and cause possible injury.
Fig.2-29
Always stand clear of the track travel path
when separating the master link section of the
track.

2.4.11 High-Pressure Fluid Lines

Always keep in mind that these systems are

under high pressure. When inspecting or re-
placing piping or hoses, always check to be
sure the pressure in the system has been re-
lieved before proceeding. Working on a sys-
tem still under pressure could lead to serious
injury, always do as follows:

• If you will be removing a line or component

with fluid in the system, always cap and
seal the opening to avoid leakage or system
contamination.
• Never carry out inspections or replace items
while the system is under pressure.
• Never use any part of your body to check or
feel for leaks. Always wear safety glasses
and leather gloves when checking for leaks
and use a piece of wood or cardboard when
checking for leaks from small holes.
• If high pressure fluids should penetrate your
skin or get into your eyes, seek medical at-
tention immediately. Fig.2-30

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 Shop Safety SY500H Hydraulic Excavator

2.4.12 Air-conditioning system maintenance

WARNING
• Refrigerant R134 a is a harmless gas
under room temperature. It will change into
highly toxic gas when burning.
• Refrigerant getting into eyes may cause
blindness. It may cause frostbite if
splashed on your skin.

• Keep fire source away when servicing air-

conditioning system.
• In maintenance of air-conditioning system,
observe the instruction on the refrigerant
cylinder and use it correctly. The type of re-
frigerant is R134a. Use of other refrigerants
may damage the air-conditioning system.
• Obey local material disposal regulations.
Never discharge refrigerant directly into the
air.
Fig.2-31

2.4.13 High voltage precautions

You must understand the elements before

testing electric circuit. High voltage or current
could lead to machine damage, spark, explo-
sion or fire.

You must know the voltage before repairing or

testing electrical system. Always check the
circuit and make sure it is disconnected be-
fore doing repair job.

Only explosion-proof light can be used when

you work near flammable fluids or explosive
Fig.2-32
system. Unapproved illumination equipment
could lead to explosion or fire.

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2.4.14 Disconnecting the System Power

Before starting any repair operations, remove

the battery leads from the battery or set the
main disconnect on the machine in the OFF
position.

For the location of the machine main electrical

disconnect switch, refer to the machines
Safety, Operation & Maintenance Manual for
location and procedures.

If the battery must be disconnected, remove

the negative (-) terminal clamp first then re-
move the positive (+) clamp last.
Fig.2-33
When reconnecting the battery, be sure every
electrical system switch is in the OFF position,
connect the positive clamp (+) first, then the
negative clamp(-) last.

2.4.15 Accumulator

If the machine is equipped with an accumula-

tor charged with high-pressure nitrogen gas, it
is important to follow these basic precautions.

• Do not disassemble the accumulator.

• Never expose the accumulator to high heat
or open flames.
• Never weld on the accumulator.
• Never drill or cut on the accumulator.
• Never strike the accumulator.
• Use only nitrogen gas to charge the accu-
Fig.2-34
mulator. Unapproved gases could be
explosive.

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 Shop Safety SY500H Hydraulic Excavator

2.4.16 Battery Hazards

Working around batteries always poses a haz-

ard, especially if the battery has been in serv-
ice for a long period of time.

Listed below are some basic precautions to

be aware of when servicing or working around
batteries.

• Always wear personal protective equipment

when working around batteries.
• Battery gasses are extremely explosive.
When opening a battery compartment, al- Fig.2-35
ways allow ample time for the gasses to es-
cape before servicing the battery.
• When working with batteries, always work
in a well ventilated area.
• If the battery is corroded, flush the area with
a baking soda and warm water mix.

Fig.2-36

• If battery acid should get on your skin or in

your eyes, flush the area immediately with
fresh water and seek medical attention.

Fig.2-37

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2.4.17 Jump-Start Safety

CAUTION
• Never use a welder or a machine with a
higher voltage system to jump-start the
machine. Doing so may damage the ma-
chine’s electrical system or cause an unex-
pected explosion or fire resulting in minor
or major injury.

When using jumper cables to start the ma-

chine, connect the positive (+) jumper first,
then the negative (-) jumper to a remote loca- Fig.2-38
tion on the chassis away from the battery.

2.4.18 Avoiding fire and explosion

WARNING
• Never smoke when handling the fuel or
maintaining the fuel system. The gases in
empty fuel tank can cause explosion
easily. Never carry out flame-cutting or
welding operation on fuel pipe, fuel tank or
fuel vessels, which can lead to fire, explo-
sion, injury or death.

• Then engine must be shut down and electri-

cal equipment must be switched off when
refueling the tank. Be extremely careful
when adding fuel to a hot engine. No sparks
shall occur around the grounding nozzle.
• Handle all solvents and dry chemicals in a
place with good ventilation according to the
steps indicated on vessel.
• Clean the machine of all dust and residuals.
Never place greasy rag or other flammable
materials on machine. Fig.2-39
• When cleaning the parts and components,
use nonflammable solvents instead of gas-
oline, diesel oil or other flammable fluids.

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 Shop Safety SY500H Hydraulic Excavator

• Store flammable liquids and materials in

suitable vessels as required by safety laws
and regulations.
• Check fire extinguishers, fire-fighting sys-
tem and fire detectors (if equipment) and
make sure they are ready for use.

2.4.19 Chemical hazard

Exposure to hazardous chemicals pose a seri-

ous danger if released or mishandled. Han-
dling hazardous materials often releases
substances that could pose a hazard. Tempo-
rary implication or possible residual injury may
result unless proper precautions are observed
while working with these materials. All work-
ers involved in handling hazardous materials
should use approved personal protective
equipment and follow all environmental safety
regulations.

2.4.20 Material Safety Data Sheets (MSDS)

Material Safety Data Sheet (MSDS) informa-

tion relating to the materials the workers could
be exposed to.

• MSDS data sheets provide both workers

and emergency personnel with the proper
procedures for handling or working with a
particular substance. Information includes
physical data, health effects, first aid, reac-
tivity, storage, disposal and protective
equipment required.
• Be sure all personnel involved are familiar Fig.2-40
with all MSDS-related information as it re-
lates to the hazardous materials they could
be exposed to. Keep MSDS data sheets
handy in site of all employees and emer-
gency personnel where they can be easily
accessed.
• Never handle hazardous materials without
the proper MSDS information. Always verify
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SY500H Hydraulic Excavator Shop Safety

the data on the MSDS sheet before han-

dling any hazardous materials.

2.4.21 Proper disposal of wastes

Improper disposal of wastes harms the envi-

ronment and ecology. Consult local environ-
mental protection department or Sany
distributors for methods of recycling and
waste disposal.

• Potential harmful substances used in Sany

products include hydraulic oil, fuel, cooling
liquid, refrigerant, filter and batteries etc..
• Use leak-proof vessels to hold discharged
fluids. Never use food or beverage
Fig.2-41
containers.
• Never dump waste fluids directly to the
ground, sewage or water source.
• Leaking of refrigerant from air conditioner
can spoil the atmosphere of the globe. Re-
lated laws and regulations must be followed
to recover or regenerate the refrigerant.

Fig.2-42

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2.5 Other Precautions

2.5.1 Sling work and giving signals

1. Only one appointed worker is allowed to

give signals and co-workers must communi-
cate with each other frequently. The appointed
signal person must give specified signals
clearly at a place where he is seen well from
the operator's seat and where he can see the
working condition easily. The signal person
must always stand in front of the load and
guide the operator safely.
• Do not stand under the load. Fig.2-43
• Do not step on the load.

2. Check the slings before starting sling work.

3. Always wear gloves during sling work.

(Wear leather gloves, if available.)

4. Measure the weight of the load by the eye

and check its center of gravity.

5. Use proper sling according to the weight of

the load and method of slinging. If too thick
wire ropes are used to sling a light load, the
load may slip and fall.

6. Do not sling a load with 1 wire rope alone. If

it is slung so, it may rotate and may slip out of
the rope. Install 2 or more wire ropes
symmetrically.

7. Limit the hanging angle to 60º, as a rule. Do

not sling a heavy load with ropes forming a
wide hanging angle from the hook. When
hoisting a load with 2 or more ropes, the force
subjected to each rope will increase with the
hanging angle. The table below shows the

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 SY500H Hydraulic Excavator Shop Safety

variation of allowable load in kN {kg} when

hoisting is made with 2 ropes, each of which
is allowed to sling up to 9.8 kN {1,000 kg} ver-
tically, at various hanging angles. When the 2
ropes sling a load vertically, up to 19.6 kN
{2,000 kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000 kg}
when the 2 ropes make a hanging angle of
120 ° . If the 2 ropes sling a 19.6 kN {2,000
kg} load at a lifting angle of 150 ° , each of
them is subjected to a force as large as 39.2
kN {4,000 kg}.

8. When installing wire ropes to an angular

load, apply softeners to protect the wire ropes.
If the load is slippery, apply proper material to
prevent the wire rope from slipping.

9. Use the specified eyebolts and fix wire

ropes, chains, etc. to them with shackles, etc.

10. Apply wire ropes to the middle portion of

the hook.
• Slinging near the tip of the hook may cause
the rope to slip off the hook during hoisting.
The hook has the maximum strength at the Fig.2-44
middle portion.

11. Do not use twisted or kinked wire ropes.

12. When lifting up a load, observe the

following.
• Wind in the crane slowly until wire ropes are
stretched. When settling the wire ropes with
the hand, do not grasp them but press them
from above. If you grasp them, your fingers
may be caught.
• After the wire ropes are stretched, stop the
crane and check the condition of the slung
load, wire ropes, and softener.

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 Shop Safety SY500H Hydraulic Excavator

• If the load is unstable or the wire rope or

chains are twisted, lower the load and lift it
up again.
• Do not lift up the load slantingly.

13. When lifting down a load, observe the

following.
• When lifting down a load, stop it temporarily
at 30 cm above the floor, and then lower it
slowly.
• Check that the load is stable, and then re-
move the sling.
• Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.

2.5.2 Using mobile crane

CAUTION
• Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.

2.5.3 Using overhead hoist crane

1. Before starting work, inspect the wire ropes,

brake, clutch, controller, rails, over wind stop
device, electric shock prevention earth leak-
age breaker, crane collision prevention de-
vice, and power application warning lamp,
and check safety.

2. Observe the signals for sling work.

3. Operate the hoist at a safe place.

4. Check the direction indicator plates (east,

west, south, and north) and the directions of
the control buttons without fail

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 SY500H Hydraulic Excavator Shop Safety

5. Do not sling a load slantingly. Do not move

the crane while the slung load is swinging.

6. Do not raise or lower a load while the crane

is moving longitudinally or laterally.

7. Do not drag a sling.

8. When lifting up a load, stop it just after it

leaves the ground and check safety, and then
lift it up.

9. Consider the travel route in advance and lift

up a load to a safe height.

10.Place the control switch on a position

where it will not be an obstacle to work and
passage.

11.After operating the hoist, do not swing the

control switch.

12.Remember the position of the main switch

so that you can turn off the power immediately
in an emergency.

13.If the hoist stops because of a power fail-

ure, turn the power switch OFF. When turning
on a switch which was turned OFF by the
electric shock prevention earth leakage break-
er, check that the devices related to that
switch are not in operation state.

14.If you find an obstacle around the hoist,

stop the operation.

15.After finishing the work, stop the hoist at

the specified position and raise the hook to at
least 2 m above the floor. Do not leave the
sling installed to the hook.

Shop Manual-June 2016 2-33

 Shop Safety SY500H Hydraulic Excavator

2.5.4 Selecting wire ropes

Select adequate ropes according to the weight of parts to be hoisted. See the table below.

Wire Rope
(Standard Z or S type of strand, ungalvanized)
Nominal Diameter Allowable Load
mm kN t
10 9.8 1.0
11.5 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.5 3.6
20 43.1 4.4
22.4 54.9 5.5
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0

CAUTION
• The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).

2-34 Shop Manual-June 2016

 SY500H Hydraulic Excavator Specifications

Specifications

3 Specifications ...................................................................................................................3-1
3.1 Dimensions ............................................................................................................................3-3
3.2 Working ranges .....................................................................................................................3-4
3.3 Technical Specifications.......................................................................................................3-5
3.4 Table of Weights....................................................................................................................3-7
3.5 Engine Oil, Fuel and Coolant...............................................................................................3-8
3.6 Engine Performance Curve .................................................................................................3-9

Shop Manual-June 2016 3-1

Specifications SY500H Hydraulic Excavator

WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.

3-2 Shop Manual-June 2016

 SY500H Hydraulic Excavator Specifications

3.Specifications
3.1 Dimensions

Fig.3-1

Item Unit SY500H

A Shipping length mm 12200
B Overall width mm 3690
C Shipping height mm 3880
D Top width mm 3265
E Overall height (to cab top) mm 3510
F Standard width of track shoe mm 600
G Gauge mm 2740
H Min. ground clearance mm 590
I Tail swing radius mm 3780
J Track grounding length mm 4410
K Track length mm 5440

Shop Manual-June 2016 3-3

 Specifications SY500H Hydraulic Excavator

3.2 Working ranges

Fig.3-2

Item Unit SY500H

a Max. cutting height mm 10950
b Max. dumping height mm 7450
c Max. digging depth mm 7490
d Max. vertical wall depth mm 5560
e Max. digging reach mm 11860
f Min. swing radius mm 5240

g Max. height at min. swing

mm 9100
radius

3-4 Shop Manual-June 2016

SY500H Hydraulic Excavator Specifications

3.3 Technical Specifications

Machine Model SY500H
Operating weight kg 49500
Bucket capacity m3 2.2
Travel speed (high/low) km/h 5.4/3.1
Overall Swing speed rpm 8.0
perform
ance Gradeability Degrees 35
Ground pressure kPa 87.1
Max bucket-dig force kN 287
Max arm-in force kN 245
ISUZU
Model
AH-6WG1
6 cylinders, 4 cycles, water
cooling, electric control,
Type
turbocharging, and air-air
intercooler
Number of cylinders -
mm 6-Φ147×154
cylinder bore × stroke
Total displacement L 15.681
Rate power kW/rpm 300 / 2000 （Calibrated）
Engine Max torque N·m/rpm 1950/ 1400 （Calibrated）
Maximum
speed, rpm 1700±20
Perform unloaded
ance Minimum
speed, rpm 850±30
unloaded
Minimum fuel
g/kWh 216
consumption
Start motor 24V/7kW
Alternator 24V/60A
Carrier rollers (one side) pcs 2
Undercar Track rollers (one side) pcs 9
riage
Number of track shoes (on
pcs 50
one side)
Hydraulic Hydraul Kawasaki (dual pumps, plunger,
Type
system ic pump variable swash plate)

Shop Manual-June 2016 3-5

Specifications SY500H Hydraulic Excavator

Machine Model SY500H

Main safety
MPa 34.3
valve pressure
Maximum main
L/min 2×400
pump flow
Control Type × quantity KMX32N/B45008×1
valve Control method Hydraulic
Nzbtesco plunger motor, variable
Travel motor oblique axis
Hydraul （Brake valve, parking brake）
ic motor Kawasaki plunger motor, oblique
Swing motor axis
（Swing stop controller）
Type Reciprocal
Hydraul
ic Boom cylinder mm Φ160×Φ110-1590
cylinders Arm cylinder mm Φ190×Φ130-1850
Bucket cylinder mm Φ170×Φ120-1305
Hydraulic tank Enclosed
Hydraulic oil filter element Tank return side
Hydraulic oil cooler Air cooling

3-6 Shop Manual-June 2016

SY500H Hydraulic Excavator Specifications

3.4 Table of Weights

Unit：kg
Machine model SY500H
Engine 1165
Radiator assembly 75
Hydraulic tank assembly (excluding hydraulic
360
oil)
Fuel tank assembly (excluding fuel) 322
Swing platform 3918
Operator station 324
Operator seat & console 70
Counterweight 8550
Hydraulic pump 290
Main control valve 360
Swing reducer assembly 548
Travel reducer assembly 650×2
Swivel joint 60
Track frame 6173
Swing bearing 784
Idler 267×2
Tensioning device 136×2
Carrier roller 36×4
Track roller 78×18
Boom assembly 3656
Arm assembly 1574
Bucket assembly 2180
Boom cylinder assembly 420×2
Arm cylinder assembly 615
Bucket cylinder assembly 400
Connecting rod 189
摇杆 65X2
Rocker arm 175

NOTICE
The table of weights is only a reference for handling the components or transportation.

Shop Manual-June 2016 3-7

Specifications SY500H Hydraulic Excavator

3.5 Engine Oil, Fuel and Coolant

Ambient temperature
Liquid
Reservoir -22 -4 -14 32 50 68 86 104 122℉
type
-30 -20 -10 0 10 20 30 40 50℃

SAE 30

SAE 10W
Engine oil
pan
SAE 10W-30

SAE 15W-40

Swing
mechanism SAE 30
case Engine oil
Idler
Track roller
Carrier
roller

SAE 10W

SAE 10W-30

SAE 15W-40

Hydraulic
system
L-HV32 low-temp, wear-
resistant
Hydraulic
oil L-HM46 wear-resistant

L-HM68 wear-resistant

ASTM D 975 No.2

Fuel tank Diesel oil

GB252 super -20#

GB252 super -35#

3-8 Shop Manual-June 2016

 SY500H Hydraulic Excavator Specifications

Ambient temperature
Liquid
Reservoir -22 -4 -14 32 50 68 86 104 122℉
type
-30 -20 -10 0 10 20 30 40 50℃

Grease
Grease NLGI No.2
fitting

Cooling Coolant
With antifreeze
system

NOTICE
• Sany recommend to use the type of engine oil with a grade over API CF-4, or at least not lower
than API CD.
• Sany recommends to use the type of gear oil GL-5.
• To ensure oil quality, please purchase genuine oils from Sany or Sany dealer.

3.6 Engine Performance Curve

Mitsubishi 6D24-TL

Testing condition:

• Temperature: 298K, under standard atmospheric pressure.

• With fan.

Shop Manual-June 2016 3-9

 Specifications SY500H Hydraulic Excavator

Fig.3-3

3-10 Shop Manual-June 2016

 SY500H Hydraulic Excavator Structure and Functions

Structure and Functions

4 Structure and Functions .............................................................................................4-1

4.1 Engine and Cooling System ................................................................................................4-7
4.1.1 Engine-relate parts......................................................................................................4-7
4.1.2 Radiator and intercooler.............................................................................................4-8
4.2 Power Train............................................................................................................................4-9
4.2.1 Power train ...................................................................................................................4-9
4.2.2 Travel reducer AS .................................................................................................... 4-10
4.2.3 Swing reduction mechanism .................................................................................. 4-12
4.2.4 Swing bearing ........................................................................................................... 4-14
4.3 Undercarriage..................................................................................................................... 4-15
4.3.1 Track frame and tensioning mechanism............................................................... 4-15
4.3.2 Idler ............................................................................................................................ 4-17
4.3.3 Carrier roller .............................................................................................................. 4-18
4.3.4 Track roller ................................................................................................................ 4-20
4.3.5 Tracks ........................................................................................................................ 4-22
4.4 Hydraulic System, Part 1................................................................................................... 4-26
4.4.1 Deployment of hydraulic parts................................................................................ 4-26
4.4.2 Hydraulic Pump (SY500H)...................................................................................... 4-27
4.4.3 Pilot pump ................................................................................................................. 4-30
4.4.4 Regulator (KR3S-9T1L-V) ...................................................................................... 4-31
4.4.4.1 General............................................................................................................... 4-31
4.4.4.2 Oil delivery control ............................................................................................ 4-47
4.4.5 Pilot pump ................................................................................................................. 4-48
4.4.6 Regulator (KR3K-9N1H-V) ..................................................................................... 4-49
4.5 Hydraulic System, Part 2................................................................................................... 4-61
4.5.1 Control valve ............................................................................................................. 4-61
4.5.1.1 General............................................................................................................... 4-61
4.5.1.2 Main valve structure ......................................................................................... 4-64
4.5.2 Hydraulic circuit (With bucket confluence function) ............................................ 4-70

Shop Manual-June 2016 4-1

 Structure and Functions SY500H Hydraulic Excavator

4.6 Hydraulic System, Part 3................................................................................................... 4-92

4.6.1 Swing motor .............................................................................................................. 4-92
4.6.2 Relief valve section .................................................................................................. 4-94
4.6.3 Anti-jerk valve ........................................................................................................... 4-95
4.6.4 Central swivel joint ................................................................................................... 4-98
4.6.5 Travel motor .............................................................................................................. 4-99
4.6.5.1 General............................................................................................................... 4-99
4.6.5.2 Operation of parking brake............................................................................ 4-105
4.6.5.3 Operation of braking valve............................................................................. 4-106
4.6.6 Control system.........................................................................................................4-115
4.6.7 Pilot valve .................................................................................................................4-116
4.6.8 Travel pilot valve..................................................................................................... 4-122
4.6.9 Solenoid valves ...................................................................................................... 4-126
4.6.10 Pilot accumulator ................................................................................................. 4-127
4.6.11 Pilot oil filter ........................................................................................................... 4-128
4.7 Work Equipment............................................................................................................... 4-129
4.7.1 Component dimensions ........................................................................................ 4-129
4.7.2 Arm dimensions...................................................................................................... 4-132
4.7.3 Bucket dimensions................................................................................................. 4-134
4.8 Air Conditioning System.................................................................................................. 4-136
4.8.1 Air Conditioning System........................................................................................ 4-136
4.8.2 Layout of A/C components ................................................................................... 4-137
4.8.3 A/C control panel.................................................................................................... 4-138
4.8.4 Diagram of electrical circuit................................................................................... 4-139
4.8.5 Refrigeration principle ........................................................................................... 4-140
4.8.6 Compressor ............................................................................................................ 4-142
4.8.7 Clutch....................................................................................................................... 4-144
4.8.8 Condenser............................................................................................................... 4-144
4.8.9 Expansion valve ..................................................................................................... 4-145
4.8.10 Evaporator ............................................................................................................ 4-145
4.8.11 Dehydrator ............................................................................................................ 4-146
4.8.12 Pressure switch.................................................................................................... 4-147
4.8.13 Refrigerant ............................................................................................................ 4-147
4.8.13.1 General .......................................................................................................... 4-147
4.8.13.2 Evacuation..................................................................................................... 4-150
4.8.13.3 Refrigerant filling operation ......................................................................... 4-152
4.8.13.4 Troubleshooting with manifold pressure gauge ....................................... 4-156
4.8.14 Compressor oil ..................................................................................................... 4-163
4.9 Engine Control.................................................................................................................. 4-164
4.9.1 General .................................................................................................................... 4-164
4.9.2 System operation ................................................................................................... 4-165
4-2 Shop Manual-June 2016
 SY500H Hydraulic Excavator Structure and Functions

4.9.3 System components .............................................................................................. 4-166

4.9.3.1 Fuel control dial............................................................................................... 4-166
4.9.3.2 Engine control unit (ECU).............................................................................. 4-167
4.10 Electrical Control System.............................................................................................. 4-172
4.10.1 Control function .................................................................................................... 4-172
4.10.2 Diagram of machine control system.................................................................. 4-173
4.10.3 Engine-pump combination control..................................................................... 4-174
4.10.4 Valve control function .......................................................................................... 4-176
4.10.5 Travel control function ......................................................................................... 4-177
4.10.6 Low engine oil pressure alarm and protection................................................. 4-179
4.10.7 High engine coolant temperature alarm and protection ................................. 4-180
4.10.8 Engine preheating control................................................................................... 4-181
4.10.9 Engine starting and energizing delay control................................................... 4-182
4.10.10 System parts and components ........................................................................ 4-183
4.10.10.1 Pump pressure sensor .............................................................................. 4-183
4.10.10.2 Pilot pressure sensor ................................................................................. 4-184
4.10.10.3 Engine speed sensor ................................................................................. 4-185
4.10.10.4 Coolant temperature sensor ..................................................................... 4-186
4.10.10.5 Fuel level sensor ........................................................................................ 4-186
4.10.10.6 Oil pressure switch..................................................................................... 4-187
4.11 Monitor System............................................................................................................... 4-188
4.11.1 General .................................................................................................................. 4-188
4.11.2 Monitor ................................................................................................................... 4-189
4.11.3 Monitor panel ........................................................................................................ 4-190
4.11.4 Monitor operation ................................................................................................. 4-192
4.11.4.1 Default page .................................................................................................. 4-192
4.11.4.2 Main Menu Password entry to system information .................................. 4-194
4.11.4.3 Main Menu ..................................................................................................... 4-195
4.11.4.4 System Lockout............................................................................................. 4-195
4.11.4.5 Engine & Throttle Signals ............................................................................ 4-196
4.11.4.6 Pilot Pressure Signals .................................................................................. 4-196
4.11.4.7 Main & Cooling Pump Signals .................................................................... 4-197
4.11.4.8 Input & Output Switch Signals .................................................................... 4-197
4.11.4.9 Failure information ........................................................................................ 4-198
4.11.4.10 GPS Information ......................................................................................... 4-198
4.11.4.11 Language Selection.................................................................................... 4-199
4.11.4.12 System Time Calibration ........................................................................... 4-199
4.11.4.13 Maintenance Information........................................................................... 4-200
4.11.4.14 Maintenance Confirmation ........................................................................ 4-200
4.11.4.15 System Setting ............................................................................................ 4-201
4.11.4.16 Machine Configuration Setting ................................................................. 4-201
Shop Manual-June 2016 4-3
Structure and Functions SY500H Hydraulic Excavator

4.11.4.17 Operation Time Calibration ....................................................................... 4-202

4.11.4.18 Machine Configuration Setup ................................................................... 4-202
4.11.4.19 Alarm Content Setting................................................................................ 4-203
4.11.4.20 Screen Backlight Adjust............................................................................. 4-203
4.11.4.21 Running Correct Setting ............................................................................ 4-204
4.11.4.22 Engine Information ..................................................................................... 4-204
4.11.4.23 Engine Failure Information ........................................................................ 4-205
4.11.4.24 Engine other information ........................................................................... 4-205
4.11.4.25 Daily maintenance information ................................................................. 4-206
4.11.4.26 System lockout information ....................................................................... 4-206

4-4 Shop Manual-June 2016

Structure and Functions SY500H Hydraulic Excavator

4-5 Shop Manual-June 2016

Structure and Functions SY500H Hydraulic Excavator

WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.

4-6 Shop Manual-June 2016

 SY500H Hydraulic Excavator Structure and Functions

4.Structure and Functions

4.1 Engine and Cooling System

4.1.1 Engine-relate parts

Fig.4-1

(1) Muffler Specifications

(2) Rubber damper AS Oil pan capacity: 52 L
(3) Engine rear seat
(4) Radiator assembly

Shop Manual-June 2016 4-7

 Structure and Functions SY500H Hydraulic Excavator

4.1.2 Radiator and intercooler

Fig.4-2

(1) CAC ASSY Specification

(2) Air conditioning radiator Radiator AS:
(3) Engine intake pipe ZH1150×450×1390-S180Z45Q/SY015028
(4) The radiator of fuel Aluminum pipe, belt-type radiator
(5) Water storage tank Radiators for the air conditioner, intercooler,
hydraulic oil and water are arranged serially.
(6) RAD ASSY Water tank capacity: 60 L
(7) Engine outlet pipe

4-8 Shop Manual-June 2016

 SY500H Hydraulic Excavator Structure and Functions

4.2 Power Train

4.2.1 Power train

Fig.4-3

(1) Swing motor (6) Accumulator

(2) Swing reducer (7) Main control valve
(3) Swing bearing (8) Reducer AS
(4) Idler (9) Main pump
(5) Swivel joint (10) Engine

Shop Manual-June 2016 4-9

 Structure and Functions SY500H Hydraulic Excavator

4.2.2 Travel reducer AS

Fig.4-4

Fig.4-5

4-10 Shop Manual-June 2016

 SY500H Hydraulic Excavator Structure and Functions

(1) Cylinder assembly (9) No. 2 sun gear

(2) Shaft (10) No. 2 planetary gear
(3) Gear hub (11) Seal ring
(4) No. 2 planetary carrier (12) Travel motor
(5) No. 1 planetary carrier (13) Filler port
(6) No. 1 planetary gear (14) Level port
(7) No. 1 sun gear (15) Drain port
(8) End cover

Specification

Reduction ratio: 60.652

No. Check item Criteria Remedy

Backlash Standard
Clearance limit
between No. 2 clearance
16 sun gear and Replace
No.2 planetary 0.13 ～ 0.47 1.00
gear
Backlash
between No. 1
17 0.17 ～ 0.57 1.10
planetary gear
and gear hub
Backlash
between No. 1
18 sun gear and 0.14 ～ 0.46 1.00
No.1 planetary
gear
Replace
Backlash
between No. 2
19 0.16 ～ 0.56 1.10
planetary gear
and gear hub
Backlash
between No. 1
20 planetary carrier 0.38 ～ 0.66 1.00
and No. 2 sun
gear

Shop Manual-June 2016 4-11

 Structure and Functions SY500H Hydraulic Excavator

4.2.3 Swing reduction mechanism

Fig.4-6

4-12 Shop Manual-June 2016

SY500H Hydraulic Excavator Structure and Functions

(1) Plug (11) No. 2 planetary gear GP

(2) Oil seal (12) No. 2 planetary gear (17 teeth)
(3) Self-aligning bearing (13) Spring pin
(4) Gear ring (52 teeth) (14) Swing reducer plug
(5) No. 2 planetary carrier (15) Grease fitting
(6) No. 1 planetary carrier (16) Self-aligning bearing
(7) No. 2 sun gear (16 teeth) (17) Bearing seal
(8) No. 1 sun gear (14 teeth) (18) Swing pinion
(9) Swing motor (19) Oil level gauge
(10) No. 1 planetary gear (18 teeth) (20) Oil filling pipe

Specification

Reduction ratio: （14+52）/14×（25.2+52）/16=22.75

No. Check item Criteria Remedy

Standard
Backlash between swing motor Clearance limit
21 clearance Replace
shaft and No. 1 sun gear
0.18～ 0.28 —
Backlash between No. 1 sun
22 0.16～ 0.50 1.00
gear and No.1 planetary gear
Backlash between No. 1
23 0.18～ 0.59 1.10
planetary gear and gear ring
Backlash between No. 1
24 planetary carrier and No. 2 sun 0.39～ 0.71 1.20
gear
Backlash between No. 2 sun
25 0.16～ 0.50 0.90 Replace
gear and No.2 planetary gear
Backlash between No. 2
26 0.18～ 0.59 1.00
planetary gear and gear ring
Backlash between No. 2
27 planetary carrier and swing 0.07～ 0.23 —
pinion
Backlash between swing pinion
28 0.22～ 1.32 2.00
and swing bearing

Shop Manual-June 2016 4-13

 Structure and Functions SY500H Hydraulic Excavator

4.2.4 Swing bearing

Fig.4-7

(1) Swing bearing inner race (83 teeth) Specification

(2) Steel ball Reduction ratio: 83/12
(3) Swing bearing outer race Grease capacity: 30±1 Kg

a. Inner race soft zone S position

b. Outer race soft zone S position

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 SY500H Hydraulic Excavator Structure and Functions

Check item Criteria Remedy

Axial clearance of Standard clearance Clearance limit
bearing
Replace
(when mounted on 0.5～1.2 3
chassis)

4.3 Undercarriage
4.3.1 Track frame and tensioning mechanism

Fig.4-8

Shop Manual-June 2016 4-15

Structure and Functions SY500H Hydraulic Excavator

(1) Idler
(2) Track frame • Dimension and number of track rollers may vary de-
(3) Carrier roller pending on the machine model, but the basic struc-
(4) Sprocket ture is the same.
• Number of track rollers
(5) Track roller Model Quantity (One side)
(6) Track shoe SY500H 9
(7) Center guard
(8) Front guard

Standard track shoe

SY500H

Unit: mm
No. Check Item Standard Remedy
Stand Toler Repair
Vertical width of idler ard size ance limit
9 Build-up
guide Track frame 158 — —
welding
Idler support 155 — — or
Track frame 302 — — replace
Horizontal width of
10 — —
idler guide Idler support 297
Standard size Repair limit
Free
length × Installa
Installa Free Installa
Outer tion
11 Tension spring tion load length tion load Replace
diame length
ter
1088 x 880 288 kN 1011 230 kN
286

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 SY500H Hydraulic Excavator Structure and Functions

4.3.2 Idler

Fig.4-9

SY500H

Unit: mm
No. Check item Criteria Remedy

Protrusion outer Standard size Repair limit

1
dia. 714 — Build-up
2 Tread outer dia 670 660 welding
3 Tread thickness 30 25 or
replace
4 Tread difference 22 27
5 Overall width 208 —

Shop Manual-June 2016 4-17

Structure and Functions SY500H Hydraulic Excavator

6 Tread width 51.5 —

Tolerance Standard
Standard Clear
Clearance clear
size Shaft Hole ance limit
7 between shaft ance
and bushing 0.036 0.39 0.286~
φ105 —
0.071 0.25 0.461
Tolerance Standard
Standard Interfer
Interference interfer
size Shaft Hole ence limit
8 between idler ence Replace
and bushing 0.087 -0.027 0.064～ bushing
φ112.6 —
0.037 -0.062 0.149
Clearance Standard clearance Clearance limit
between
bushing and
9
support (Sum of 0.4～0.9 —
clearances at
both sides)

4.3.3 Carrier roller

Fig.4-10

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SY500H Hydraulic Excavator Structure and Functions

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Flange outer dia
φ190 —
2 Tread outer dia. φ160 146
3 Tread width 60.5 —
4 Tread thickness 45.5 38.5
5 Flange width 17 —
Tolerance Standard
Standard Clear
Clearance clear
size Shaft Hole ance limit
6 between shaft ance Replace
and bushing -0.06 +0.23 0.15～
φ65 —
-0.09 +0.09 0.32
Tolerance Standard
Standard Interfer
Interference interfer
size Shaft Hole ence limit
7 between roller ence
and bushing +0.190 +0.07 +0.07 ～
φ69 —
+0.140 +0.03 +0.16
Axial clearance Standard clearance Clearance limit
8
of roller 0.5～0.7 —

Shop Manual-June 2016 4-19

 Structure and Functions SY500H Hydraulic Excavator

4.3.4 Track roller

Fig.4-11

SY500H

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SY500H Hydraulic Excavator Structure and Functions

Unit: mm
No. Check item Criteria Remedy
Standard clearance Repair limit
1 Flange outer dia.
φ250 —
φ210 Build-up
2 Tread outer dia. 194
welding
3 Tread thickness 59 51 or
4 Overall width 278 — replace
5 Tread width 60 —
6 Flange width 31 —
7 Inner width 96 —
Tolerance Standard Clear
Standard
Clearance clear ance
size Shaft Hole
8 between shaft ance limit
and bushing -0.185 +0.3 0.225 ～
φ85 —
+0.18 +0.04 0.4 Replace
Tolerance Standard Interfer bushing
Standard
Interference interfer ence
size Shaft Hole
9 between roller ence limit
and bushing +0.14 +0.02 +0.07 ～
φ92 —
+0.09 -0.02 +0.16
Clearance Standard clearance Clearance limit
between
bushing and
10 Replace
collar (Sum of 0.5 ～ 1.0 —
clearance at
both sides)

Shop Manual-June 2016 4-21

Structure and Functions SY500H Hydraulic Excavator

4.3.5 Tracks

Fig.4-12

SY500H

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Link pitch
228.6 231.6 Reverse or
Standard size Reverse replace
2 Bushing outer diameter
68 66
3 Thickness of bushing metal 12 7
Repair or replace
4 Link height Standard size Repair limit

4-22 Shop Manual-June 2016

SY500H Hydraulic Excavator Structure and Functions

129 119
Thickness of link metal
5 (bushing press-fitting 33.5 23.5
portion)
6 184
7 Shoe bolt pitch 144
8 76.2
9 Inside width 106
10 Link Overall width 55
11 Tread width 47
Protrusion Regular 3
12
of pin Master 4.5
Regular 5.25 Adjust or replace
Protrusion
13
of bushing Master 0
Overall Regular 261
14 length of
pin Master 174.4

Overall Regular 164.5

15 length of
bushing Master 164

16 Thickness of spacer —
17 Bushing 441 ～ 980 kN{45 ～ 100 tons}
Press-fitting
18 Regular pin 343 ～ 686 kN{35 ～ 70 tons} —
force
19 Master pin 198 ～ 392 kN{20 ～ 40 tons}

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Structure and Functions SY500H Hydraulic Excavator

Unit: mm
No. Check item Criteria Remedy
Tightening torque (Nm Retightening angle
{kgm}) (deg.)
a. Regular
link Triple
1368±50
grouser —
{140±5.1}
shoe
Shoe bolt Retighten
Tightening Lower
20
torque Retightening angle torque
b. Master
(Nm (deg.) limit (Nm
link
{kgm}) {kgm})
— — —
Number of track shoes
50 —
(on one side)
Tolerance Standard
Standard
interfer
Interference between size Shaft Hole
21 ence
bushing and link
+0.4 +0.074 0.276～
φ71
+0.35 0 0.4
Interference between +0.05 -0.288 0.288～
22 φ48.85
regular pin and link 0 -0.35 0.4
Tolerance Standard
Standard
Clearance between clearShaft
size Shaft Hole
23 regular pin and Hole ance
bushing +0.05 +0.95 Adjust or
φ48.85 0.4～0.95
0 0.45 replace
Tolerance Standard
Standard
clearShaft
Interference between size Shaft Hole
24 Hole ance
master pin and link
-0.1 -0.288 0.138～
φ48.85
-0.15 -0.35 0.25
Tolerance Standard
Standard
Clearance between clearShaft
size Shaft Hole
25 master pin and Hole ance
bushing -0.1 +0.95
φ48.85 0.55～1.1
-0.15 +0.45

Tri-grouser track shoe

4-24 Shop Manual-June 2016

 SY500H Hydraulic Excavator Structure and Functions

Fig.4-13

Tri-grouser track shoe

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Height
36 21
2 Thickness 16
3 33
Length of base
4 26 Build-up welding or
5 25 replace
6 Length at tip 20
7 22
Standard size Repair limit
8 Thickness
52 15

Shop Manual-June 2016 4-25

 Structure and Functions SY500H Hydraulic Excavator

4.4 Hydraulic System, Part 1

4.4.1 Deployment of hydraulic parts

(1) Bucket cylinder

(2) Arm cylinder

(3) Boom cylinder

(4) Hydraulic tank

(5) Hydraulic oil filter

(6) Main control valve

(7) Main pump

(8) Radiator

(9) Accumulator

(10) Left travel motor

(11) Right travel motor

(12) Swing motor

(13) Hydraulic lockout control

(14) Left pilot valve

(15) Swivel joint

(16) Right pilot valve

(17) Travel pilot valve

Fig.4-14
(18) Solenoid valve AS

18A. Pilot valve lockout

18B. Bucket confluence

18C. Travel speed shift

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SY500H Hydraulic Excavator Structure and Functions

Fig.4-15

4.4.2 Hydraulic Pump (SY500H)

Type: K5V212DPH+K3VL28/C

Shop Manual-June 2016 4-27

 Structure and Functions SY500H Hydraulic Excavator

Fig.4-16

Outline

• This pump consists of 2 variable capacity swash plate plunger pumps, 2 regulators, and 1 pilot
gear pump.
a1: Front pump principal pressure detection port

a2: Rear pump principal pressure detection port

a3: Front pump regulator pressure detection port

a4: Rear pump regulator control pressure detection port

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 SY500H Hydraulic Excavator Structure and Functions

a5: Pilot gear pump output pressure detection port

PH1: Front pump pressure sensor mounting port

PH2: Rear pump pressure sensor mounting port

A1: Oil delivery port (front pump)

A2: Oil delivery port (rear pump)

A3: Oil delivery port (pilot gear pump)

Psv1: Regulator control port (front pump)

Psv2: Regulator control port (back pump)

Dr1: Oil drain port

Dr2: Educator plug of pump

Dr3: Oil drain port（cooling pump）

Dr4: Oil drain port（cooling pump）

B1: Oil suction port (pump)

B2: Oil suction port （cooling pump）

1: Front pump

2: Rear pump

3: Pilot gear pump

4: cooling pump

5: Front pump regulator

6:Rear pump regulator

Shop Manual-June 2016 4-29

Structure and Functions SY500H Hydraulic Excavator

4.4.3 Pilot pump

Fig.4-17

307: Valve stem 361: Body

308: Valve seat 433: Screw
309: Retainer ring 434: Screw
310: Spring 435: screw
311: Adjusting screw 466: Plug
312: Nut 700: Washer
351: Body 710: O-ring
353: Gear shaft 725: O-ring
354: Gear shaft 732: O-ring
355: Filter element 850: Washer

Function

The engine drives the main pump shaft and the pilot pump shaft through the coupling. The pilot
pump is operated through gear engagement.

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SY500H Hydraulic Excavator Structure and Functions

4.4.4 Regulator (KR3S-9T1L-V)

4.4.4.1 General

Fig.4-18

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Structure and Functions SY500H Hydraulic Excavator

No. Part name Material Quantity Part No. Remark

Socket-
924 headed Alloy steel 1 60008743
setscrew
898 Pin Bearing steel 1 60008738 φ8.5×10L
897 Pin Bearing steel 1 60008736 φ5×19L
887 Pin Carbon steel 1 60008546
876 Pin Bearing steel 2 60008735 φ5×8L
875 Pin Bearing steel 2 60008733 φ4×8L
874 Pin Bearing steel 1 60008734 φ4×11.7L
JISB 2804
858 Lock ring Tool steel 2 60009937
RR-15
836 Retainer ring Tool steel 1 60008748
JISB 2804
814 Retainer ring Tool steel 1 60009938
SR-10
802 Hex nut Rolled steel 1 60008506 M10
JISB 1181
801 Hex nut Rolled steel 2 60008857
RN-M8
JISB 2401-
763 O-ring NBR 1 60008693
G35
JISB 2401-
757 O-ring NBR 1 60008698
P12.5
JISB 2401-
756 O-ring NBR 1 60008706
P26
JISB 2401-
755 O-ring NBR 5 60008697
P11
753 O-ring NBR 2 60008709 JISB 2401-P9
JISB 2401-
734 O-ring NBR 1 60008692
G25
JISB 2401-
733 O-ring NBR 1 60008703
P20
JISB 2401-
732 O-ring NBR 2 60008701
P16
JISB 2401-
730 O-ring NBR 1 60008704
P22
JISB 2401-
728 O-ring NBR 1 60008702
P18
JISB 2401-
725 O-ring NBR 1 60008696
P10
724 O-ring NBR 8 60008708 JISB 2401-P8

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SY500H Hydraulic Excavator Structure and Functions

No. Part name Material Quantity Part No. Remark

722 O-ring NBR 3 60008707 JISB 2401-P6
JISB 2401-
708 O-ring NBR 1 60008694
G75
656 Blind Cast iron 1 60008548
Adjusting
655 Spring steel 1 60008540
spring
654 Recoil spring Spring steel 1 60008541
653 Spring Carbon steel 1 60008539
652 Spool Alloy steel 1 60008538
651 Sleeve Alloy steel 1 60008503
646 Guide spring Spring steel 1 60008498
Adjusting
645 Carbon steel 1 60008525
ring(Q)
644 Spring (Q) Alloy steel 1 60008495
643 Pilot plunger Alloy steel 1 60008520
641 Guide cover Cast iron 1 60008510
631 PF sleeve Cast iron 1 60008502
630 Locknut Rolled steel 1 60008537
629 Cover (C) Cast iron 1 60008529
Adjusting bolt
628 Carbon steel 1 60008497
(C)
Adjusting bolt
627 Carbon steel 1 60008526
(C)
626 Inner spring Spring steel 1 60008547
625 Outer spring Spring steel 1 60008499
Spring seat
624 Alloy steel 1 60008494
(C)
623 Offset piece Alloy steel 1 60008524
622 Piston casing Cast iron 1 60008536
621 In-cavity cock Alloy steel 1 60008535
615 Offset piston Carbon steel 1 60008534
Supporting
614 Carbon steel 1 60008533
pin
613 Lever (2) Alloy steel 1 60008522
612 Lever (1) Alloy steel 1 60008532

Shop Manual-June 2016 4-33

Structure and Functions SY500H Hydraulic Excavator

No. Part name Material Quantity Part No. Remark

Feedback rod
611 Alloy steel 1 60008551
block
601 Housing Cast iron 1 60008513
545 Steel ball Bearing steel 2 60008886
543 Block 1 Alloy steel 2 60008885
541 Seat Alloy steel 2 60008884
496 Plug Carbon steel 15 60008728
467 Plug Rolled steel 1 60008507 G3/8×M8
466 Plug Alloy steel 1 60008724 G1/4
Socket- JISB 1176
439 Alloy steel 3 60008844
headed screw M6-35
Socket- JISB 1176
438 Alloy steel 10 60008842
headed screw M6-20
Socket- JISB 1176
418 Alloy steel 2 60008841
headed screw M5-12
Socket- JISB 1176
413 Alloy steel 2 60008849
headed screw M8-70
Socket- JISB 1176
412 Alloy steel 2 60008847
headed screw M8-50
- Regulator - 1 60000733

Function

• The regulator controls flow of main pump

according to command pressure signals.
This will limit pump driving power to not
more than the power of engine.
• Pump 1 and pump 2 are each equipped
with a regulator. The regulator mainly con-
sists of a proportional reducing solenoid
valve (1), hydroelectric shift valve (2), varia-
ble frequency regulator (3), positive flow
regulator (4), servo piston (5) and direction-
al servo valve (6). According to command
pressure signals, the regulator opens or
closes the oil passage of servo piston (5), Fig.4-19
changes the inclination of swash plate, and
controls the flow of pump as a result.

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 SY500H Hydraulic Excavator Structure and Functions

Electric current control in normal

operation

By changing the command current value I to

the proportional reducing solenoid valve, incli-
nation angle (output flow) of the swash plate
of pump can be regulated freely. As a regula-
tor of positive flow control (forward control),
the output flow Q increases as the command
current value I rises. With such a device, input
a current necessary for flow required by corre-
sponding operation. In this way, the pump only
delivers a flow desired and no power will be
wasted.

Hydraulic power control in emergency

• In control of hydraulic power, the rising of

pump output pressure Pd automatically re-
duces the inclination (output flow) of swash
plate. As a result, the input torque is limited
under certain value. (In case of constant
speed, the input power is constant too.)
• When power control is exercised, regulator
of each pump is controlled to the same incli-
nation (output flow). Therefore, power con-
trol is performed irrelevant to the load of
both pumps. Overload of prime mover is
prevented as a result.
• With this mechanism, optimum power can
be achieved in pump operation.
• Although the regulator has the two control
mechanisms described above, each control
in joint action can put small inclination (flow)
command to priority via mechanical
calculation.
Adjustment of regulator

Shop Manual-June 2016 4-35

 Structure and Functions SY500H Hydraulic Excavator

Fig.4-20

531: Inclination pin

532: Servo piston

548: Feedback pin

807: Retaining nut

808: Retaining nut

953: Adjusting screw

954: Adjusting screw

Maximum or minimum flow can be regulated

via the adjusting screws (953, 954) on the
side of pump body. The adjusting screw (C)
(628) and adjusting wheel (C) (627) of the reg-
ulator can be used to adjust power control
characteristics. The Allen screw (924) can be
used to adjust flow control characteristics.

Fig.4-21

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 SY500H Hydraulic Excavator Structure and Functions

Changing the maximum flow (at pump

body side)

Loosen the hex nut (808). Tighten (or loosen)

socket-headed setscrew (954). No control
characteristics except the maximum flow
changes.

Fig.4-22

Changing the minimum flow (at pump

body side)

Loosen the hex nut (806). Tighten (or loosen)

the socket-headed setscrew (953). Though
this action is the same as the adjustment of
maximum flow and all the other control char-
acteristics do not change, power required for
maximum output pressure (overflow) is likely
to increase if over-tightened. Be careful in this
case.

Fig.4-23

Input power

Adjusting the outer spring

Loosen the nut (630) and tighten or loosen

the screw (C) (628) to perform adjustment.
When screw (C) (628) is tightened, the control
line, as shown in the right figure, moves right-
ward. The input power increases. Moreover,
When the screw (C) (628) is turned by N
turns, inner spring (626) also changes along
with its setting. So turn the adjusting wheel
(C) (627) in the opposite direction by N×A Fig.4-24
turns.

(For value of A see the annexed table. )

Shop Manual-June 2016 4-37

 Structure and Functions SY500H Hydraulic Excavator

Adjusting the inner spring

Loosen the nut (802) and tighten or loosen

the adjusting wheel (C) (627) to perform ad-
justment. When adjusting wheel (C) (627) is
tightened, the flow increases as shown in the
right figure. The input power rises too.

Fig.4-25

Changing flow control characteristics

Loosen the nut (810) and tighten or loosen

the screw (924) to perform adjustment. When
the screw (924) is tightened, the control line
moves rightward as shown in the right figure.

Fig.4-26

Action description

As shown by the right figure, the output flow of

pump can be controlled steplessly via com-
mand current I when pump speed is certain.

Fig.4-27

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 SY500H Hydraulic Excavator Structure and Functions

1) In electric control

Flow-increasing operation

When command current I increases, the sec-

ondary pressure Pz of proportional pressure
reducing solenoid valve rises. As a result, the
pilot plunger (643) moves toward A and it
does not stop until Pz is balanced to the pilot
spring (646). The movement of pilot plunger is
transmitted to lever (2) (613) via the pin (875).
The lever (2) (613) turns around pivot B in the
arrow- indicated direction. Rotation of lever
(2) is also transmitted to feedback bar (611)
Fig.4-28
via the pin (897). The feedback bar (611) piv-
ots on C and turns in the same direction with
B. Along with this, the spool (652) connected
with the feedback bar moves in direction D. If
the spool moves toward D, port C1 will be
connected through the port of tank. So pres-
sure in head end of servo piston is released.
The output pressure Pd1 through the rod end
pushes the servo piston (532) toward E. The
flow increases as a result. As the feedback
bar is in connection with the servo piston and
spool, when servo piston moves toward E, the
feedback bar turns around pivot F. In this way,
the spool goes back to its original position.
Through such movement the gap between
spool and housing is gradually closed. The Fig.4-29
servo piston will not stop until it is fully closed.

Shop Manual-June 2016 4-39

 Structure and Functions SY500H Hydraulic Excavator

Flow-decreasing operation

When command current I decreases, the sec-

ondary pressure Pz of proportional pressure
reducing solenoid valve drops. As a result, the
pilot plunger (643) moves toward G and it
does not stop until Pz is balanced to the pilot
spring (646). The movement of pilot plunger is
transmitted to feedback bar (611) via the pin
(897). The feedback bar (611) pivots on I and
turns in the same direction with H. Along with
this, the spool (652) connected with the feed-
back bar moves in direction J. If the spool
moves toward J, the output pressure Pd1 will Fig.4-30
be introduced to the head end of servo piston
via the spool and port C1. On the other hand,
the rod end of servo piston is usually intro-
duced with output pressure Pd1. As a result of
the difference in area, the piston moves to-
ward K, the inclination reduces, and the flow
decreases too. As the feedback bar is in con-
nection with the servo piston and spool, when
servo piston moves toward K, the feedback
bar turns around pivot L. In this way, the spool
goes back to its original position. Through
such movement the gap between spool and
housing is gradually closed. The servo piston
will not stop until it is fully closed.
Fig.4-31

2) Hydroelectric control

Power control in emergency

• As shown in the right figure, the increase of

load pressure reduces the inclination of
pump, thus preventing overloading of the
prime mover.
• Similar to flow control, power control is pre-
sented in brief as the following.

Fig.4-32

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 SY500H Hydraulic Excavator Structure and Functions

Operation against overloading

When the self pump output pressure Pd1 in-

creases, the output pressure Pd1 is acted on-
to the ladder portion of the offset piston (621) ,
and as a result, the offset rod (623) moves in
direction M until the output pressure Pd1 bal-
ances the elastic forces of outer spring (625)
and inner spring (626). The movement of the
offset rod is transmitted to the lever (1) (612)
via pin (875) and rotate in the arrow direction
with N as the pivot. Then, the movement of
lever (1) is transmitted to feedback rod (611)
via pin (897) and rotates in the same arrow di- Fig.4-33
rection as N with O as the pivot. Along with
this, spool (652) which is connected to the
feedback rod moves in direction P. If the spool
moves in direction P, output pressure Pd1 en-
ters the large diameter end of the servo piston
through the spool and port C1. However, out-
put pressure Pd1 enters the small diameter
end of the servo piston, and as a result of the
area difference, the servo piston moves in di-
rection Q. The inclination is reduced as a re-
sult and the flow is also reduced. Since the
feedback rod, the servo piston and the spool
is a whole unit, when the servo piston is mov-
ing in direction Q, the feedback rod rotates
with R as the pivot. This allows the spool to
Fig.4-34
move to its original position. Through this
movement, the opening portion between the
spool and the valve block is slowly closed.
The servo piston stops moving when the
opening portion is completely closed.

Shop Manual-June 2016 4-41

 Structure and Functions SY500H Hydraulic Excavator

Flow-recovering operation

When the self pump output pressure Pd1

drops, elastic force offset rod (623) of outer
spring (625) and inner spring (626) moves in
direction S to a point where the elastic force of
the outer spring and the inner spring balances
the output pressure Pd1. The movement of
the offset rod (623) is transmitted to lever (1)
(612) via pin (875) and rotates in the arrow di-
rection with T as the pivot. Then, the move-
ment of lever (1) is transmitted to feedback
rod (611) via pin (897) and rotates in the same
arrow direction as T with U as the pivot. Along Fig.4-35
with this, spool (652) which is connected to
the feedback rod moves in direction V. If the
spool is moving in direction V, port C1 is con-
nected with the tank port, and the pressure in-
side the large diameter end of the servo
piston is relieved as a result. Servo piston
(532) moves in direction W through the output
pressure Pd1 of the small diameter end. The
flow is increased in this way. Since the feed-
back rod, the servo piston and the spool is a
whole unit, if the servo piston is moving in di-
rection W, the feedback rod will rotate with X
as the pivot. This allows the spool to move to
its original position. Through this movement,
the opening portion between the spool and Fig.4-36
the valve block is slowly closed. The servo
piston stops moving when the opening portion
is completely closed.

Prior mechanism of small inclination

(small flow) command

As described above, though the inclination

command of delivery control and power con-
trol is transmitted to the feedback rod (611)
and spool (652) via lever (2) (613) and the big
diameter end of lever (1) (612) respectively,
pin (φ5) on the big hole (φ9) , as a protrusive
structure, only contacts with the rod and pin at
the small inclination side. It does not contact

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 SY500H Hydraulic Excavator Structure and Functions

with the rod φ9 and pin (897) on the large in-

clination side. Through this mechanical op-
tion, the inclination command of the delivery
control and power control is placed in priority.
Annexed table: Regulator adjusting values

Model of regulator KR3S-9T1L-V

RPM (min-1) 2100
Adjusting screw (954)
+1/4
screw-in (rotation)
Max. flow regulation
Delivery change (l/
6
min)
Adjusting screw (953)
+1/4
screw-in (rotation)
Min. flow regulation
Delivery change (l/
5
min)
Adjusting screw (928)
+1/4
screw-in (rotation)
Compensation control
Adjustment of outer start pressure (kgf/ 16
spring cm²)
Input torque changing
4.3
Adjustment of input amount (kgf·m)
horse power A 1.8
Adjusting screw (925)
+1/4
screw-in (rotation)
Adjustment of inner Delivery change (l/
10
spring min)
Input torque change
4.2
(kgf·m)
Adjusting screw (924)
+1/4
screw-in (rotation)
Delivery control
Adjustment of flow control characteristics starting pressure 1.5
change (kgf/cm²)
Delivery change (l/
14
min)

Internal structure of hydraulic pump

Shop Manual-June 2016 4-43

Structure and Functions SY500H Hydraulic Excavator

Fig.4-37

Fig.4-38

4-44 Shop Manual-June 2016

SY500H Hydraulic Excavator Structure and Functions

724. Front shaft 8. Oil distributor

953. Min. delivery adjusting screw 9. End cover
214. Swash plate 113. Rear shaft
143. Slipper 13. Piston
151. Plunger 554. Max delivery adjusting screw
7. Cylinder block

Fig.4-39

Shop Manual-June 2016 4-45

Structure and Functions SY500H Hydraulic Excavator

Function • Swash plate (4) has flat surface (A), and slip-
• The torque of the engine is transmitted to the per (5) is always pressed against this sur-
pump shaft (1), and drives cylinder block (7) face while sliding in a circular movement.
to rotate. At the same time, nine plungers (6) • Swash plate (4) conducts high pressure oil
slide along the oil distributor (8). Plunger (6) to cylinder surface (B), and forms a static
moves back and forth inside cylinder block pressure bearing when it slides.
(7) and pressurized oil is sucked in and dis- • Plunger (6) carries out relative movement in
charged alternatively. the axial direction inside each cylinder cham-
• It is possible to change the displacement by ber of cylinder block (7).
changing the swash plate angle. • Cylinder block (7) seals the pressurized oil
Structure to oil distributor (8) and carries out relative
• Cylinder block (7) is supported to shaft (1) by rotation.
spline (17). • This surface is designed so that the oil pres-
• Shaft (1) is supported by front and rear bear- sure balance is maintained at a suitable
ings (18). level.
• Tip of plunger (6) is shaped as a concave • The oil inside the respective cylinder cham-
ball and slipper (5) is caulked to it to form bers of cylinder block (7) is sucked in and
one unit. discharged through oil distributor (8).
• Plunger (6) and slipper (5) constitute the
spherical bearing.

Working process

• Cylinder block (7) rotates together with

shaft (1), and slipper (5) slides on flat sur-
face (A).
• When this happens, swash plate (4) moves
along cylindrical surface (B), so angle (a)
between central line (X) of swash plate (4)
and the axial direction of cylinder block (7)
changes.
• (a) stands for the angle of the swash plate.
• With central line (X) of swash plate (4) at a Fig.4-40
swash plate angle (a) in relation to the axial
direction of cylinder block (7), flat surface
(A) acts as a cam in relation to slipper (5).

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SY500H Hydraulic Excavator Structure and Functions

• In this way, plunger (6) slides on the inside

of cylinder block (7), so a difference be-
tween volumes (E) and (F) is created inside
cylinder block (7).
• A single plunger sucks and discharges the
oil by the amount (F) – (E).
• As cylinder block (7) rotates and the volume
of chamber (E) becomes smaller, the pres-
surized oil is discharged.
• On the other hand, the volume of chamber
(F) grows larger and, in this process, the oil
Fig.4-41
is sucked in.

• As central line (X) of swash plate (4) over-

laps the axial direction of cylinder block (7)
(swash plate angle (a) = 0), the difference
between volumes (E) and (F) inside cylinder
block (7)becomes 0.
• Suction and discharging of pressurized oil
is not carried out in this state. Namely
pumping action is not performed. (In reality,
however, the swash plate angle is not set to
0)

Fig.4-42

4.4.4.2 Oil delivery control

• If swash plate angle (a) becomes larger, the

difference between volumes (E) and (F) be-
comes larger and pump delivery (Q)
increases.
• Piston (13) is used for changing swash
plate angle (a).
• Piston (13) makes linear reciprocal move-
ment under the control of the adjustor.
• This linear motion is transmitted to swash
plate (4) via drive pin (16). The sliding of the
swash plate changes the swash plate angle
and changes the displacement of the main Fig.4-43
pump.

Shop Manual-June 2016 4-47

Structure and Functions SY500H Hydraulic Excavator

4.4.5 Pilot pump

Fig.4-44

307: Valve stem 361: Body

308: Valve seat 433: Screw
309: Retainer ring 434: Screw
310: Spring 435: screw
311: Adjusting screw 466: Plug
312: Nut 700: Washer
351: Body 710: O-ring
353: Gear shaft 725: O-ring
354: Gear shaft 732: O-ring
355: Filter element 850: Washer

Function

The engine drives the main pump shaft and the pilot pump shaft through the coupling. The pilot
pump is operated through gear engagement.

4-48 Shop Manual-June 2016

SY500H Hydraulic Excavator Structure and Functions

4.4.6 Regulator (KR3K-9N1H-V)

Fig.4-45

Shop Manual-June 2016 4-49

Structure and Functions SY500H Hydraulic Excavator

No. Part name Material Quantity Part No. Remark

Socket-headed
924 Alloy steel 1 60008743
setscrew
898 Pin Bearing steel 1 φ9×11L
897 Pin Bearing steel 1 60008736 φ5×19L
887 Pin Carbon steel 1 60008546
876 Pin Bearing steel 2 60008735 φ5×8L
875 Pin Bearing steel 2 60008733 φ4×8L
874 Pin Bearing steel 1 60008734 φ4×11.7L
858 Lock ring Tool steel 2 60009937 JISB 2804 RR-15
836 Retainer ring Tool steel 1 60008748
814 Retainer ring Tool steel 1 60009938 JISB 2804 SR-10
802 Hex nut Rolled steel 1 60008506 M10
JISB 1181 RN-
801 Hex nut Rolled steel 2 60008857
M8
763 O-ring NBR 1 60008693 JISB 2401-G35
756 O-ring NBR 1 60008706 JISB 2401-P26
755 O-ring NBR 7 60008697 JISB 2401-P11
753 O-ring NBR 2 60008709 JISB 2401-P9
735 O-ring NBR 1 JISB 2401-P12
734 O-ring NBR 1 60008692 JISB 2401-G25
733 O-ring NBR 1 60008703 JISB 2401-P20
732 O-ring NBR 2 60008701 JISB 2401-P16
730 O-ring NBR 1 60008704 JISB 2401-P22
728 O-ring NBR 1 60008702 JISB 2401-P18
725 O-ring NBR 1 60008696 JISB 2401-P10
724 O-ring NBR 8 60008708 JISB 2401-P8
722 O-ring NBR 3 60008707 JISB 2401-P6
708 O-ring NBR 1 60008694 JISB 2401-G75
699 Blind Cast iron 1
697 Blind Cast iron 1
655 Adjusting spring Spring steel 1 60008540
654 Recoil spring Spring steel 1 60008541
653 Spring Carbon steel 1 60008539
652 Spool Alloy steel 1 60008538

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SY500H Hydraulic Excavator Structure and Functions

No. Part name Material Quantity Part No. Remark

651 Sleeve Alloy steel 1 60008503
646 Guide spring Spring steel 1 60008498
Adjusting
645 Carbon steel 1 60008525
ring(Q)
644 Spring (Q) Alloy steel 1 60008495
643 Pilot plunger Alloy steel 1 60008520
641 Guide cover Cast iron 1 60008510
631 PF sleeve Cast iron 1 60008502
630 Locknut Rolled steel 1 60008537
629 Cover (C) Cast iron 1 60008529
Adjusting bolt
628 Carbon steel 1 60008497
(C)
Adjusting ring
627 Carbon steel 1 60008526
(C)
626 Inner spring Spring steel 1 60008547
625 Outer spring Spring steel 1 60008499
624 Spring seat (C) Alloy steel 1 60008494
623 Offset piece Alloy steel 1 60008524
622 Piston casing Cast iron 1 60008536
621 In-cavity cock Alloy steel 1 60008535
615 Offset piston Carbon steel 1 60008534
614 Supporting pin Carbon steel 1 60008533
613 Lever (2) Alloy steel 1 60008522
612 Lever (1) Alloy steel 1 60008532
Feedback rod
611 Alloy steel 1 60008551
block
601 Housing Cast iron 1 60008513
545 Steel ball Bearing steel 2 60008886
543 Block 1 Alloy steel 2 60008885
541 Seat Alloy steel 2 60008884
496 Plug Carbon steel 6 60008728
482 Plug Rolled steel 1 60008724 G1/4
Socket-headed
438 Alloy steel 6 60008842 JISB 1176 M6-20
screw

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 Structure and Functions SY500H Hydraulic Excavator

No. Part name Material Quantity Part No. Remark

Socket-headed
436 Alloy steel 2 JISB 1176 M6-30
screw
Socket-headed
413 Alloy steel 2 60008849 JISB 1176 M8-70
screw
Socket-headed
412 Alloy steel 2 60008847 JISB 1176 M8-50
screw
Socket-headed
407 Alloy steel 4 JISB 1176 M6-70
screw
- Regulator - 1
- Regulator - 1 60000733

Operating principle

• The regulator controls flow of main pump

according to command pressure signals.
This will limit pump driving power to not
more than the power of engine.
• Pump 1 and pump 2 are each equipped
with a regulator. The regulator of front pump
includes variable frequency regulator (2),
negative flow regulator (3), servo piston (4)
and directional servo valve (5). The regula-
tor of rear pump includes electromagnetic Fig.4-46
proportional pressure reducing valve (1),
variable frequency regulator (2), negative
flow regulator (3), servo piston (4) and di-
rection servo valve (5). According to com-
mand pressure signals, the regulator opens
or closes the oil passage of servo piston
(5), changes the inclination of hydraulic cyl-
inder block, and controls the flow of pump
as a result.

Fig.4-47

Adjustment of regulator

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 SY500H Hydraulic Excavator Structure and Functions

Fig.4-48

531: Inclination pin

532: Servo piston

548: Feedback pin

807: Retaining nut

808: Retaining nut

953: Adjusting screw, minimum flow

954: Adjusting screw, maximum flow

Maximum or minimum flow can be regulated

via the adjusting screws (953, 954) on the
side of pump body. The adjusting screw (C)
(628) and adjusting wheel (C) (627) of the reg-
ulator can be used to adjust power control
characteristics. The Allen screw (924) can be
used to adjust flow control characteristics.

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 Structure and Functions SY500H Hydraulic Excavator

Changing the maximum flow (at pump

body side)

Loosen the hex nut (808). Tighten (or loosen)

socket-headed setscrew (954). No control
characteristics except the maximum flow
changes.

Fig.4-49

Changing the minimum flow (at pump

body side)

Loosen the hex nut (806). Tighten (or loosen)

the socket-headed setscrew (953). Though
this action is the same as the adjustment of
maximum flow and all the other control char-
acteristics do not change, power required for
maximum output pressure (overflow) is likely
to increase if over-tightened. Be careful in this
case.

Fig.4-50

Input power

Adjusting the outer spring

Loosen the nut (630) and tighten or loosen

the screw (C) (628) to perform adjustment.
When screw (C) (628) is tightened, the control
line, as shown in the right figure, moves right-
ward. The input power increases. Moreover,
When the screw (C) (628) is turned by N
turns, inner spring (626) also changes along
with its setting. So turn the adjusting wheel
(C) (627) in the opposite direction by N×A Fig.4-51
turns.

(For value of A see the annexed table. )

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 SY500H Hydraulic Excavator Structure and Functions

Adjusting the inner spring

Loosen the nut (802) and tighten or loosen

the adjusting wheel (C) (627) to perform ad-
justment. When adjusting wheel (C) (627) is
tightened, the flow increases as shown in the
right figure. The input power rises too.

Fig.4-52

Changing flow control characteristics

Loosen the nut (810) and tighten or loosen

the screw (924) to perform adjustment. When
the screw (924) is tightened, the control line
moves rightward as shown in the right figure.

Fig.4-53

Action description

As shown by the right figure, the output flow of

pump can be controlled steplessly via com-
mand current I when pump speed is certain.

Fig.4-54

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 Structure and Functions SY500H Hydraulic Excavator

Flow-increasing operation

When the feedback pressure Pi2 reduces, pi-

lot plunger (643) moves toward A until P2 is
balanced with the force of pilot spring (646).
Movement of pilot plunger is transmitted to
lever (2) (613) via the pin (875). Lever (2) ro-
tates on pivot B in the arrow-indicated direc-
tion. Movement of lever (2) is also transmitted
to the feedback bar (611) via the pin (897).
The feedback bar rotates on pivot C in the
same direction as indicated on B. Along with
Fig.4-55
this, the spool (652) connected with the feed-
back bar moves in direction D. If the spool
moves toward D, port C1 will be connected
through the port of tank. So pressure in head
end of servo piston is released. The output
pressure Pd1 through the rod end pushes the
servo piston (532) toward E. The flow in-
creases as a result. As the feedback bar is in
connection with the servo piston and spool,
when servo piston moves toward E, the feed-
back bar turns around pivot F. In this way, the
spool goes back to its original position.
Through such movement the gap between Fig.4-56
spool and housing is gradually closed. The
servo piston will not stop until it is fully closed.

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 SY500H Hydraulic Excavator Structure and Functions

Flow-decreasing operation

When the feedback pressure Pi2 increases,

the pilot plunger (643) moves toward G and it
does not stop until P2 is balanced to the pilot
spring (646). The movement of pilot plunger is
transmitted to feedback bar (611) via the pin
(897). The feedback bar (611) pivots on I and
turns in the same direction with H. Along with
this, the spool (652) connected with the feed-
back bar moves in direction J. If the spool
moves toward J, the output pressure Pd1 will
Fig.4-57
be introduced to the head end of servo piston
via the spool and port C1. On the other hand,
the rod end of servo piston is usually intro-
duced with output pressure Pd1. As a result of
the difference in area, the piston moves to-
ward K, the inclination reduces, and the flow
decreases too. As the feedback bar is in con-
nection with the servo piston and spool, when
servo piston moves toward K, the feedback
bar turns around pivot L. In this way, the spool
goes back to its original position. Through
such movement the gap between spool and
housing is gradually closed. Fig.4-58

Power control in overloading

• As shown in the right figure, the increase of

load pressure reduces the inclination of
pump, thus preventing overloading of the
prime mover.
• Similar to flow control, power control is pre-
sented in brief as the following.

Fig.4-59

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 Structure and Functions SY500H Hydraulic Excavator

Overload-preventive operation

When self-pump output pressure Pd1 rises,

as the output pressure Pd1 acts on the step of
compensation plunger (621), the compensa-
tion bar (623) moves toward M until the output
pressure Pd1 is balanced to the forces of out-
er spring (625) and inner spring (626). Move-
ment of compensation bar is transmitted to
lever (1) (612) via the pin (875). The lever (1)
(612) turns around pivot N in the arrow-indi-
cated direction. Rotation of lever (1) is also
Fig.4-60
transmitted to feedback bar (611) via the pin
(897). Along with this, the spool (652) con-
nected with the feedback bar moves in direc-
tion P. If the spool moves toward P, the output
pressure Pd1 will be introduced to the head
end of servo piston via the spool and port C1.
But the rod end of servo piston is usually intro-
duced with output pressure Pd1. As a result of
the difference in area, the piston moves to-
ward Q, the inclination reduces, and the flow
decreases too. As the feedback bar is in con-
nection with the servo piston and spool, when
servo piston moves toward Q, the feedback Fig.4-61
bar turns around pivot R. In this way, the spool
goes back to its original position. Through
such movement the gap between spool and
housing is gradually closed. The servo piston
will not stop until it is fully closed.

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 SY500H Hydraulic Excavator Structure and Functions

Flow-recovering operation

When self-pump output pressure Pd1 drops,

the forces of outer spring (625) and inner
spring (626) push the compensation bar (623)
toward S until the output pressure Pd1 is bal-
anced to the forces of outer spring (625) and
inner spring (626). Movement of compensa-
tion bar is transmitted to lever (1) (612) via the
pin (875). The lever (1) (612) turns around piv-
ot T in the arrow-indicated direction. Rotation
of lever (1) is also transmitted to feedback bar
Fig.4-62
(611) via the pin (897). The feedback bar piv-
ots on U and rotates in direction opposite to
the arrow-indicated direction of T. Along with
this, the spool (652) connected with the feed-
back bar moves in direction V. If the spool
moves toward V, port C1 will be connected
through the port of tank. So pressure in head
end of servo piston is released. The output
pressure Pd1 through the rod end pushes the
servo piston (532) toward W. The flow in-
creases as a result. As the feedback bar is in
connection with the servo piston and spool,
when servo piston moves toward W, the feed- Fig.4-63
back bar turns around pivot X. In this way, the
spool goes back to its original position.
Through such movement the gap between
spool and housing is gradually closed. The
servo piston will not stop until it is fully closed.

Prior mechanism of small inclination

(small flow) command

As described above, though the inclination

command of delivery control and power con-
trol is transmitted to the feedback rod (611)
and spool (652) via lever (2) (613) and the big
diameter end of lever (1) (612) respectively,
pin (φ5) on the big hole (φ9) , as a protrusive
structure, only contacts with the rod and pin at
the small inclination side. It does not contact
with the rod φ9 and pin (897) on the large in-
clination side. Through this mechanical

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 Structure and Functions SY500H Hydraulic Excavator

option, the inclination command of the flow

control and power control is placed in priority.

Power shift control (reducing the power)

• As shown in the right fi gure, power setting

of the pump is controlled freely with the
power shift pressure Pf.
• When the power shift pressure Pf in-
creases, the pin (898) and compensation
plunger (621) push the compensation bar
(623) rightward. As described in the para-
graph of overload-preventing operation, this
reduces pump inclination and thus the
power setting. On the contrary, reduction of
Fig.4-64
pressure Pf will increase the power setting.
• The power shift pressure Pf is 0 Mpa when
the pump is working normally. It is 4.9 Mpa
in case of emergency.
Annexed table: Regulator adjusting values

Model of regulator KR3K-9N1H-V

RPM (min-1) 2000
Adjusting screw (954)
4
screw-in (rotation)
Max. flow regulation
Delivery change (l/
6
min-1)
Adjusting screw (953)
+1/4
screw-in (rotation)
Min. flow regulation
Delivery change (l/
5
min-1)
Adjusting screw (928)
+1/4
screw-in (rotation)
Compensation control
Adjustment of outer start pressure (kgf/ 16
Adjustment of input spring cm²)
horse power Input torque changing
4.3
amount (kgf·m)
A 1.8
Adjustment of inner Adjusting screw (925)
+1/4
spring screw-in (rotation)

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SY500H Hydraulic Excavator Structure and Functions

Delivery change (l/

10
min-1)
Input torque change
4.2
(kgf·m)
Adjusting screw (924)
+1/4
screw-in (rotation)
Delivery control
Adjustment of flow control characteristics starting pressure 1.5
change (kgf/cm²)
Delivery change (l/
14
min-1)

4.5 Hydraulic System, Part 2

4.5.1 Control valve

4.5.1.1 General

General view

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Structure and Functions SY500H Hydraulic Excavator

Fig.4-65

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SY500H Hydraulic Excavator Structure and Functions

P1: Pump port (P1 side) PAcs： Pilot port, bucket (IN) travel limit
P2: Pump port (P2 side) Pna1： Pilot port, arm 1 logic control valve
Aa: Rod end port, arm cylinder (OUT) Pns： Pilot port, swing logic control valve
Ba1： Head end port, arm cylinder (IN) PG： Pilot pressure source port
(Ba2)：Head end port, arm cylinder (IN) PH： Pilot pressure source port
Pz： Pilot pressure for boosting main relief
Ab： Head end port, boom cylinder (UP)
valve
Bb： Rod end port, boom cylinder (DOWN) PaL： Pilot port, lock valve (arm rod end )
Ac： Rod end port, bucket cylinder (OUT) PbL： Pilot port, lock valve (boom head end)
Bc： Head end port, bucket cylinder (in) Px： Signal port used for work equipment
Atr： Motor port, right travel Py： Signal port used for travel
Btr： Motor port, right travel Drl： Oil drain port
AtL： Motor port, left travel Dr2： Oil drain port
BtL： Motor port, left travel Dr3： Oil drain port
As： Motor port, swing Dr4： Oil drain port
Bs： Motor port, swing Dra： Oil drain port
XAtr： Pilot port, right travel Drb： Oil drain port
XBtr： Pilot port, right travel R1： Oil return port
XAtL： Pilot port, left travel (R2)： Oil return port
XBtL： Pilot port, left travel R3： Oil return port
XAs： Pilot port, swing Rs1： Oil fill port
XBs： Pilot port, swing Rs2： Oil fill port
XBb1： Pilot port, boom 1 (DOWN) (Ao)： Backup port
XAb1： Pilot port, boom 1 (UP) (Bo)： Backup port
XBb2： Pilot port, boom confuence (DOWN) (XAo)： Backup pilot port
XAb2： Pilot port, boom confuence (UP) (XBo)： Backup pilot port
XBa1： Pilot port, arm 1 (IN) (PTa)
XAa1： Pilot port, arm 1 (OUT) (PTb)
XBa2： Pilot port, arm 2 (IN) (N1)
XAa2： Pilot port, arm 2 (OUT) (N2)
XAc： Pilot port, bucket (OUT) (P3)
XBc： Pilot port, bucket （in） (P4)

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Structure and Functions SY500H Hydraulic Excavator

XBp1： Pilot port, bypass stop valve spool (P1

(R4)
side)
XBp2： Pilot port, bypass stop valve spool (P2
side)

4.5.1.2 Main valve structure

Fig.4-66

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SY500H Hydraulic Excavator Structure and Functions

Fig.4-67

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Structure and Functions SY500H Hydraulic Excavator

Fig.4-68

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SY500H Hydraulic Excavator Structure and Functions

Fig.4-69

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Structure and Functions SY500H Hydraulic Excavator

Torque Torque
No. Part name Qty No. Part name Qty
（N.m） （N.m）
101 Valve body A 1 305 Swing spool 1
102 Valve body B 1 306 Spool, arm 2 1
103 Valve body C 1 307 Spool, boom 2 1
Spool AS,
151 Oil plug 6 13~17 308 1
straight travel
152 Oil plug 2 34~39 309 Backup 1
Spool, bypass
153 Oil plug 10 69~78 310 2
stop
161 O-ring seal 4 323 Spring 2
162 O-ring seal 6 324 Spring 2
163 O-ring seal 9 331 Spring seat 4
164 O-ring seal 2 332 Spring seat 20
165 O-ring seal 4 333 Bolt with washer 2 16~18
166 O-ring seal 12 334 Stopper 2
167 O-ring seal 6 336 Bolt with washer 10 37~41
168 O-ring seal 3 337 Stopper 10
169 O-ring seal 10 341 Oil plug 1 34~39
201 Spring cap 9 342 Piston 1
Throttle
202 Spring cap 2 351 3 7.8~9.8
plug(φ0.7)
203 Spool cap 9 371 Spring 8
204 Spring cap 1 372 Spring 1
205 Spool cap 1 375 Spring 1
211 Plate 1 511 Cone valve 10
213 Flange 2 512 Cone valve 2
Check valve
214 1 513 Cone valve 2
plate
Pipeless
275 opening 1 514 Cone valve 1
cover plate
Pipeless
216 opening 1 515 Cone valve 2
cover plate
Lock valve
252 2 9.8~14 521 Spring 12
selector GP

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SY500H Hydraulic Excavator Structure and Functions

Torque Torque
No. Part name Qty No. Part name Qty
（N.m） （N.m）
Logic valve
253 component, 1 522 Spring 3
arm 1
Logic valve
254 component, 1 523 Spring 2
swing
Logic control
255 2 52~62 531 Spring seat 1
valve
Stop valve
257 GP, arm 1 120~140 541 Steel ball 1
regeneration
261 O-ring seal 11 542 Spring seat 1
262 O-ring seal 2 543 Spring 1
263 O-ring seal 9 551 Oil plug 17 370~410
264 O-ring seal 3 552 Oil plug 2 230~260
265 O-ring seal 1 553 Oil plug 2 370~410
266 O-ring seal 1 554 Oil plug 1 25~29
267 O-ring seal 1 555 Oil plug 1 220~260
Bolt, socket
271 40 52~62 561 O-ring seal 19
head
Bolt, socket
272 4 25~34 562 O-ring seal 2
head
Bolt, socket
273 4 210~260 563 O-ring seal 1
head
Bolt, socket
275 12 140~180 601 Main relief valve 1 120~140
head
Bolt, socket
276 4 25~34 602 Port relief valve 6 120~140
head
Bolt, socket
277 4 83~110 605 Port relief valve 2 120~140
head
301 Travel spool 2 971 Bolt, socket head 12 390~470
Spool GP,
302 1 991 Nameplate 1
arm 1
Spool GP,
303 1 992 Rivet 2
boom 1
304 Bucket spool 1

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 Structure and Functions SY500H Hydraulic Excavator

4.5.2 Hydraulic circuit (With bucket confluence function)

Hydraulic circuit

Fig.4-70

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 SY500H Hydraulic Excavator Structure and Functions

Operating principle

1) When spool is neutral position

(Main circuit)

• When all spools are in neutral position, the working oil from (front) hydraulic pump enters the
pump port P1, is guided to the main oil passage (1), and returns to the oil tank via the return
ports R1 and R3 by passing through the neutral bypass (2) (function of neutral M-shaped spool)
of each spool in straight travel (308), left travel (301), boom 1 (303), bucket (304) and arm 2
(306).
• The working oil from (rear) hydraulic pump enters the pump port P2, is guided to the main oil
passage (3), and returns to the oil tank via the return ports R1 and R3 by passing through the
neutral bypass (4) (function of neutral M-shaped spool) of each spool in right travel (301), swing
(305), boom 2 (307), backup (309) and arm 1 (302).

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 Structure and Functions SY500H Hydraulic Excavator

Fig.4-71

2) Travel

(Pilot circuit)

• When switched to left travel spool or right travel spool, the side oil passage closes and the pres-
sure in port Py (travel signal port) rises.
(Main circuit)

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 SY500H Hydraulic Excavator Structure and Functions

• When pressure is present in pilot port XBtL used for left travel spool (301), the neutral bypass
(2) at the side of boom 1 closes. The working oil fed from (front) hydraulic pump is delivered
through port BtL to the left travel motor.
• Likewise, when pressure is present in pilot port XBtr used for right travel spool (301), the neutral
bypass (2) at the side of arm 1 closes. The working oil fed from (rear) hydraulic pump is deliv-
ered through port Btr to the right travel motor.
• On the other hand, the oil returning from both the left and right travel motors via port AtL (Atr)
passes the left (right) travel spool and goes back to the oil tank via return ports R1 and R3.
• When operating travel in the opposite side (pressurizing the pilot ports XAtr and XAtL), the
above principle also applies.

Fig.4-72

3) Arm

Arm-out operation

(Pilot circuit)

• When switched to the arm 2 spool (302), the side oil passage closes and the pressure in port Px
(work equipment signal port) rises.
(Main circuit)

• When performing the arm-out operation, the pilot oil is fed to port XAa1 and port XAa2. When pi-
lot oil is delivered to the two sides of port XAa1 and port XAa2, arm 1 spool and arm 2 spool are
switched to the left, as shown in Fig. 4-52. As a result, the working oil from port P2 is introduced
into the neutral bypass (4) via the main passage (3). The neutral bypass is cut off by switching

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Structure and Functions SY500H Hydraulic Excavator

the arm 1 spool (302). Therefore, the working oil in the parallel passage pushes open the cone
valve (253) of the logic valve, and enters the arm 1 spool (302) via the U passage. The oil from
arm 1 spool (302) is then delivered to the rod end (R) of arm cylinder.
• On the other hand, the working oil coming from port P1 is guided to the neutral bypass (2) via
the main oil passage (1). The neutral bypass is cut off by switching the arm 2 spool (306). There-
fore, the working oil in the parallel passage pushes open the cone valve (514) of logic valve, and
working oil from neutral bypass pushes open the cone valve (511) of the check valve and flows
into the arm 2 spool (306) via the U passage. The oil then comes into confluence with oil from
port Aa in the passage of neutral bypass (306) and is fed to the rod end (R) of the arm cylinder.
• Return oil from the arm cylinder head end (H) via port BaI flows respective tank circuits of arm 1
and arm 2, and returns to working oil tank via tank ports R1 and R3.

Fig.4-73

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 SY500H Hydraulic Excavator Structure and Functions

Arm-in operation

(Pilot circuit)

• When switched to the arm 1 spool (302), the side oil passage closes and the pressure in port Px
(work equipment signal port) rises. Pressurized oil is fed to the port PaL at the same time. Relief
signal is sent to the lock valve selector GP (252).
(Main circuit)

• When performing the arm-in operation, pilot oil is fed to ports XBa1 and XBa2. When pilot oil is
delivered to the two sides of port XBa1 and port XBa2, arm 1 spool and arm 2 spool are switched
to the right as shown in Fig. 4-53. As a result, working oil from P2 is guided to the neutral bypass
(4) via the main passage (3). The neutral bypass is cut off by switching arm 1 spool (302). There-
fore, the working oil in the parallel passage pushes open the cone valve (253) of the check valve
and flows to the arm 1 spool (302) via the U passage. Then, it flows to the periphery of arm 1
spool (302) and is delivered to the arm cylinder head end (H) via port Ba.
• On the one hand, the working oil from port P1 is guided to the neutral bypass (2) via the main
passage (1). The neutral bypass is cut off by switching the arm 2 spool (306). Therefore, the
working oil in the parallel passage pushes open the cone valve (514) of the arm 2 check valve,
and the working oil from neutral bypass pushes open the cone valve (511) of the check valve
and flows to the arm 2 spool (306) via the U passage. Then, it comes into confluence with oil
from port BaI in the internal passage of arm 2 spool (306).
• On the other hand, the oil returning from the arm cylinder rod end (R) and the working oil whose
pressure rises due to the dead weight of arm goes back to the port Aa. The working oil returned
to the port Aa flows into the valve spool via the holes (a) on the periphery of arm 1 spool (302),
pushes open the cone valve (302-317) only under light load, and comes into confluence in the
peripheral holes with oil from port BaI.
• If the pressure at the arm cylinder head end and in the U passage rises, arm regeneration check
valve spool (257-103) switches to the left, as shown in Fig. 4-54, and closes due to the back
pressure of the cone valve (302-317) in the spool. In this way, the arm regeneration function is
deactivated and return oil from the arm cylinder rod end (R) flows to the spool via the hole (a) on
the periphery of arm 1 spool (302). Then, it flows into arm regeneration stop valve (257) via hole
(c) on the periphery of arm 1 spool (302), and returns to the working oil tank via tank ports R1
and R3.
● Light load

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Structure and Functions SY500H Hydraulic Excavator

Fig.4-74

● When pressure in arm cylinder head end (H) rises

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 SY500H Hydraulic Excavator Structure and Functions

Fig.4-75

4) Boom

Boom-up operation

(Pilot circuit)

• When switched to the boom 1 spool (307), the side passage is closed and the pressure in port
Px (work equipment signal port) rises.
(Main circuit)

• When boom-up operation is performed, the pilot oil is fed to port XAb1 and boom 1 spool (303)
moves to the left as shown in Fig. 4-55. The working oil from port P1 is introduced to the neutral
bypass (2) via the main passage (1). The neutral bypass is cut off by switching boom 1 spool

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Structure and Functions SY500H Hydraulic Excavator

(303). In this way, the working oil in the parallel passage pushes open the cone valve (511) of
the check valve, and flows to the boom 1 spool (303) via the U passage. It then flows to the pe-
riphery of boom 1 spool (303) and is delivered to the boom cylinder head end (H) via port Ab.
• At the same time, the pilot oil is also fed to port XAb2 and boom 2 spool (307) moves to the left
as shown in Fig. 4-55. The working oil from P2 flows the parallel passage. As the switching
boom 2 spool (307) cuts off the neutral bypass, the working in the parallel passage flows into
boom 2 spool (307) via the U passage. The oil then pushes open the cone valve (511) of the
check valve, comes into confluence with the oil from port Ab, and is fed to the boom cylinder
head end (H). (This is called the boom confluence function.)
• On the other hand, the oil flows to the periphery of boom 1 spool (303) via port Bb from oil return
side of the boom cylinder rod end (R) and goes back to the working oil tank via the ports R1 and
R3.

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Fig.4-76

Boom-down operation

(Pilot circuit)

• When switched to the boom 1 spool (303), the side passage is closed and the pressure in port
Px (work equipment signal port) rises. Pressurized oil is fed to the port PbL at the same time.
Relief signal is sent to the lock valve selector GP (252).
(Main circuit)

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 Structure and Functions SY500H Hydraulic Excavator

• When boom-down operation is performed, the pilot oil is fed to port XBb1 and boom 1 spool
(303) moves to the right as shown in Fig. 4-56. The working oil from port P1 is introduced to the
neutral bypass (2) via the main passage (1). The neutral bypass is cut off by switching boom 1
spool (303). In this way, the working oil in the parallel passage pushes open the cone valve
(511) of the check valve, and flows to the boom 1 spool (303) via the U passage. It then flows to
the periphery of boom 1 spool (303) and is delivered to the boom cylinder rod end (R) via port
Bb.
• On the other hand, the oil returning from the head end (H) of boom cylinder flows to the hole (a)
and periphery of boom 1 spool (303).
• The pressure of return oil rises due to the dead weight of boom. To maintain sufficient pressure,
with the help of the oil passage inside the spool, the cone valve (303-317) in spool is pushed to
the right, as shown in Fig. 4-56, and the oil flows out of the spool. As the working oil for boom-
down operation, the pressurized oil is again delivered to the boom cylinder rod end (R) (which is
called boom regeneration function). The return oil entering the internal passage of spool via the
hole (a) partially goes back to the oil tank via the hole (b).

Fig.4-77

5) Bucket

Bucket-dig operation

(Pilot circuit)

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• When switched to the bucket spool (304), the side passage is closed and the pressure in port Px
(work equipment signal port) rises. The pressure oil is fed to port XBp2 at the same time.
(Main circuit)

• When bucket-dig operation is performed, the pilot oil is fed to the port XBc and the bucket spool
(304) moves to the left as shown in Fig. 4-57. The working oil from port P1 is guided to the neu-
tral bypass (2) via main passage (1). As the neutral bypass is cut off by switching bucket spool
(304), the working oil in the parallel passage pushes open the cone valve (511) of the check
valve, and flows to the bucket spool (304) via the U passage. It then flows to the periphery of
bucket spool (304) and is fed to the bucket cylinder head end (H) via port Bc.
• On the other hand, return oil from the bucket cylinder rod end (R) flows in via port Ac. It then
goes back to the oil tank via the ports R1 and R3 from the periphery of spool.
• When boom-up and bucket-dig operations are performed at the same time, the pilot oil is led to
the port PAcs. Therefore, the travel of bucket spool is not restricted to the end, but can be held
in a position on the way. As a result, bucket cylinder passage is throttled and working oil flows to
boom 1 spool (303) via bucket spool (304). In this way, boom-up operation have the priority.

Fig.4-78

Bucket-dump operation

(Pilot circuit)

• When switched to the bucket spool (304), the side passage is closed and the pressure in port Px
(work equipment signal port) rises. The pilot oil is also fed to the port XBp2 at the same time.
(Main circuit)

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 Structure and Functions SY500H Hydraulic Excavator

• When bucket-dump operation is performed, the pilot oil is fed to the port XAc and bucket spool
(304) moves to the right as shown in Fig. 4-58. The working oil from port P1 is led to the neutral
bypass (2) via the main passage (1). The neutral bypass is cut off by switching bucket spool
(304). Therefore, the working oil in the parallel passage pushes open the cone valve (511) of the
check valve and flows to the bucket spool (304) via the U passage. It then flows to the periphery
of bucket spool (304) and is fed to the bucket cylinder rod end (R) via the port Ac.
• On the other hand, return oil from the bucket cylinder head end (H) enters via the port Bc,
passes the spool periphery of spool, and goes back to working oil tank via the ports R1 and R2.

Fig.4-79

Bucket confluence

• When bucket-dig or -dump operation is performed, the pilot oil is fed to the port XBp2 and the
neutral bypass stop valve spool (310) is switched. Working oil from port P2 is led to the neutral
bypass (4) via the main passage (3). The neutral bypass is cut off by switching neutral bypass
valve spool (310). Therefore, working oil pushes open the check valve (515) and comes into
confluence with bucket spool (304) via the internal passage and the U passage.
6) Swing

When swing operation performed separately

(Pilot circuit)

• When switched to the swing spool (305), the side passage is closed and the pressure in the port
Px (work equipment signal port) rises.
(Main circuit)

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• When swing is operated separately, the pilot oil is fed to the port XAs (or XBs) and swing spool
(305) is switched. Working oil from port P2 is led to the neutral bypass (4) via the main passage
(3). Neutral bypass is cut off by switching swing spool (305). Therefore, working oil in the parallel
passage pushes open the logic cone valve (254-101) of the swing logic component and flows to
the swing spool (305) via the U passage. It then flows to the periphery of swing spool (305) and
is delivered to the swing motor via port As (or Bs).
• On the other hand, return oil from the swing motor flows in via port Bs (or port As). Then, it flows
into tank ports R1 and R2 from the periphery of spool and goes back to the working oil tank.

Fig.4-80

7) Priority function

• This function enables the working oil from port P to be sufficiently allocated to the work equip-
ment under higher load in order to improve the operability when the arm-in operation is per-
formed along with swinging operation.
• The following shows the priority of swinging operation relative to the arm-in operation.
(Main circuit)

• When pressure oil is applied to the port Pna1 of the logic control valve (255), the piston (255-
356) and spool (253-107) move upward. The lifting distance of cone valve (253-101) is limited.

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 Structure and Functions SY500H Hydraulic Excavator

• In this way, the passage from the parallel passage to the U passage is throttle. As a result, oil
from the arm 1 spool has the priority to go to the swing spool, giving the priority to the boomup
operation.

Fig.4-81

8) Backup

The backup spool is used to control attachment such as hydraulic shear.

Backup operation

(Pilot circuit)

• When switched to the backup spool (309), the side passage is closed and the pressure in port
Px (work equipment signal port) rises.
(Main circuit)

• When the backup is operated, the pilot oil is fed to the port XAo (or XBo) and the backup spool
(309) is switched. Working oil from port P2 is fed to the neutral bypass (4) via the main passage
(3). Neutral bypass is cut off by switching backup spool (309). Therefore, working oil in the paral-
lel passage pushes open the cone valve (511) of the check valve and flows to the backup spool
(309) via the U passage. Then, it flows into the periphery of backup spool (309) and is supplied
into the attachment via port Ao (or Bo).
• On the other hand, return oil from the attachment flows in via port Bo (or port Ao). Then, it flows
into tank ports R1 and R2 from the spool periphery and returns to the working oil tank.

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Fig.4-82

Backup confluence

To achieve backup confluence, pilot oil is also fed to port XBp1 and the bypass stop valve spool
(310) is switched. Working oil from port P1 is introduced into neutral bypass (2) via main passage
(1). Neutral bypass is cut off by switching bypass valve spool (310). Therefore, working oil pushes
open the cone valve (515) of check valve and comes into confluence with backup spool (309) via
the internal passage and the U passage.

9) Straight travel

When travel spool (301) is operated along with other spools at the same time.

The following case shows when travel spool (301) and swing spool (305) are operated at the same
time.

(When pilot oil is delivered to the ports XAtL, XAtr and Xas)

(Pilot circuit)

• Close the side passage of right/left travel spool (301) and the downstream side passage of
swing spool (305). Pilot oil from port PG is fed to port PTa in order to switch the straight travel
spool (308).
(Main circuit)

• When straight travel spool (308) is switched, the port P2 and the right/left travel spool (301) are
interconnected through for priority. The port 1 and the parallel passage of swing - boom 2 - back-
up - arm 1 oil circuit / boom 1 - bucket/ - arm 2 circuit are interconnected through for priority.

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 Structure and Functions SY500H Hydraulic Excavator

Therefore, the working oil from port P2 is mainly delivered to the ports Atl and Atr and distributed
evenly to the two travel motors.
• On the other hand, the working oil from port P1 is delivered to the swing motor via port As.
• When oil pressure in the port P2 is lower than that in the port P1, the working oil form port P1 will
be partially delivered to the port P2. In this way, sudden drop of travel speed can be prevented.

Fig.4-83

10) Function of lockout valve

The lockout valve selector module (252) is mounted between the arm cylinder rod end (R) and the
arm 2 spool (302) and arm 2 spool (306). It is used to reduce the internal leakage of the spool due
to cylinder pressure.

Likewise, lockout valve selector module (252) is also mounted between the boom cylinder head
end (H) and the arm 1 spool (303) and boom 2 spool (307) to reduce the internal leakage of he
spool due to cylinder pressure.

The figure below shows the case of boom cylinder head end (H). (Similar case applies to the arm
cylinder rod end (R).)

Spool in neutral position

• When boom 1 spool (303) and boom 2 spool (307) are in a neutral position, the spool (252-511)
inside the lockout valve selector module is pressed against the seat of the body (252-101) of the
lockout valve selector module, as shown in Fig. 4-63, by the preload of spring (252-512).
• In this position, working oil in the boom cylinder head end (H) flows in via hole (a) and flows out
from hole (b) through the periphery of the lockout valve selector module spool (252-511), press-
ing the cone valve (513) against the seat of the valve block via hole (b). By this means, oil leak-
age is reduced.

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Fig.4-84

Boom-down operation

In boom-down operation the pilot oil is fed to the ports PbL, XBb1 and XBb2. Spool (252-511) in-
side the lockout valve selector module is pushed to the top by the pilot oil as shown in Fig. 4-64.
Due to the movement of spool (252-511) inside the lockout valve selector module, hole (a) is cut
off and working oil from boom cylinder head end (H) does not go to spring chamber (RH). In addi-
tion, oil in the spring chamber (RH) enters the oil leak circuit via the hole (b). In this way, the cone
valve (513) is pushed open by the pressure in boom cylinder head end (H) and the function of the
lockout valve selector module (252) is deactivated.

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 Structure and Functions SY500H Hydraulic Excavator

Fig.4-85

Boom-up operation

In boom-up operation the pilot oil is fed to the ports XAb1 and XAb2. The cone valve (513) is
pushed open by the oil from boom 1 spool (303) and boom 2 spool (307). The working oil goes to
the port Ab as a result.

11) Function of main relief valve

The main relief valve is mounted on the valve block A (101). It has the following functions:

• Working oil fulfils the cavity (a) through the hole in valve post housing (601-101) and valve post
(601-511). The valve post (601-511) is therefore pressed against the housing (601-101). Reli-
able sealing has formed as a result.
• When pressure in passage (P) exceeds the preload of spring (601-521), the cone valve (611)
opens. Therefore, the working oil passes through the gap between the housing (601-101) and
valve pocket (601-102) from the periphery of cone valve (601-401) and goes to the low pressure
passage (R).

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• Opening of cone valve (601-401) causes pressure drop in cavity (a). So the valve post (601-
511) is opened. In this way, working oil in passage (P) flows to the low pressure passage (R)
directly.
• When pressure oil higher than 3MPa is fed to the port Pz, it pushes plunger (601-302) to the left.
The preload of spring (601-512) increases as a result and pressure boosts at the moment.

Fig.4-86

12) Function of port relief valve

The port relief valve, mounted between the oil tank port and low pressure passage, can prevent
cavitation as an oil compensation check valve except working as a port relief valve. Functions of
the valve are given below:

Functioning as a relief valve

• Working oil fulfils into cavity (B) via the hole (A) on plunger (301). Valve post (511) is pressed
against valve seat (541), and valve seat (541) is pressed onto the seat of the valve block, form-
ing a reliable sealing.

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Structure and Functions SY500H Hydraulic Excavator

Fig.4-87

• When pressure in passage (P) exceeds the preload of spring (621), cone valve (611) is pushed
open. Therefore, working oil flows through hole (C) via the periphery of cone valve (611) and en-
ters the low pressure passage (R).

Fig.4-88

• Opening of cone valve (611) causes pressure in cavity (B) to drop and valve post (511) is
opened. In this way, working oil in passage (P) goes to the low pressure passage (R) directly.

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Fig.4-89

Functioning as oil complement check valve against cavitation

When negative pressure is formed in passage (P), working oil is fed from passage (R). When pres-
sure in passage (R) exceeds the pressure in passage (P), valve seat (541) moves to the right di-
rection. Therefore, working oil is delivered from passage (R) to passage (P) via the periphery of
valve seat (541). Cavitation is prevented as a result.

Fig.4-90

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Structure and Functions SY500H Hydraulic Excavator

4.6 Hydraulic System, Part 3

4.6.1 Swing motor

Fig.4-91

A: Main oil port PG: Brake release port

B: Main oil port SH: Brake command port
M: Oil compensation port L: Dipstick
PA: Pressure detection port IP: Gear oil feed port
PB: Pressure detection port 1. Safety valve
DB: Lubricant port 2. Anti-jerk valve

Specifications

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SY500H
Model M5×250CHB-10A-15A/275
Theoretical displacement 250.1 cm3/rev
Safety valve pressure setting 26.9MPa
rated speed of engine 1520rpm
Brake release pressure 3.0-4.9 MPa

Fig.4-92

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 Structure and Functions SY500H Hydraulic Excavator

(1) Spacer (6) Spring (11) Plate

(2) Housing (7) Check valve (12) Piston
(3) Disc (8) Oil distributor (13) Drive shaft
(4) Brake spring (9) Cylinder barrel
(5) Shell (10) Brake piston

4.6.2 Relief valve section

Structure

• The relief valve section consists of relief valves (1) and (2) and check valves (3) and (4).
Function

• When the machine is in the swing holding mode, control valve (5) closes the motor outlet circuit,
but the motor rotation is continued due to inertial force. The motor output is, therefore, abnor-
mally increased, which could damage the motor.
• In order to prevent the motor from being damaged, the relief valve relieves the abnormally high
pressure oil to port (M) from the outlet side (high-pressure side) of the motor.

Operation

1. When starting swing (suppose pressurized

oil is delivered to port A)

• When the swing control lever is set to the

right- swing, pressurized oil from the pump
is delivered to port (A) via control valve (5).
• The pressure at port (A) rises, the starting
torque is generated in the motor, and the
motor starts to rotate.
• The pressurized oil from the outlet port of
the motor passes from port (B) through the Fig.4-93
control valve (5) and returns to the tank.

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2. When swing is stopped

• When the swing control lever is set neutral,

the supply of pressurized oil from the pump
to port (A) is stopped.
• The pressurized oil from the motor outlet
can't return to the tank since the returning
circuit to the tank is closed from control
valve (5). Thus, the pressure on port (B)
increases.
• Swing resistance is generated on the motor
and hence the brake starts working. Fig.4-94
• Pressurized oil will be relieved when the
pressure on port (B) rises to the set pres-
sure of relief valve (2).
• A high braking torque acts on the motor,
thereby stopping the motor.
• When relief valve (2) is being actuated, the
relieved oil and the pressurized oil from port
(M) are fed to port (B) via check valve (4).
• The above prevents the formation of cavita-
tion on port (B).

4.6.3 Anti-jerk valve

Operation diagram

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 Structure and Functions SY500H Hydraulic Excavator

Fig.4-95

Effect illustration

Fig.4-96

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Outline

• The iner t ia of the swing body, the counter-

action and rigidity of the mechanical sys-
tem, or the compressibility of the hydraulic
oil can cause shaking of machine during
swing operation. The anti-jerk valve is able
to reduce such impact. It is effective in pre-
venting collapsing of load when the swing is
stopped and in reducing the cycle time (by
better positioning performance and quicker
movement for next operation). Fig.4-97

Operation

1. When braking pressure is generated at port

(B)

• Pressure (MB) is conducted to chamber (d)

via the notch. The pressure compresses
spring (6) by use of the difference in areas
of circles (D1 > D2) of spool (5) and moves
the spring (6) to the left side. Port (B) and
chamber (e) will be interconnected. Since
pressure (A) is lower than the set pressure
of spring (3), spool (2) does not move and Fig.4-98
the pressurized oil is stopped by spool (2).
Thus the braking force is ensured.

2. When motor is stopped

• The motor rotation is reversed by the clos-

ing pressure generated at port (B). (1st re-
versing) Reversing pressure is generated
on port (A) under the above condition. Pres-
sure (A) is conducted to chamber (a), and
spool (2) moves spring (3) to the right side,
and A and B is interconnected. At this time,
b is interconnected with f via the orifice on
spool (5), and reversing pressure on port A
is bypassed to port T in order to prevent
Fig.4-99
second reversing.

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Structure and Functions SY500H Hydraulic Excavator

4.6.4 Central swivel joint

Fig.4-100

(1) Swivel shaft (10) Dust ring

(2) Revolving body (11) Plug
(3) Cap (12) Washer
(4) Baffle (13) Washer
(5) Flexible baffle ring for shaft (14) Bolt
(6) O-ring (15) washer
(7) Rotary seal
(8) Abrasion Proof Ring
(9) O-ring

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4.6.5 Travel motor

4.6.5.1 General

Fig.4-101

Ps: Port for two-speed pilot tubing PB: Main oil port
PmA: Pressure detection port A. Installation surface for sprocket
PmB: Pressure detection port B. Installation surface for undercarriage
Dr: Oil drain port 1. Installation hole for sprocket
PA: Main oil port 2. Installation hole for undercarriage

Motor specifications

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Structure and Functions SY500H Hydraulic Excavator

SY500H
Equivalent displacement cm3/rev q×i
High q1 cm3/rev 290.7
Displacement
Low q2 cm3/rev 170.1
Speed reduction ratio i 60.652
2-speed Low to high Mpa Above 1.5
switching pilot
pressure High to low Mpa Under 0.4

Parking brake torque N•m 1171×i

Operating flow L/min 370
Operating pressure Mpa Under 34.3
Peak pressure Mpa Under 44.1
Acting times (between 34.3 Mpa and 44.1 Mpa） T times Under 1.2 million
High capacity rpm
Motor shaft
Low capacity rpm Under 5600
Swing speed
High capacity rpm
Reducer
Low capacity rpm Under 37.7
Output torque kN•m 71.023
Normal PS
"Under 210
Input power (Within 30
Maximum PS
consecutive
seconds)"
Normal Mpa Under 0.2

Drain pressure "Under 0.5

Momentary maximum Mpa (Under 0.30
MHz)"
Weight kg 647

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Fig.4-102

Double-balanced valve

Function:

• When external load makes the plunger motor tend to go faster than the rated rotating speed of
feed flow (hereunder referred to pump effect), this valve controls motor speed and prevents
over-speed of the motor in relation with the feed flow.
• The double-balanced valve and the relief valve constitute the braking circuit. The braking circuit
applies braking force onto the swing of plunger motor and stops the motor gradually.
• This valve can serve as a shuttle valve for high pressure selection to release the brake under its
own pressure.
• The structure of a standard double-balanced valve is shown below. The following information
describes the operating principle of a standard double-balanced valve.
A. When stopped

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Structure and Functions SY500H Hydraulic Excavator

• When the main valve is neutralized (motor stopped), port M1 and port M2 are shut off by spool
(1) and check valve (2) since no pressure is generated at port P1 and port P2. The motor is not
rotating.

Fig.4-103

B. When motor is started

• When the hydraulic oil from the main pump enters port P1 of the double-balanced valve, spring
(3) is pushed to the left by check valve (2-1), opening circuit C1. The hydraulic oil enters the
plunger motor via port M, trying to make the motor rotating. At the same time, return oil from the
plunger motor enters the counterbalance valve via port M2, but it is stopped by check valve (2-
2). The output pressure of the main pump increases as a result, and the hydraulic oil works on
the inside of spring chamber (1) and damper chamber (A1) via orifice (4-1) and check valve (5-
1). The force generated in this way pushes spring (7-2) on the other side and moves plunger (1)
to the right. At this time, return oil from port M2 passes through circuit of the notch on the periph-
ery of plunger (1), and through port P2 when pressure is generated at port M2, and enters the
tank via the main valve finally. The motor starts rotating at this time.

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Fig.4-104

C. Counterbalance function

• When the engine runs at an excessively high speed because of external force applied on it, the
motor may lose control. At this time, port P1 serves as the inlet side, and the pressure drops.
Pressure in spring chamber (1) and damper chamber A1 also drop. As a result, plunger (1)
moves to the left under the force of spring (7-2), closing circuit B. Circuit at the suction side is al-
so closed at the same time when the circuit at return side is closed. When circuit B is closed,
pressure at port P1 rises due to hydraulic oil from the main pump, moving plunger (1) to the right
again. In this way, when external load generates pump effect, slight movement of plunger (1)
keep circuit B open. The rotation speed of the motor keeps in line with fuel supply of the main
pump, and the motor will not lose control because of the vacuum in the hydraulic system.
D. Braking of motor

• The double-balanced valve and the relief valve forms the braking circuit. When the main valve is
in neutral position, hydraulic oil from the main pump is cut off, and pressure at port P1 and P2 is
the same. As a result, plunger (1) moves to the neutral position, and the opening area of circuit
B decreases. At the same time, because of the inertia of external force, the motor does not stop
rotating (pump effect), and pressure at port M2 rises and serves as the braking force of motor ro-
tation. When the pressure at port M2 reaches the set pressure of relief valve (8), cone valve (8-
1) at port M1 overcomes the force of spring (8-2) and moves to the left, and hydraulic oil flows to

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Structure and Functions SY500H Hydraulic Excavator

the port M1. In this way, the impacting force due to inertia at port M2 is under control, and vac-
uum at port M1 is avoided.

Fig.4-105

E. Shuttle valve function for high pressure selection

• The double-balanced valve can function as a shuttle valve to release travel brake. When hy-
draulic oil is fed to port P1, plunger (1) moves to the right, as shown in fig. 4. At this time, drain
passage F of motor housing is cut off, and passage D leading to cylinder chamber E for travel
braking is opened. Hydraulic oil flows to passage G via the orifice, and enters travel brake cylin-
der chamber E to release the travel brake. In addition, plunger (1) moves to neutral position, as
shown in fig 5 when motor stops. Passage D is closed and drain passage F of motor housing is
opened. Hydraulic oil in travel braking cylinder chamber E is conducted to the drain passage of
motor housing, and travel brake is applied.

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Fig.4-106

4.6.5.2 Operation of parking brake

1) When starting travel

• As the travel lever is operated, pressurized

oil from the pump activates back pressure
valve spool (10), opens the parking brake
circuit, and flows to chamber A of brake pis-
ton (12). Pressurized oil overcomes the
force of spring (11) and pushes piston (12)
toward the left.
• Since the pushing force to plate (13) and
disc (14) disappears, plate (13) is separated
from disc (14) and the brake is released. Fig.4-107

2) When travel is stopped

• As the travel lever is placed in neutral, back

pressure valve spool (10) returns to the
neutral position and closes the parking
brake circuit. The pressurized oil in cham-
ber (A) of brake piston (12) passes through
the orifice of the brake piston and is drained
to the motor casing. Brake piston (12) is
pushed to the right by spring (11). Plate (13)
and disc (14) are pushed against each oth-
er, and the brake is applied. As brake piston Fig.4-108
(12) returns, a time delay is formed by mak-
ing the pressurized oil pass through a

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throttle valve in the slow return valve (22).

This time delay ensures an active brake
after the machine is stopped.

4.6.5.3 Operation of braking valve

• The brake valve consists of a suction safety

valve (8A) and a counterbalance valve (18).
As shown in the illustration on the right,
functions and operations of respective com-
ponents are described below.

1) Counterbalance valve and check valve

Function

• When traveling downhill, the weight of the

machine tends to make the travel speed
faster than the motor speed. If the machine
Fig.4-109
travels with the engine at low speed, the
motor may rotate at zero load, resulting in
run away and inviting a very dangerous sit-
uation. These valves are used to avoid such
a situation by controlling the machine to
travel according to the engine speed (pump
flow).

Operation when pressurized oil is supplied

• Operating the travel control lever conducts

the pressurized oil from the control valve to
port (PA). The pressurized oil opens suction
safety valve (8A) and then flows to motor
outlet port (MB) via motor inlet port (MA).
The motor outlet side is closed by suction
safety valve (8B) and spool (19), so the
pressure at the supply side rises, as shown
in the right illustration.

Fig.4-110

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 SY500H Hydraulic Excavator Structure and Functions

• The pressurized oil on the supply side flows

to chamber (S1) via orifice (E1) and orifice
(E2) of the spool (19). As the pressure in
chamber (S1) goes above the spool shift
pressure, spool (19) is pushed toward the
right. Port (MB) and port (PB) are con-
nected, the motor outlet port side opens
and the motor starts rotating, as shown in
the right illustration.

Fig.4-111

Operation of brake when travelling

downhill

• If the machine goes out of control while

travelling downhill, the motor will be caused
to rotate without load to decrease the inlet
side oil pressure. Pressure in chamber (S1)
drops via orifices (E1) and (E2). As the
pressure in chamber (S1) goes below the
spool selector pressure, spool (19) is re-
turned to the left by spring (20) and outlet
port (MB) is throttled. The pressure at the
Fig.4-112
outlet port side rises, generating rotation re-
sistance on the motor to prevent the ma-
chine from losing control. On the other
hand, the spool moves to a position where
the pressure on outlet port (MB) can be bal-
anced against the machine's own weight
and the inlet port pressure. Oil flow from the
outlet circuit is reduced to ensure the travel
speed corresponded to the pump delivery,
as shown in the right illustration.
2) Safety valve

Function

• When the machine travel is stopped (or it is travelling downhill), the double-balanced valve
closes the inlet and outlet circuits of the motor. Since the motor is rotated by inertial force, pres-
sure in the motor outlet port side is abnormally increased, potentially resulting in damages on

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Structure and Functions SY500H Hydraulic Excavator

the motor and piping. The safety valve relieves this abnormal pressure to the inlet port side of
the motor in order to prevent damages to the equipment.

Operation

a) When travel is stopped (or when travel-

ling downhill) (Right swing)

• Reduction of the pressure at motor inlet

(PA) decreases the pressure in chamber
(S1). When it drops beyond the spool shift
pressure, the spool is returned to the left by
spring (20), throttling the oil outlet passage
(B1). At this time, the motor continues rotat-
ing due to its inertial force, thus pressure on
the outlet port (MB) is increased, as shown Fig.4-113
in the right illustration.

• When the pressure rises above the set

pressure of the suction safety valve (8A),
the poppet opens. The pressurized oil
passes through notch (A1) of spool (19) into
chamber (MA) of the circuit at the opposite
side, as shown in the right illustration.

Fig.4-114

b) When starting travel (or traveling

normally)

• As the travel control lever is operated, the

pressurized oil from the pump moves the
counterbalance valve spool (19) toward
right. In this case, the passage to the suc-
tion safety valve functions as a circuit which
passes through notch (B2) of spool (19),
producing large differential pressure. The
pump pressure rises, providing a large trac-
tional force to the valve, as shown in the
Fig.4-115
right illustration.

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3) Overload relief valve

• The structure of the relief valve is shown in

the right figure. This valve is an areadiffer-
ential and direct-acting relief valve. It has
impact damping function during starting and
braking.

Fig.4-116

A. Operating principle and function

• When the main valve makes the motor to

start or brake, front pressure of cone valve
(2-9-2) rises above the set pressure and the
force of spring (2-9-5), and moves cone
valve (2-9-2) to the right and off the valve
seat. Pressurized oil in the front of cone
valve (2-9-2) is bypassed to the low pres-
sure side. The impact due to inertia energy
at the high pressure side is put under con-
trol and vacuum is prevented from occurring Fig.4-117
at the low pressure side through bypassing
pressurized oil to the low pressure side.

B. Damping function

• When the relief valve begins to function,

damping piston (2-9-9) moves to the left. As
a result, low pressure is maintained in
spring chamber D. At this time, the loaded
area of cone valve (2-9-2) is S1, and gener-
ally it is much larger than the set loaded
area S1-S2 of the relief valve. So, when
damping piston (2-9-9) is moving, the func-
tional pressure of relief valve is maintained
at 1/3 of normal set pressure in order to ab- Fig.4-118
sorb the impact at the high pressure circuit
side due to inertial energy. When the

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Structure and Functions SY500H Hydraulic Excavator

movement of damping piston stops, pres-

sure in spring chamber D rises. Pressure at
both side of cone valve (2-9-2) is the same,
and the relief valve is working at normal set
pressure. In this way, the relief valve re-
duces the impact during motor starting and
braking by a two-stage action to provide ex-
cellent performance.

Fig.4-119

• Repair standard of motor components

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SY500H Hydraulic Excavator Structure and Functions

Components Check item Allowable limit Remedy

Grind the boot sliding
surface. Replace the
Roughness 0.8a or
cylinder block
1. Boot sliding surface surface roughness,
assembly if the
scratch 0.02mm+
bruises cannot be
corrected.
1-4-2 Plunger Roughness 1.2a or
2. Plunger outer
assembly surface roughness,
diameter
scratch 0.02mm+
3. Plunger outer Replace the cylinder
diameter and 4-1 block assembly.
Clearance 0.060.
cylinder block inner
diameter
4. Boot end clearance Clearance 0.4.
Grind the boot sliding
surface. Replace the
Roughness 0.8a or
1. Valve leaf and cylinder block
surface roughness,
sliding surface assembly if the
scratch 0.02mm+.
bruises cannot be
corrected.
Roughness 1.6a or
2. Shaft hole inner
surface roughness,
diameter
scratch 0.02mm+.
1-4-1 Cylinder block
3. Shaft hole inner
diameter and 4-2
Clearance 0.060.
plunger assembly Replace the cylinder
outer diameter block assembly
Roller distance below
38.749 (measuring
4. Spline at shaft joint pin diameter
φ3.333(V1=2.80)); or
damaged
Grind the sliding
Roughness 0.8a,
surface. Replace the
1-21 Oil distribution scratch 0.02mm+ on
1. Sliding surface valve sheet if the
plate sliding surface or
bruises cannot be
burned sign
corrected.
Roughness 0.8a,
1-4-3 Retainer
scratch 0.02mm+ on Replace the retaining
1-4-4 Retaining 1. Sliding surface
sliding surface or sign plate or the retainer
assembly
of burning

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Structure and Functions SY500H Hydraulic Excavator

Grind the sliding

Roughness 0.8a,
surface. Replace the
abrasion on sling
1. Sliding surface valve sheet if the
surface or scratch
bruises cannot be
0.02mm+
corrected.
1-5 Swash plate Roughness 1.6a.
2. Hole for assembling Scratch on spherical
steel ball surface 0.02mm+ or Replace the swash
surface roughness plate.
3. Hole for assembling
Ball depth 14.5
steel ball
Roughness 1.6a oil
1. Sliding port of oil seal lip sliding sign.
Replace swash plate
seal outer diameter Scratch 0.02mm + or
surface roughness
Roller distance below
2. Spline of cylinder 47.380(measuring pin
1-3 Shaft
block diameter φ3.00); or
damaged
Replace shaft
Roller distance below
3. Drive gear 30.498 (measuring
connection pin diameter φ3.33);
or damage
1. Dimension Height 38.2
2. Sliding surface Roughness 2.5a
1-15 Brake piston Replace brake piston
Scratch 0.02mm+ or
3. Appearance
surface roughness
1. Dimension Thickness 3.2
Deep scratch on
1-13 Disc plate sliding surface Replace disc plate
2. Appearance
orfriction material
peeling
1. Rolling surface Peeling or fracture
1-8 Ball bearing Abnormal rotation Replace ball bearing
1-9 Ball bearing 2. Action (noise•uneven
rotation)
Roughness 1.6a, Grind sliding surface;
1. Sliding shoe sliding
1-7 Plunger assembly surface roughness, replace flange plate
surface
scratch 0.02mm+ parts if unrepairable

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SY500H Hydraulic Excavator Structure and Functions

Roughness 1.2a,
2. Piston outer
surface roughness,
diameter
scratch 0.02mm+
3. Piston outer
Replace flange plate
diameter and 1-1
Gap 0.040. parts
flange plate part inner
diameter
4. Ball end clearance
Clearance 1.0
of sliding shoe
Roughness 0.8 a,
1. Piston outer
scratch 0.02mm+ or
diameter
1-2-2 Plunger surface roughness.
Replace valve sheet
assembly 2. Piston outer
diameter and valve Clearance 0.060.
sheet inner diameter
1. Assembly2-2 Roughness 0.8 a,
plunger assembly scratch 0.02mm+ or
hole surface roughness
2. Valve sheet inner
diameter and piston Clearance 0.060
outer diameter
3. Assembly2-11 Roughness 0.8 a,
sliding valve spool scratch 0.02mm+ or Replace valve sheet
1-2-1 Valve sheet
assembly hole surface roughness and parts
4. Sliding valve sheet
inner diameter and
Clearance 0.060
valve spool outer
diameter
5. Relief valve
Scratch 0.02mm+ or
assembly sliding
surface roughness
piston and valve seat
Roughness 0.8 a,
1. Valve spool out
scratch 0.02mm+ or
diameter
surface roughness Replace valve sheet
1-2-9 Spool assembly 2. Slide valve spool 2. Slide valve spool
outer and parts outer and parts
Clearance 0.060.
diameter and valve
sheet inner diameter
1. Sliding portion of
1-2-7-9 Movable Scratch 0.02mm+ or Replace relief valve
valve sheet and valve
piston surface roughness assembly
seat

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Structure and Functions SY500H Hydraulic Excavator

1. Sling portion of the

Scratch 0.02mm+ or
1-2-7-1 Case movable piston (outer
surface roughness
diameter)
1. Dimension Free length 61.0
1-4-7 Spring Deformation and
2. Appearance
surface damage
1. Dimension Free length 39.0
1-18 Spring Deformation and
2. Appearance
surface damage
1. Dimension Free length 41.5
1-20 Spring Deformation and
2. Appearance
surface damage
1. Dimension Free length 48.5
1-2-4 Spring Deformation and
2. Appearance
surface damage
1. Dimension Free length 28.3
1-2-10 Spring Deformation and
2. Appearance
surface damage
Replace o-ring and oil
O-ring and oil seal When removed
seal

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SY500H Hydraulic Excavator Structure and Functions

4.6.6 Control system

Fig.4-120

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Structure and Functions SY500H Hydraulic Excavator

Joystick operation
(1) Travel PPC valve (8) Hydraulic pump (1) HOLD (8) Arm OUT
(2) Travel control lever
(9) Main control valve (2) Boom UP (9) Right swing
(L)
notice：Other
(3) Travel control lever
components no longer (3) Boom DOWN (10) Left swing
(R)
mark
(4) Joystick control
(4) Bucket DUMP (11) Neutral
(R)
(5) Joystick control (L) (5) Bucket DIG (12) Travel BWD
(6) Transitional block (6) HOLD (13) Travel FWD
(7) Accumulator (7) Arm IN

4.6.7 Pilot valve

Manual pilot valve

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 SY500H Hydraulic Excavator Structure and Functions

Fig.4-121

P: From pilot pump relief valve

P1: L.H. Pilot valve: Arm OUT/R.H. Pilot valve: Boom DOWN

P2: L.H. Pilot valve: Arm IN/R.H. Pilot valve: Boom UP

P3: L.H. Pilot valve: Swing LEFT/R.H Pilot valve: Bucket DIG

P4: L.H. Pilot valve: Swing RIGHT/R.H. Pilot valve: Bucket DUMP

T: To tank

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Structure and Functions SY500H Hydraulic Excavator

Fig.4-122

(1) Plunger (6) Nut (for lever connection)

(2) Adjusting spring (7) Connector
(3) Center spring (8) Plate
(4) Piston (9) Retainer
(5) Disc (10) Valve body

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 SY500H Hydraulic Excavator Structure and Functions

Operation

1. When in neutral

• Ports (A) and (B) of the control valve and

ports (P1) and (P2) of the pilot valve are
connected to drain chamber (D) via orifice
(f) in plunger (1).

Fig.4-123

2. During fine control (Neutral to fine control)

• When piston (4) is pushed by disc (5), re-

tainer (9) is pushed, plunger (1) is also
pushed by adjusting spring (2), and moves
down.
• When orifice (f) is shut off from drain cham-
ber (D), it is almost simultaneously intercon-
nected to pump pressure chamber (PP).
Pilot pressurized oil of the control pump is
led to port (A) from port (P1) via orifice (f).
When the pressure at port (P1) becomes
higher, plunger (1) is pushed back and ori-
fice (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release
the pressure at port (P1). As a result,
plunger (1) moves up and down until the
force of adjusting spring (2) is balanced with Fig.4-124
the pressure at port (P1).
• The relationship of the position of plunger
(1) and body (10) [orifice (f) is in the middle

Shop Manual-June 2016 4-119

 Structure and Functions SY500H Hydraulic Excavator

between drain chamber (D) and pump pres-

sure chamber (PP)] does not change until
retainer (9) contacts plunger (1). Adjusting
spring (2) contracts in proportion to the
stroke of the control lever. Pressure at port
(P1) also rises in proportion to the stroke of
the control lever. In this way, the control
valve plunger moves to a position where
the pressure of chamber (A) (same as pres-
sure at port (P1)) and the force of the return
spring of the control valve plunger are
balanced.

3. Fine control (When control lever returns)

• When disc (5) starts to return, plunger (1) is

pushed up by the force of center spring (3)
and the pressure at port (P1).
• Because of this, orifice (f) is connected to
drain chamber (D), and the pressurized oil
at port (P1) is released.
• If the pressure of port (P1) is lowered ex-
cessively, plunger (1) is pushed down by
adjusting spring (2).
• Orifice (f) is shut off from drain chamber
(D), and it is almost simultaneously inter-
connected to pump pressure chamber (PP).
Pump pressure is supplied until the pres-
sure at port (P1) recovers to the level equiv-
alent to the lever position.
• When the plunger of the control valve re-
turns, the oil in drain chamber (D) flows in Fig.4-125
from orifice (f) in the valve on the side that
is not working. The oil passes through port
(P2) and enters chamber (B) to replenish
the chamber with pressurized oil.

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 SY500H Hydraulic Excavator Structure and Functions

4. At full stroke

• Disc (5) pushes down piston (4), and re-

tainer (9) pushes down plunger (1).
• Orifice (f) is shut off from drain chamber
(D), and is interconnected to pump pressure
chamber (PP).
• Therefore, the pilot pressure oil from the
self pressure reducing valve passes
through orifice (f) and flows to chamber (A)
from port (P1) to push the control valve
plunger.
• The oil returning from chamber (B) passes
from port (P2) through orifice (f) and flows
to drain chamber (D).

Fig.4-126

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Structure and Functions SY500H Hydraulic Excavator

4.6.8 Travel pilot valve

Fig.4-127

P: From pilot pump P4: R.H. forward

P1: L.H. backward P5: Travel signal
P2: L.H. forward P6: Travel signal
P3: R.H. backward T: To tank

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 SY500H Hydraulic Excavator Structure and Functions

Fig.4-128

(1) Plate

(2) Body

(3) Piston

(4) Collar

(5) Center spring

(6) Adjusting spring

(7) Valve

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 Structure and Functions SY500H Hydraulic Excavator

Operation

1. When in neutral

• Ports (A) and (B) of the control valve and

ports (P1) and (P2) of the pilot valve are
connected to drain chamber (D) via orifice
(f) in spool (1).

Fig.4-129

2. Fine control (Neutral to fine control)

• When piston (4) is pushed by lever (5), re-

tainer (9) is pushed, and plunger (1) is also
pushed by adjusting spring (2), and moves
downward.
• When orifice (f) is shut off from drain cham-
ber (D), it is almost simultaneously intercon-
nected to pump pressure chamber (PP).
• Pilot pressurized oil of the control pump is
led to port (A) from port (P1) via orifice (f).
• When the pressure at port (P1) becomes
higher, plunger (1) is pushed back and ori-
fice (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
Fig.4-130
connected to drain chamber (D) to release
the pressure at port (P1).
• As a result, plunger (1) moves up and down
until the force of adjusting plunger (2) is bal-
anced with the pressure at port (P1).
• The relationship of the position of plunger
(1) and body (10) [orifice (f) is in the middle
between drain chamber (D) and pump pres-
sure chamber (PP)] does not change until
retainer (9) contacts plunger (1).
• Adjusting spring (2) contracts in proportion
to the stroke of the control lever.

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 SY500H Hydraulic Excavator Structure and Functions

• Pressure at port (P1) also rises in propor-

tion to the stroke of the control lever.
• In this way, the control valve spool moves to
a position where the pressure of chamber
(A) (same as pressure at port (P1)) and the
force of the return spring of the control valve
spool are balanced.

3. Fine control (When control lever returns)

• When lever (5) starts to return, plunger (1)

is pushed up by the force of center spring
(3) and pressure at port (P1).
• Because of this, orifice (f) is connected to
drain chamber (D), and the pressurized oil
at port (P1) is released.
• If the pressure of port (P1) is lowered ex-
cessively, plunger (1) is pushed down by
adjusting spring (2).
• Orifice (f) is shut off from drain chamber
(D), and it is almost simultaneously inter-
connected to pump pressure chamber (PP).
• Pump pressure is supplied until the pres-
Fig.4-131
sure at port (P1) recovers to the level equiv-
alent to the lever position.
• When the spool of the control valve returns,
the oil in drain chamber (D) flows in from or-
ifice (f) in the valve on the side that is not
working. The oil passes through port (P2)
and enters chamber (B) to replenish the
chamber with pressurized oil.

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 Structure and Functions SY500H Hydraulic Excavator

4. At full stroke

• Lever (5) pushes down piston (4), and re-

tainer (9) pushes down plunger (1).
• Orifice (f) is shut off from drain chamber
(D), and is interconnected to pump pressure
chamber (PP).
• Therefore, the pilot pressure oil from the
self pressure reducing valve passes
through orifice (f) and flows to chamber (A)
from port (P1) to push the control valve
spool.
• The oil returning from chamber (B) passes
from port (P2) through orifice (f) and flows
to drain chamber (D). Fig.4-132

4.6.9 Solenoid valves

Pilot valve lockout, bucket confluence and travel speed.

Fig.4-133

1.Pilot lockout solenoid valve

2. Travel speed shift solenoid valve

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 SY500H Hydraulic Excavator Structure and Functions

3. Boom Priority to swing solenoid valve

4. Spare

5. Boom 2 confluence solenoid valve

6. Boom Priority to bucket solenoid valve

4.6.10 Pilot accumulator

1. Gas plug

2. Shell

3. Poppet

4. Holder

5. Bladder

6. Oil port

Specifications

Gas capacity: 500 cc (for PPC)

Fig.4-134

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 Structure and Functions SY500H Hydraulic Excavator

4.6.11 Pilot oil filter

Fig.4-135

(1) Nameplate Specifications

(2) Head cover Max. delivery: 40 L/min
(3) O-ring Filter fineness: 10 um
(4) Seal ring Operating pressure: 20 Mpa
(5) Filter Max. operating pressure: 40 Mpa
(6) Casing Pressure loss: 0.05 Mpa
Max. allowable pressure difference: 1 Mpa
Specification of inlet/outlet port O-ring: 30×3.1

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SY500H Hydraulic Excavator Structure and Functions

4.7 Work Equipment

4.7.1 Component dimensions

Fig.4-136

SY500H

Unit：mm
Check Tolerance Std. Clearance
No. Std. size Remedy
item Pin Hole clearance limit
Clear –0.036 +0.259 0.26～
1 120 1.0 Replace
ance –0.071 +0.224 0.33

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Structure and Functions SY500H Hydraulic Excavator

between
the pin
and
bushing
connect
ing the
boom and
swing
platform
Clear
ance
between
the pin
and –0.036 +0.259 0.26 ～
2 120 1.0
bushing –0.071 +0.224 0.33
connect
ing the
boom and
arm
Clear
ance
between
the pin
and –0.036 +0.51 0.496 ～
3 100 1.0
bushing –0.071 +0.46 0.581
connect
ing the
arm and
linkage
Clear
ance
between
the pin
and –0.036 +0.51 0.496 ～
4 110 1.0
bushing –0.071 +0.46 0.581
connect
ing the
arm and
bucket
Clear
ance
between –0.036 +0.51 0.496 ～
5 110 1.0
the pin –0.071 +0.46 0.581
and
bushing

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SY500H Hydraulic Excavator Structure and Functions

connect
ing the
linkage
and
bucket
Clear
ance
between
the pin
–0.036 +0.51 0.496 ～
6 and 110 1.0
–0.071 +0.46 0.581
bushing
connect
ing the
linkage
Bucket
7 clearance 0.5-1.0
(a) Adjust the
Bucket shims
8 clearance 1-5
(b)

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Structure and Functions SY500H Hydraulic Excavator

4.7.2 Arm dimensions

Fig.4-137

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SY500H Hydraulic Excavator Structure and Functions

Unit：mm
SY500H
No.
Std. size Tolerance
+0.087
1 φ110
0
+1
2 142
+0.5
0
3 420
–0.5
+0.063
4 φ136
0
5 925 —
6 471 —
7 963 —
8 3000 —
9 3028 —
10 515 —
11 751 —
12 683 —
13 570 —
14 1821 —
+0.2
15 φ110
0
+0.5
16 442
+0.2
+0.2
17 φ110
0
Arm body 410 —
18 When bushing is
454 —
installed
Min. 1990 —
19
Max. 3295 —

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Structure and Functions SY500H Hydraulic Excavator

4.7.3 Bucket dimensions

Fig.4-138

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SY500H Hydraulic Excavator Structure and Functions

Unit：mm
SY500H
No.
Std. size Tolerance
1 570 ±0.5
2 107° —
3 1821 —
+0.2
4 φ110
+0.1
+0.2
5 φ110
+0.1
+2
6 478
+1
+0.5
7 442
+0.2
8 520 —
9 40 —
10 89 —
11 73 —
+0.5
12 227
+0.2
+0.2
13 φ170
0
14 148 —
15 186 —
16 148 —
17 125 —
18 600 —

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Structure and Functions SY500H Hydraulic Excavator

4.8 Air Conditioning System

4.8.1 Air Conditioning System

Fig.4-139

(1) Hot water piping (7) Refrigerating unit (SG443200-7194)

(2) A/C compressor (DENSO.2) (8) Air duct
(3) Refrigerant piping A. Fresh air
(4) Condenser (SG447750-A040) B. Recirculated air
(5) Reservoir (DENSO.4) C. Warm air/cool air
(6) Hot water return piping

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 SY500H Hydraulic Excavator Structure and Functions

4.8.2 Layout of A/C components

Fig.4-140

(1) Sunlight sensor

(2) Control panel

(3) Air conditioning unit

(4) Condenser

(5) Compressor

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 Structure and Functions SY500H Hydraulic Excavator

4.8.3 A/C control panel

Fig.4-141

(1) OFF switch (5) Auto mode switch

(2) Fan speed control switch (6) Fresh air/recirculation control
(3) Temperature control switch (7) LCD display
(4) Air outlet mode switch (8) A/C power

Remark:

When auto mode switch (5), fresh air/recirculation control (6) and A/C power (8) are turned on, in-
dicator lights above these switches will light up.

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SY500H Hydraulic Excavator Structure and Functions

4.8.4 Diagram of electrical circuit

Fig.4-142

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Structure and Functions SY500H Hydraulic Excavator

4.8.5 Refrigeration principle

Refrigeration cycle diagram

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SY500H Hydraulic Excavator Structure and Functions

Fig.4-143

Heating cycle diagram

Fig.4-144

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 Structure and Functions SY500H Hydraulic Excavator

4.8.6 Compressor

Fig.4-145

(1) Stator (9) Slipper

(2) Front radial bearing (10) Front cylinder block
(3) Thrust bearing (11) Piston
(4) Front radial bearing (12) Front cylinder head
(5) Rear cylinder head (13) Shaft seal
(6) Safety valve (14) Main shaft
(7) Rear cylinder block (15) Boss
(8) Swash plate (16) Rotor

Operating principle

Compressor type: 10S15C. This compressor has 5 plungers in total with a piston at both sides of
each plunger. The rotation of the swash plate drives the pistons to move back and forth and trans-
forms the refrigerant sucked from the evaporator from low temperature and low pressure gas state
to high temperature and high pressure state.

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Fig.4-146

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 Structure and Functions SY500H Hydraulic Excavator

4.8.7 Clutch

(1) Rotor

(2) Stator coil

(3) Clasp

(4) Ball bearing

(5) Stator

(6) Center piece

• The electromagnetic clutch is used to trans-

mit moment of torsion. When the engine is
operating, the compressor may not be Fig.4-147
working. The clutch controls the operation
of the compressor only when the air condi-
tioner is under refrigerating mode.
• Operating principle
When the A/C power is turned on, the clutch
coil with an electromagnet generates a
magnetic field and attracts the metal piece.
The stator and rotor of the clutch are en-
gaged and bring the main shaft of the com-
pressor into rotation.

4.8.8 Condenser

Fig.4-148

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(1) Condenser core Function

(2) Bracket • The condenser changes high-temperature,
high-pressure gas refrigerant (16Kg/cm², ap-
(3) Bolt with washer
prox. 80 ℃ ) to high-temperature and high-
(4) Refrigerant inlet
pressure liquid refrigerant (16Kg/cm², below
(5) Refrigerant outlet approx. 60℃ ) through radiating.

4.8.9 Expansion valve

(1) Spring

(2) Diaphragm

(3) Probe

(4) Needle valve

Operating principle

• Refrigerant from the reservoir spurts out via

the orifice, turns into low-temperature, low-
pressure liquid (mist) after expanding, and
enters the evaporator.

Fig.4-149

4.8.10 Evaporator

(1) Expansion valve

(2) Evaporator

Operating principle

• The evaporator is a kind of heat exchanger

that looks like a condenser. Warm air in the
cab is conducted into the evaporator via the
blower motor and undergoes heat ex-
change with the surface of the evaporator.
Heat is absorbed and warm air turns into
cool air, which flows into the cab through
the air ducts. Evaporator surface absorbs
Fig.4-150
heat → Refrigerant in the evaporator ab-
sorbs heat → Refrigerant evaporates .

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 Structure and Functions SY500H Hydraulic Excavator

Evaporated refrigerant (gas) is absorbed by

the compressor.

4.8.11 Dehydrator

(1) Inlet

(2) Outlet

(3) Receiver/dehydrator

(4) Desiccant

Function

• Temporary storage of refrigerant

• Dehydration of refrigerant
• Removing dust from refrigerant
• Measuring the volume of refrigerant

Fig.4-151

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4.8.12 Pressure switch

(1) O-ring

(2) Mobile contact point

(3) Hood

(4) Plug and fixed contact

(5) Spring

(6) Chamber

(7) Diaphragm

Function

• The pressure switch is installed between

the reservoir and the expansion valve (hi-
pressure pipe). It is a combination switch
Fig.4-152
(Hi-Lo pressure combination switch).
• When pressure is excessively high, the
compressor stops.
• When pressure is excessively low, the low-
temperature condition disappears.
Operating features

Features

High pressure
Low pressure

Medium pressure

4.8.13 Refrigerant

4.8.13.1 General

General property of refrigerant

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Structure and Functions SY500H Hydraulic Excavator

• High heat absorption and easy liquefaction

• Non-flammable, nonexplosive
• Stable chemical composition
• Non-toxic
• Non-corrosive
•No hazard to clothing
Refrigerant cycle

• After evaporation in the evaporator, refrigerant turns from gas into liquid via the compressor and
the condenser, which finishes a refrigerant cycle.

• Refrigerant cycle principle (pressure - enthalpy diagram)

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Fig.4-153

Feeding of refrigerant

• Filling method and volume:

(1) Refrigerant: HFC-134a;
(2) Feeding volume: 900 ±50 g (for
reference);
(3) Feeding method: Feeding of liquid refrig-
erant from the low-pressure end is not al-
lowed. If feeding operation fails, discharge
the refrigerant that has been fed before re-
feeding.

Fig.4-154

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 Structure and Functions SY500H Hydraulic Excavator

• Inspect the state of the refrigerant in the A/

C circulation system through the sight
glass:

(1) Correct feeding: Foam is hardly observed

when the refrigerant is flowing. When engine
speed increases from idling to 1500 rpm,
foam disappears and the refrigerant turns
clear.

(2) Over-feeding: No foam can be observed

when refrigerant is flowing.

(3) Under-feeding: Foam is always observed

when refrigerant is flowing. Fig.4-155

4.8.13.2 Evacuation

• Reason of evacuation
No moisture shall be mixed inside the air conditioning unit. Refrigerant (R134a) is soluble in water.
Very small amount of moisture in the unit can cause the orifice of the expansion valve to ice up, or
cause the valve of the compressor to rust. To avoid such problems, moisture in the system shall be
removed before refrigerant is fed. To reduce the residual moisture in the system to the minimum,
moisture in the system can evaporate through evacuating. No better means is available so far.

• Evacuating steps
1. Connection of manifold pressure gauge:
A. Close the high-pressure valve (HI) and
low-pressure valve (LO) of the manifold
pressure gauge.
B. Connect the air hose (red, blue) to the
auxiliary valve of the compressor.
Red hose——High pressure side (Mark D)
Blue hose——Low pressure side (Mark S)
● Connect the end of the air hose with a L
to the auxiliary valve of the compressor. If
connected inversely, the valve will not open.
Besides, do not inversely connect the high-
pressure end and the low-pressure end. Fig.4-156
C. Connect the middle hose (green) to the
vacuum pump.
2. Evacuating

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A. Open the high-pressure valve (HI) and

low-pressure valve (LO) on the manifold
pressure gauge.
B. Turn on the vacuum pump and evacuate
for about 15 minutes.
C. When negative pressure reading on the
gauge (degree of vacuum) reaches above
750 mmHg, turn off the vacuum pump and
close the Hi-pressure valve and the Lo-
pressure valve on the gauge.

3. Air - proof check

A. Keep the Hi- and Lo-pressure valve of the

manifold pressure gauge under closed state
for more than 5 minutes, and make sure the
pointer on the gauge does not return to zero.

B. If the pointer returns to near zero, a leak-

age is available somewhere. Check and ad-
just the pipe joint. Tighten the joint and
conduct another evacuating operation until no Fig.4-157
leakage is detected.

4. Leak check

A. Connect the air hose (green) that is previ-

ously connected to the vacuum pump to the
fluorine cylinder.

B. Connect the other end of the hose (green)

to the pressure gauge. Open the valve of the
cylinder and press the vent valve of the pres-
sure gauge. (Do not press the valve with
naked hand to avoid frostbite caused by re-
frigerant). Release the air in the hose with the
pressure of the refrigerant. (Release the vent
valve when you hear a squeezing sound).
Fig.4-158

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 Structure and Functions SY500H Hydraulic Excavator

C. Add refrigerant until pressure reading on

the Lo-pressure gauge is 1kgf/cm2. Hi-pres-
sure valve of the gauge is open at this time.
Close the Hi-pressure valve when feeding is
finished.

D. Use a leak detector to check if leakage is

present in the cooling system.

E. Make necessary repairs (tightening) if leak-

age is observed.

Fig.4-159

4.8.13.3 Refrigerant filling operation

• When evacuation is finished, fill refrigerant into the cooling system as per the following
instruction:

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 SY500H Hydraulic Excavator Structure and Functions

• Fill from the hi-pressure side

1. Remove the air hose (green) of the mani-

fold pressure gauge from the vacuum pump
and connect it to the fluorine cylinder.

2. Open the valve of the cylinder and press

the vent valve on the pressure gauge. Use the
pressure of the refrigerant to release the air in
the hose.

CAUTION
• Release the vent valve when you hear a
squeezing sound. Do not press the vent
valve with naked hand to avoid frostbite. Fig.4-160

3. With the engine stopped, open the high-

pressure valve on the manifold pressure
gauge and the fluorine cylinder valve and fill
in one and a half cylinder of fluorine (approxi-
mate 600g).

WARNING
• Do not run the compressor at this moment.
Once the compressor is started, the refrig-
erant could flow back, causing the fluorine
cylinder and hose to burst.
• Operating the compressor without refriger-
ant will burn the compressor. Never run the
Fig.4-161
compressor without refrigerant.
• Do not open the low-pressure valve on the
manifold pressure gauge (liquid compres-
sion will occur, causing damage tot he
compressor).

4. Close the high-pressure valve on manifold

pressure gauge and the fluorine cylinder
valve.

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 Structure and Functions SY500H Hydraulic Excavator

• Fill from lo-pressure side (additional filling)

1. Confirm the hi-pressure valve of the mani-

fold pressure gauge is closed.

2. Start the engine and open the cab door.

3. Turn on the air conditioner, and set Temper-

ature control switch to minimum.

4. Adjust engine speed to 1300 – 1500 rpm. Fig.4-162

5. Open the Lo-pressure valve of the manifold

pressure gauge and the valve of the fluorine
cylinder, and fill refrigerant into the reservoir
until no foam is observed.

NOTICE
• Manifold pressure gauge reading (for
reference):
• High pressure 13~17kg/cm2 (ambient tem-
perature 30℃ );
• Low pressure 1.5~2kg/cm2 (ambient tem-
perature 30℃ ).

6. When refrigerant filling is finished, close the

Lo-pressure valve of the manifold pressure
gauge and the valve of the fluorine cylinder.

7. Check carefully for air leaks with a leak

detector.

Fig.4-163

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WARNING
• Never open the Hi-pressure valve of the
manifold pressure gauge. If it is opened,
high-pressure gas will counterflow and
cause the air hoses and the fluorine cylin-
der to explode, resulting in serious injury.
• Do not position the fluorine cylinder upside
down (when engine is operating and filling
in progress). If the cylinder is placed up-
side down, liquid refrigerant will be sucked
directly into the compressor and cause
liquid compression, resulting in damage to
the compressor valve and the gaskets.
Place the cylinder vertically and fill gas
refrigerant.

8. When ambient temperature is low When re-

frigerant filling can not be performed due to
low ambient temperature, place the cylinder in
water of less than 40 ℃ to increase the pres-
sure of the refrigerant inside the cylinder.

9. When ambient temperature is very high,

cool the compressor with an electrical fan.

Fig.4-164

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 Structure and Functions SY500H Hydraulic Excavator

• Replace the fluorine cylinder

When the refrigerant in a cylinder is used up,

replace the cylinder as per the following
instruction:

1. Close the Hi- and Lo-pressure valves of the

manifold pressure gauge.

2. Raise the needle and disc plate of the cylin-

der and remove the empty cylinder.

3. Install a new cylinder onto the cylinder

valve.
Fig.4-165
4. Release the air in the hose as per the fol-
lowing instruction:
A. Tighten the valve of the fluorine cylinder,
and then, loosen it a bit.
B. Open the Lo-pressure valve of the manifold
pressure gauge a bit.
C. Press the vent valve and allow a little refrig-
erant to come out. Immediately close the
valve of the cylinder and the Lo-pressure
valve of the manifold pressure gauge.
● Do not press the vent valve with naked hand
to avoid frostbite by refrigerant.

5. Turn the handle of the cylinder valve to

pierce the cylinder and continue filling Fig.4-166
operation.

4.8.13.4 Troubleshooting with manifold pressure gauge

After the engine has been preheated, read the pressure value on the gauge under the following
conditions:

1. Temperature at air inlet: 30 – 35℃

2. Engine speed: 1500 rpm

3. Fan speed: High

4. Temperature control: Minimum

5. Air mode: Recirculation

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•Refrigerating system under normal condition

Gauge reading:

Lo-pressure end 0.15~0.25 Mpa (1.5~2.5 Kg/cm²)

Hi-pressure end 1.37~1.57 Mpa (14~16 Kg/cm²)

Fig.4-167

• Moisture in the refrigerating system

Fault: Intermittent refrigeration to non-refrigeration

Fig.4-168

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 Structure and Functions SY500H Hydraulic Excavator

Symptom Cause Analysis Remedy

• When the system is • Moisture in the sys- • Over-saturation of • Replace receiver/

operating, pressure tem ices up at the dehydrator. dehydrator
at the Lo-pressure expansion valve • Moisture in the sys- • Remove the mois-
end unstable causing temporary tem ices up at the ture in the system
(sometimes vac- stop of circulation. expansion valve through constant
uum, sometimes When ice melts, the and hinders the cir- pumping.
normal) system becomes culation of the re- • Add proper volume
normal again. frigerating system. of new refrigerant.

• Insufficient refrigeration

Fault: Insufficient refrigeration.

Fig.4-169

Symptom Cause Analysis Remedy

• Check for air leak-

age with a leak de-
tector. Make
• Pressure at both Hi-
necessary repairs.
and Ho-pressure
• Add proper amount
ends very low
• Air leaks some- • Insufficient refriger- of refrigerant.
• Foam is continu-
where in the refrig- ant in the system • When connected
ously observed via
erating system • Leak of refrigerant with the gauge, if
the sight glass
the reading is near
• Insufficient
zero, set the system
refrigeration.
under vacuum state
after inspection and
repair.

• Defective refrigerant circulation

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Fault: insufficient refrigeration

Fig.4-170

Symptom Cause Analysis Remedy

• Pressure at both Hi-

and Lo-pressure • Contaminant in the
sides very low reservoir hinders
• Blocked reservoir • Replace reservoir
• Frosting on the pip- the flow of
ing between parts refrigerant.
and reservoir

• Refrigerant not circulating

Fault: Non-refrigeration (intermittent refrigeration)

Fig.4-171

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 Structure and Functions SY500H Hydraulic Excavator

Symptom Cause Analysis Remedy

• Check the expan-

sion valve and ERP.
• Blow the contami-
nant in the expan-
• Vacuum at Lo-pres- • Moisture or contam-
sion valve or
sure side; pressure inant in the refriger-
replace the expan-
at Hi-pressure side ant hinders the flow
sion valve if
extremely low of refrigerant.
• Refrigerant not necessary.
• Frosting or conden- • Air leak at the ther-
sation on the pipes mal pipe of the ex-
circulating • Replace the
receiver
around the expan- pansion valve
sion valve or re- hinders the flow of
• Release internal air
and add refrigerant.
ceiver/dehydrator refrigerant.
If air leaks from
thermal pipe, re-
place expansion
valve.

• Over-filling of refrigerant or insufficient refrigeration of condenser

Fault: Insufficient refrigeration

Fig.4-172

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Symptom Cause Analysis Remedy

• Pressure at both Hi- • Over-filling of refrig- • Excessive refriger- • Clean the

and Lo-pressure erant in the system. ant in system → condenser
sides very high Refrigerating per- Over-filling of • Check the working
• No foam can be ob- formance refrigerant condition of fan
served via the sight inadequate. • Insufficient refriger- motor
glass even when • Insufficient refriger- ation of condenser • If the two above
engine speed ation of condenser → Radiator fins of items are normal,
drops. condenser plugged check the volume of
or failure of fan refrigerant. Add re-
motor frigerant as
required.

• Air present in refrigerating system

Fault: Poor refrigeration

If refrigerant is added with no evacuation operation performed, the following gauge reading will
appear:

Fig.4-173

Symptom Cause Analysis Remedy

• Pressure at both Hi-

and Lo-pressure • Check if compres-
ends very high • Air enters the refrig- sor oil is contami-
• Lo-pressure piping • Air enters the refrig- erant system nated or
feeling hot erating system • Insufficient inadequate.
• Foam is observed evacuation • Evacuate and add
through the sight new refrigerant.
glass

• Improper installation of expansion valve/thermal pipe defect (wide opening)

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 Structure and Functions SY500H Hydraulic Excavator

Fault: insufficient refrigeration

Fig.4-174

Symptom Cause Analysis Remedy

• Check the installa-

tion of thermal
• Pressure at both Hi-
• Improper installa- • Excessive refriger- piping
and Lo-pressure
ends very high
tion of thermal pipe/ ant in Lopressure • If thermal piping is
defective thermal piping normal, check the
• Frosting or conden-
pipe (excessively • Expansion valve expansion valve.
sation on Lo-pres-
wide opening) opening too wide Replace expansion
sure piping
valve if found
defective.

• Compressing error
Fault: No refrigeration

Fig.4-175

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Symptom Cause Analysis Remedy

• Pressure at Lo-
• Compressing fault;
pressure side very
• Compressor inter- • Leaking or dam- • Repair or replace
high
nal leakage aged valve, or miss- compressor
• Pressure at Hi-pres-
ing parts
sure side very low

4.8.14 Compressor oil

Oil shall be added into the A/C system for lubrication. Compressor oil is solved in the refrigerant
and circulates in the system. When the air conditioning system is shut down, compressor oil will
stay inside the components. If no compressor oil is added into the system when replacing compo-
nents, inadequate lubrication will result. Add compressor oil according to the chart below:

ND8# (10P, 10PA, 10S series compressor)

Compressor oil grade
ND9# (TV series compressor)

CAUTION
• Add oil into a new compressor according to the required volume of the system. When the com-
pressor is to be replaced, discharge the surplus oil in it.
• Filling of improper amount of compressor oil: Over-filling of compressor oil will reduce the refrig-
erating capacity. Short of compressor oil in the system will lead to an abnormal compressor.
• Keep the pipe connectors and O-ring seals free from contamination when disassembling the
compressor.

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Structure and Functions SY500H Hydraulic Excavator

4.9 Engine Control

4.9.1 General

Fig.4-176

(1) Battery relay Outline

(2) Battery • Start and stop the engine only with the en-
gine start switch (3).
(3) Start switch
• The controller (8) receives the signal from
(4) Fuel control dial
the fuel control dial (4) and send the object
(5) Start motor speed to engine controller through can bus
(6) Controller the governor lever angle of fuel injection
(7) Fuel injection pump pump (7) and control the engine speed.

(8) Controller
• When engine start switch (3) is turned to the
OFF position, the engine controller (6)
closes the injection nozzle of the fuel injec-
tion pump to cut off the engine fuel supply.
Then, the engine stops.

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4.9.2 System operation

Engine start

• When the start switch is turned to the

START position and the pilot switch is
locked, the starting signal is sent to the start
motor. Then, the start motor starts the
engine.
• When it happens, the engine controller de-
tects the signal voltage sent from the fuel
control dial and sets the engine speed to
the speed set by the fuel control dial.

Fig.4-177

Engine speed control

• The fuel control dial sends to the controller

a signal voltage corresponding to its angle.
According to the signal voltage, the control-
ler sends speed signal to ECM controller in
order to control the fuel injection pump,
hence controlling the engine speed.

Fig.4-178

Engine shutdown

• When the start switch is turned to the STOP

position, then sends stop signal to ECM
controller in order to control the fuel injec-
tion pump stop working.

Fig.4-179
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 Structure and Functions SY500H Hydraulic Excavator

4.9.3 System components

4.9.3.1 Fuel control dial

Fig.4-180

(1) Knob

(2) Dial

(3) Spring

(4) Ball

(5) Potentiometer

(6) Plug

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Function

• Turning of the fuel control dial changes the

resistance of the sliding rheostat inside the
dial and the voltage signal collected by the
controller. The controller calculates the col-
lected signals and sends speed signal to
ECM controller and controls the injection of
the fuel pump so that the engine can run at
an optimal speed.
• When throttle voltage is beyond the area,
the controller sends out alarm code and the Fig.4-181
engine runs at low idle. The area under the
sloping line is the abnormality detection
area.

NOTICE
The leftmost position is 0%; and the right-
most position is 100%.

4.9.3.2 Engine control unit (ECU)

Diagram and description of ECU terminal block

Fig.4-182

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Structure and Functions SY500H Hydraulic Excavator

Termi- Termi-
nal Connected to nal Connected to
NO. NO.
1、2、3 Cylinder
1 OP-COM1A 25 IA-THW Water TEMP.
common
1、2、3 Cylinder
2 OP-COM1B 26 SG-5VRT4 Sensor GND
common
1、2、3 Cylinder
3 OP-COM1C 27 N.C. /
common
Crank angle sensor
4 N.C. / 28 SG-SLD5
shield
5 OM-EBM3 Motor:EGR-A W 29 N.C. /
6 SP-5V4 Sensor Power 30 OP-PCV2 PCV2
7 N.C. / 31 OS-INJ1 Injection order 1
8 N.C. / 32 OS-INJ5 Injection order 5
9 IA-THL Fuel Leakage TEMP 33 OS-INJ4 Injection order 4
10 IA-THBST Boost TEMP 34 N.C. /
11 IA-PFUEL Common rail pressure 35 OM-EBM1 Motor:EGR-A U
IA-
12 Oil pressure 36 N.C. /
OILPRESS
13 IA-MAP Boost pressure 37 N.C. /
14 N.C. / 38 N.C.
15 OP-PCV2 PCV2 39 N.C.
4、5、6 Cylinder
16 OP-COM2A 40 SG-5VRT7 Sensor GND
common
4、5、6 Cylinder
17 OP-COM2B 41 SG-5VRT5 Sensor GND
common
4、5、6 Cylinder
18 OP-COM2C 42 SG-5VRT6 Sensor GND
common
Cam angle sensor
19 N.C. / 43 SG-SLD6
shield
20 OM-EBM2 Motor:EGR-A V 44 N.C. /
21 SP-5V5 Sensor Power 45 OP-PCV1 PCV1
22 SP-5V6 Sensor Power 46 OS-INJ3 Injection order 3
23 SP-5V7 Sensor Power 47 OS-INJ6 Injection order 6
24 N.C. / 48 OS-INJ2 Injection order 2

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Termi Termi
nal Connected to nal Connected to
NO. NO.
49 N.C. / 85 IA-ACCEL1 Accel position
50 N.C. / 86 IA-ACCEL2 Accel position
51 N.C. / 87 IA-BARO Baro
52 IS- EGR Brush-less DC 88 CC- DIAG CAN_L
EBMPOS1 motor-A Position U ISOCAN-L
53 IS- EGR Brush-less DC 89 PS-+B ECM Power
EBMPOS2 motor-A Position V
54 IS- EGR Brush-less DC 90 SG-5VRT1 Sensor GND
EBMPOS3 motor-A Position W
55 N.C. / 91 N.C. /
56 IF-CAM Cam angle sensor 92 N.C. /
57 IF-CRANK Crank angle sensor 93 N.C. /
58 SG-SLD8 Common rail sensor 94 N.C. /
shield
59 N.C. / 95 N.C. /
60 OP-PCV1 PCV1 96 N.C. /
61 PG- Power GND 97 PG-SIGN Sign GND
POWER
62 PG- Power GND 98 N.C. /
POWER
63 PG- Power GND 99 N.C. /
POWER
64 PG- Power GND 100 IS-START start sign
POWER
65 PG- Power GND 101 N.C. /
POWER
66 PG- Power GND 102 N.C. /
POWER
67 PS-+B ECM Power 103 N.C. /
68 N.C. / 104 N.C. /
69 SP-5V2 Sensor power 105 N.C. /
70 SP-5V3 Sensor power 106 N.C. /
71 N.C. / 107 N.C. /
72 CC- Diag plug 108 N.C. /
KW2000
73 N.C. / 109 N.C. /

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Structure and Functions SY500H Hydraulic Excavator

74 N.C. / 110 CC- DIAG CAN_H

ISOCAN-H
75 N.C. / 111 PS-+B ECM power
76 N.C. / 112 SG-5VRT3 Sensor GND
77 N.C. / 113 N.C. /
78 N.C. / 114 OS-MAINR RELAY:MAIN
79 N.C. / 115 N.C. /
80 N.C. / 116 N.C. /
81 IA-IAT Intake air TEMP 117 N.C. /
82 N.C. / 118 N.C. /
83 IA- Fuel filter pressure 119 PG-SIGN Sign GND
FIPRESS
84 N.C. / 120 N.C. /

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Terminal NO. Connected to

121 IS-ENGSTP SWITCH:ENG. STOP
122 N.C. /
123 N.C. /
124 OS-OILRL LAMP: OIL PRESSURE
125 N.C. /
126 N.C. /
127 N.C. /
128 N.C. /
129 N.C. /
130 OS-DIAGL LAMP:DIAG
131 N.C. /
132 CC-CAN-L CAN_L
133 PS-+B ECM POWER
134 IS-IGKEY SWITCH: IGNITION(ON)
135 SG-5VRT2 Sensor GND
136 OS-MAINR RELAY:MAIN
137 PG-CASE CASE GND
138 N.C. /
139 N.C. /
140 N.C. /
141 IS-DIAG DIAG
142 IS-MEMCL Memory clear
143 N.C. /
144 N.C. /
145 OS-GLOWL LAMP:GLOW
146 N.C. /
147 N.C. /
148 N.C. /
149 N.C. /
150 N.C. /
151 N.C. /
152 OS-STARTR RELAY:STARTER CUT
153 OS-GLOWR RELAY:GLOW
154 CC-CAN-H CAN_H

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4.10 Electrical Control System

4.10.1 Control function

• See “Troubleshooting” for more information on self-diagnostic function.

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4.10.2 Diagram of machine control system

Fig.4-183

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Fig.4-184

NOTICE
The above diagram is a schematic drawing of electrical control. For more information on the hy-
draulic circuit, see the description in Hydraulic Part.

4.10.3 Engine-pump combination control

Diagram of control function

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Fig.4-185

NOTICE
The above diagram is a schematic drawing of electrical control. For more information on the hy-
draulic circuit, see the description in Hydraulic Part.

Function

• This function allows operator to change the engine torque and the pump absorption torque ac-
cording to the kind of job that the machine is to be engaged.

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• Pump controller controls the pump so that the pump is able to absorb all torques at engine out-
put point. These torques are determined by the pump absorption torque specification, fuel con-
trol dial setting and real engine speed under each mode.
ESS Control

Function

• Changing of the engine speed due to load change controls the pump power, and engine output
can be used more efficiently. (This function can also prevent the engine from losing control when
the machine is operating under harsh conditions (eg. high - altitude area).
Operation

• The engine control panel controls the target operating speed of the engine.
• The engine controller collects the actual speed signal from the speed sensor, and preform a loop
control with the target operating speed. Then, the controller involves the output of loop control
with the calculation of the solenoid valve control signal, and sends the fi nal regulating current
signal to the pump proportional solenoid valve.
• The solenoid valve controls pump flow by feeding pilot oil to the pump regulator according to the
signal sent from the controller.

4.10.4 Valve control function

Bucket confluence

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Fig.4-186

Function

• In order to make the machine applicable under high load, a two-level relief function is adopted to
enhance its digging power.
• The relief pressure is 34.3Mpa (350 kg/ cm2) under normal working condition.

4.10.5 Travel control function

Travel speed control

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Fig.4-187

Function

• The monitor control panel is used to change travel motor displacement, hence the control of
travel speed. In this way, the travel performance can match certain working environment and
work category.
• High/Low Travel speeds are shown below.

Reducer High speed Low speed

GM85 5.4km/h 3.1km/h

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4.10.6 Low engine oil pressure alarm and protection

Fig.4-188

Function

• The controller collects signal from oil pressure sensor. If the oil pressure is too low with the en-
gine running at a speed of more than 600 rpm, alarm information will be generated and sent to
the monitor. The monitor receives the alarm information and lights up the alert indicator.
• As the monitor alarms, the controller will force the engine to run at low idle in order to protect the
engine.

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4.10.7 High engine coolant temperature alarm and protection

Fig.4-189

Function

• The controller collects signal from water temperature sensor. If coolant temperature is too high
(exceeding 105 ℃ ), alarm information will be generated and sent to the monitor. The monitor re-
ceives the alarm signal and lights up the alert indicator.
• As the monitor alarms, the controller will force the engine to run at low idle in order to protect the
engine.

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4.10.8 Engine preheating control

Fig.4-190

Function

• When the engine is started, engine control unit (ECU) will detect coolant temperature and deter-
mine whether the engine is to be preheated.
• When ECU determines that preheating is necessary, it will send preheating control signal to
close the preheat relay. The engine preheating plug will be energized and activated.

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4.10.9 Engine starting and energizing delay control

Fig.4-191

Function

• When the start switch is turned to the START position, the controller closes K-3 relay after de-
tecting that the hydraulic lockout control in the safe position. After the start relay is energized,
the start motor will bring the flywheel into rotation. The engine is then started.
• When the start switch is turned to the OFF position, ECM of the engine is de-energized, the en-
gine shutdown device shuts off fuel supply of the engine, and the controller sends an eightsec-
ond high level signal to close K-12 shutdown relay after detecting that the wiring 13# has been
de-energized. The whole vehicle will be powered off after eight (8) seconds.

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4.10.10 System parts and components

4.10.10.1 Pump pressure sensor

Fig.4-192

Operation

• The relationship between the pressure ap-

plied to sensors (P) and output voltage (E)
is shown in the figure on the right.

Fig.4-193

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4.10.10.2 Pilot pressure sensor

Fig.4-194

Operation

• The relationship between the pressure ap-

plied to sensors (P) and output voltage (E)
is shown in the figure on the right.

Fig.4-195

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4.10.10.3 Engine speed sensor

Fig.4-196

Function
• •
The engine revolution sensor is installed to If the engine speed sensor is not tightened
the ring gear of the engine flywheel. It electri- to the specified torque, the sensor may send
cally calculates the number of the gear teeth out no signals. Tighten the engine speed
which pass in front of it and transmits the re- sensor to the specified torque.
sult to the engine controller.
Operation
• Measure the resistance between terminal 1
and terminal 2 when using it.
Standard value at 25℃ 2.3±0.2kΩ

• If the measured value exceeds the standard

value, replace the sensor.

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4.10.10.4 Coolant temperature sensor

Fig.4-197

(1) 1. Sensor

(2) 2. Connector

Function Specifications
• The output resistance of the engine coolant
temperature sensor changes with the cool-
ant temperature. The controller collects and
processes coolant temperature signals and
works out the coolant temperature.

4.10.10.5 Fuel level sensor

Fig.4-198

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(1) Float (3) Housing

(2) Lever (4) Connector

4.10.10.6 Oil pressure switch

Fig.4-199

(1) 1. O-ring

(2) 2. Sensor

(3) 3. Connector

Function Specifications
• The oil pressure switch is installed on the • Type of contact: Normally close contact
outlet circuit of the oil filter. It detects oil pres- • Operating pressure: 1.9 kgf
sure and transmit the signal to the controller.

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4.11 Monitor System

4.11.1 General

Fig.4-200

• The machine condition is monitored by the sensors mounted on different locations of the ma-
chine. The controller processes the signals and transmits the signals to the monitor display, in-
forming the operator of the machine condition.
• The monitor panel also contains mode selector, functional keys and machine operation control
outputs.
• Information on the monitor display includes primarily:

1. Alert information in case of machine failure

2. Operating condition (coolant temperature, hydraulic oil temperature, fuel level, etc. )

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4.11.2 Monitor

Fig.4-201

Outline Input and output signals

• The monitor is used to display monitoring in-
formation and select a working mode.
• The monitor has a CPU (Central Processing
Unit) which processes, displays, and outputs
information.
• The monitor uses a LCD (Liquid Crystal
Display).

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NOTICE
• The LCD may have black spots (which do not light up) or bright spots (which stay on). Products
having 10 or less black or bright spots conform to the product specification; such condition is
quite normal.
• Continuous operation of the monitor may cause the LCD to display bright blue spots on a black
background; it is quite normal.
• When the monitor is turned on, blinking strips may appear on the LCD. This is normal.

4.11.3 Monitor panel

• Stop operation immediately when the alert

indicator is on. Check and repair related
parts.
• The monitor does not display all working
conditions of the machine.
• Do not solely depend on what is displayed
on the monitor when maintaining and check-
ing the machine.

The monitor panel performs the functions of

monitoring and displaying, selecting a working
mode, and switching on/off an electrical
element.

Overview

The monitor consists of three parts:

A: SANY log display

B: LCD display Fig.4-202

C: Operation keys

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SANY log display

Display SANY log

When the excavator starter switch to “on” po-

sition， the display is supplied by the battery
and enter into the interface.

Fig.4-203

Default display

When the excavator start switch is turned to

the on position, the monitor is energized by
the battery and initializes. A fully displayed
screen is as shown in the right figure, where
in,

1. System time

2. Working mode (Divided by engine speed

level)

3. GPS information

4. Engine speed level (According to the throt-

tle knob position)
Fig.4-204
5. Operation time

6. Fuel level gauge

7. Lock indicator (Lock countdown reminder)

8. Maintenance indicator and time

9. Fuel instaneous flow

10.Operate time of this time

11.Coolant temperature gauge

12.Malfunction alert and signal indicators

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13.Video page

14.Auto deceleration

15.High/low travel speed

16.Icon for entering Failure Information

17.Icon for entering System Information

Operation keys

The operation keys include five function keys.

Function keys

The function keys include F1, F2, F3, F4 and F5, as show by the figure. Function of each key is de-
fined by the icon above it.

• A different icon defines different function of a key.

• When no icon is shown, the corresponding key is undefined

4.11.4 Monitor operation

4.11.4.1 Default page

主页

主页是指挖掘机正常工作时的操作界面。

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The Default page is the normal operation dis-

play of the monitor.

Operation

1. Enter the Video Page

If the machine is equipped with a camera,
press F1 enter the Video Page.

2. Auto-idle and Non auto-idle mode

Press F2 to switch between auto-idle and Non
auto-idle mode.
When the icon above F2 shows , press the
n/min

key to disable auto idle. When the icon shows

, press the key to enable auto idle.
n/min
Fig.4-205
NOTE: Auto-idle mode is the default mode
after the machine is powered on.
• Auto idle is on as default. When all controls
are in neutral position, engine speed will
drop by 100 rpm after 0.2 second and then
enter auto idle after another 3 seconds (as
the controller automatically changes engine
speed to idling) in order to save fuel and re-
duce noise.
• In auto idle, if the controller detects any ma-
neuver or gear position change, engine
speed will rise to corresponding level.

3. High and low travel speed

Press F3 to switch between high and low travel
speed.
When the icon above F3 shows , press the
key to select high travel speed. When the icon
shows , press the key to select low travel
speed.

NOTICE
Default travel speed is Low after the machine
is powered on.

4. Failure Information
When the alert indicator is on, failure code ap-
pears on bottom of monitor screen. Above the

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 Structure and Functions SY500H Hydraulic Excavator

key F4 you will see a red . Press this key to

view failure Information.

5. Main menu (5)

Press F5 view system information.

NOTICE
Password is required to access system infor-
mation. You may contact local Sany distribu-
tor to get the password.

4.11.4.2 Main Menu Password entry to system information

Choose “Running Iinformation” on the “Main

Menu”, Press F3 to call the password entry to
system information (After power-on, you only
should enter the correct passwords to access
at the first time).

Operation

• F1 Increase or decrease the number at the

cursor.
• F2 Move the cursor to the left or to the right.
• F3 Confirmation
• F4 Access System Lockout page
• F5 Return to the default page

Fig.4-206

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4.11.4.3 Main Menu

Press F5 on the default page of monitor to en-

ter Main Menu. This page contains a list of
system functions. You can select an item and
enter corresponding page.

Operation

• F1 Selection function
• F2 -
• F3 Confirmation
• F4 Access System Setting page
• F5 Return to the default page

Fig.4-207

4.11.4.4 System Lockout

Operation

• F1 Increase or decrease the number at the

cursor.
• F2 Move the cursor to the left or to the right.
• F3 Confirmation
• F4 -
• F5 Return to the default page

Fig.4-208

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4.11.4.5 Engine & Throttle Signals

Select Running Information on the Main Menu

page to access Engine & Throttle Signals at
first.

Operation

• F1 Enter Input & Output Switch Signals

query.
• F2 Enter Pilot Pressure Signals.

Fig.4-209

4.11.4.6 Pilot Pressure Signals

Press F2 on the Engine & Throttle Signals

page or press F1 on the Main & Cooling Pump
Signals page to access Pilot Pressure
Signals.

This page displays real-time pilot pressure

signals collected by the controller.

Operation

• F1 Enter Engine & Throttle Signals.

• F2 Enter Main & Cooling Pump Signals.

Fig.4-210

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4.11.4.7 Main & Cooling Pump Signals

Press F2 on the Engine & Throttle Signals

page or press F1 on the Input & Output Switch
Signals page to access Main & Cooling Pump
Signals.

Operation

• F1 Enter Pilot Pressure Signals.

• F2 Enter Input & Output Switch Signals.

Fig.4-211

4.11.4.8 Input & Output Switch Signals

Press F2 on the Main & Cooling Pump Signals

page or press F1 on the Engine & Throttle Sig-
nals page to access Input & Output Switch
Signals.

Operation

• F1 Enter Main & Cooling Pump Signals.

• F2 Enter Engine & Throttle Signals.

Fig.4-212

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4.11.4.9 Failure information

Select Failure Information on the Main Menu

to enter and check failure code and
information.

Operation

• F1 Return to the previous page.

• F2 -
• F3 -
• F4 -
• F5 Return to Main Menu page

Fig.4-213

4.11.4.10 GPS Information

Select GPS Information on the Main Menu to

check GPS information.

Operation

• F1 -
• F2 -
• F3 -
• F4 -
• F5 Return to Main Menu page

Fig.4-214

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4.11.4.11 Language Selection

Select Language Selection on the Main Menu

to enter Language Setting page, the currently
available languages are Chinse and English.

Operation

• F1 -
• F2 Chinse
• F3 English
• F4 -
• F5 Return to Main Menu page

Fig.4-215

4.11.4.12 System Time Calibration

Select System Clock on the Main Menu to en-

ter System Time Calibration page.

Operation

• F1 Increase or decrease the number at the

cursor.
• F2 Move the cursor to the left or to the right
• F3 Confirmation
• F4 -
• F5 Return to Main Menu page

NOTICE
System clock can only be set up once after
the system is powered on. When the ma-
chine is powered on and the F1 key is
pressed, you will only see the prompt of set- Fig.4-216
up result.

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4.11.4.13 Maintenance Information

Select Maintenance Information on the Main

Menu to enter Maintenance Info. page. Main-
tenance Information includes maintenance
items of every 50 & 250 & 500 & 1000 & 2000
service hours.

NOTICE
Just enter operation when maintenance is
reminded.

Operation

• F1 -
• F2 -
• F3 Enter maintenance code confirmation
• F4 Pause and open of maintenance items
cycle play Fig.4-217
• F5 Return to Main Menu page

4.11.4.14 Maintenance Confirmation

Press F3 on the Main Menu to access Main-

tain Password page and input password to
confirm maintenance.

Operation

• F1 Increase or decrease the number at the

cursor
• F2 Move the cursor to the left or to the right
• F3 Confirme maintenance
• F4 -
• F5 Return to Main Menu page

Fig.4-218

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4.11.4.15 System Setting

Press F4 on the Main Menu to access System

Setting page, Password is required to access
Operation Time Calibration. For method of en-
tering the password see Password Entry to
System Information.

Operation

• F1 Selection
• F2 -
• F3 Confirme maintenance
• F4 -
• F5 Return to Main Menu page

Fig.4-219

4.11.4.16 Machine Configuration Setting

S e l e c t M a c h i n e C o n fi g u r a t i o n o n
t h e System Setting page to check the ma-
chine configuration information.

Operation

• F1 -
• F2 -
• F3 -
• F4 -
• F5 Return to Main Menu page

Fig.4-220

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4.11.4.17 Operation Time Calibration

Press Operating Hours on the System Setting

page to calibrate operating time. Password is
required to access Operation Time Calibra-
tion. For method of entering the password see
Password Entry to System Information.

Operation

• F1 Increase or decrease the number at the

cursor
• F2 Move the cursor to the left or to the right
• F3 Confirmation
• F4 -
• F5 Return to System Setting page

Fig.4-221

4.11.4.18 Machine Configuration Setup

Select Machine Demarcration on the System

Setting page to calibrate machine configura-
tion information. Password is required to ac-
cess Machine Configuration Setting. For
method of entering the password see Pass-
word Entry to System Information.

Operation

• F1 Change Machine S/N

• F2 Change engine model
• F3 Confirm and Return to System Setting
page
• F4 Change model of the hydraulic system
• F5 Change controller model

Fig.4-222

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4.11.4.19 Alarm Content Setting

Select Alarm Contet on the System Setting

page to acess Alarm Content Setting page.

Operation

• F1 Select setting item

• F2 -
• F3 Confirm setting item
• F4 -
• F5 Return to System Setting page

Fig.4-223

4.11.4.20 Screen Backlight Adjust

Select Screen Backlight on the System Set-

ting page to acess Alarm Content Adjust
page.

Operation

• F1 Enhance the backlight

• F2 Dim the backlight
• F3 Confirmation
• F4 -
• F5 Return to System Setting page

Fig.4-224

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4.11.4.21 Running Correct Setting

System set the second level password to

enter.

Operation

• F1 Select setting item

• F2 Increase the number at the cursor
• F3 Decrease the number at the cursor
• F4 Confirmation
• F5 Return to System Setting page

Fig.4-225

4.11.4.22 Engine Information

Display history fail and work times of engine.

Operation

• F1 Display history fail and work times

• F2 Enter the history fails query page
• F3 Confirm sending request
• F4 Enter the engine other information page
• F5 Return to System Setting page

Fig.4-226

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4.11.4.23 Engine Failure Information

Display engine history fails.

Operation

• F1 Enter the next page

• F2 -
• F3 -
• F4 -
• F5 Return to Engine Information page

Fig.4-227

4.11.4.24 Engine other information

Display engine related information.

Operation

• F1 Enter basic engine information-4 page

• F2 Enter basic engine information-2 page
• F3 -
• F4 -
• F5 Return to Engine Information page

Fig.4-228

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4.11.4.25 Daily maintenance information

It pop up automatically when stars at first time

every day.

Operation

• F1 -
• F2 -
• F3 -
• F4 -
• F5 Return to Engine Information page

Fig.4-229

4.11.4.26 System lockout information

The excavator enters level system lockout

when receive lockout singals. Lockout singals
include two kinds system status of level 1 and
level 2.

Operation

• F1 -
• F2 -
• F3 -
• F4 -
• F5 Enter system unlock page

Fig.4-230

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Standard Values

5 Standard Values...............................................................................................................5-1
5.1 Standard Values for Engine-Related Parts .......................................................................5-3
5.2 Standard Values for Chassis-Related Parts......................................................................5-4

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WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.

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5.Standard Values
5.1 Standard Values for Engine-Related Parts
Applicable Models SY500H
Engine AH-6WG1X
Standard
Item Measurement condition Unit values for Repair limits
new machine
High idling rpm 1700±20 1700±30
Engine speed Low idling rpm 850±20 850±30
Rated speed rpm 1800 1800
Valve Intake valve mm 0.4 —
clearance Exhaust valve mm 0.4 —
Compression Oil temp: 40-60℃ 2.94 2.26
Mpa {kg/cm2}
pressure Engine speed 200 rpm 30 23
Between fan belt pulley and
Fan belt alternator belt pulley
mm 6~8 6~8
tension Deflection when pressed with
finger force of 98 N {10 kg}
Between fan belt pulley and
A/C
compressor belt pulley
compressor mm 5~8 5~8
Deflection when pressed with
belt tension
finger force of 58.8 N {6 kg}

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Standard Values SY500H Hydraulic Excavator

5.2 Standard Values for Chassis-Related Parts

Applicable Models SY500H
Standard
Value for Permissi-
Category Item Measurement Condition Unit
New ble Value
Machine
● Engine coolant
temperature: Within
operational range
● Hydraulic oil
temperature: Within
2 pumps at 1,600 ～
operational range rpm 1650±50
relief 1,700
● Engine running at high
Engine idle
Speed ● Heavy-load operating
mode (H)
● Arm-in relief condition
Speed ● Engine running at high
when auto idle
1,080 ～
decelera ● Auto idling switch on rpm 1100±20
1,120
tion is ● All control levers
operated neutral
Boom 11.0 ～
Raise mm 11.5 ± 0.5
control 12.0
valve Lower mm 9.5± 0.5 9.0 ～ 10.0
11.0 ～
Arm control ● Engine In mm 11.5 ± 0.5
12.0
valve stopped
Out mm 9.5± 0.5 9.0 ～ 10.0
● For
Spool Bucket measuring
Stroke control points see Curl/dump mm 9.5± 0.5 9.0 ～ 10.0
valve “Control
Swing valve” on
control page 3-11. Travel (L) mm 9.5± 0.5 9.0 ～ 10.0
valve
Travel
Forward &
control mm 9.5± 0.5 9.0 ～ 10.0
Reverse
valve
Boom ●Engine stopped
Travel of control ● Control lever grip at mm 85 ± 10 75 ～ 95
Control lever center
Lever Arm control ●Max. reading up to
mm 85 ± 10 75 ～ 95
lever stroke end (except lever

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SY500H Hydraulic Excavator Standard Values

Applicable Models SY500H

Standard
Value for Permissi-
Category Item Measurement Condition Unit
New ble Value
Machine
Bucket play in NEUTRAL
control position) mm 85 ± 10 75 ～ 95
lever
Swing
control mm 85 ± 10 75 ～ 95
lever
Travel
control mm 115 ± 12 103 ～ 127
lever
● Engine Work
mm Max. 15 Max. 20
stopped Equipment
● Slightly
push the
control
lever with
your hand.
Play of
Stop
control
pushing
lever Travel mm Max. 20 Max. 25
when you
feel clear
resistance
● Max.
reading up
to stroke
end

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Standard Values SY500H Hydraulic Excavator

Applicable Models SY500H

Standard
Measure-
Value for Permissible
Category Item ment Unit
New Value
Condition
Machine
Boom control ● Hydraulic oil Max. 19.6 Max. 24.5
lever temp: Within {Max. 2.0} {Max. 2.5}
operational Max. 19.6 Max. 24.5
Arm control
range {Max. 2.0} {Max. 2.5}
lever
● Engine
Operating Bucket running at Max. 15.6 Max. 21.6
Force of control lever high idle {Max. 1.6} {Max. 2.2}
N {kg}
Control Lever Swing control ● Control Max. 15.6 Max. 21.6
and Pedal lever lever grip at {Max. 1.6} {Max. 2.2}
center
Travel control Max. 30.4 Max. 39.2
● Pedal at tip
lever {Max. 3.1} {Max. 4.0}
● Max.
Travel control reading at Max. 93.1 Max. 107.6
pedal stroke end {Max. 9.5} {Max. 11}
● Hydraulic oil
temp: Within
operational
range
● Engine
running at
high idle
Unloaded ● Working 3.5 ± 1.0 2.5 ～ 4.5
pressure mode: H {36 ± 10} {26～46}
● Hydraulic
pump output
pressure with
Hydraulic all control MPa {kg/cm2}
Pressure levers in
neutral
position
● Hydraulic oil 34.3 ± 1.0 34.3～35
Boom relief
temp: Within {350 ± 10} {350 ～ 360}
operational 34.3 ± 1.0 34.3～35
Arm relief range {350 ± 10} {350 ～ 360}
● Operate
correspond
ing control 34.3 ± 1.0 34.3～35
Bucket relief
lever after the {350 ± 10} {350 ～ 360}
engine runs at

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SY500H Hydraulic Excavator Standard Values

Applicable Models SY500H

Standard
Measure-
Value for Permissible
Category Item ment Unit
New Value
Condition
Machine
high idling
speed.
● Working
mode: H
● Hydraulic
pump output
pressure with
all
measurement
circuits
relieved
● Hydraulic oil 27± 1.0 27～28
Swing relief
temp: Within {275± 10} {275 ～ 285}
operational
range
● Operate
correspond
ing control
lever after the
engine runs at
high idling
speed. 33.4 ± 1.0 32.4 ～ 34.4
Travel relief ●Working {342 ± 10} {330 ～ 351}
mode: H
● Hydraulic
pump output
pressure with
all
measurement
circuits
relieved

Shop Manual-June 2016 5-7

Standard Values SY500H Hydraulic Excavator

Applicable Models SY500H

Standard
Measure-
Value for Permissible
Category Item ment Unit
New Value
Condition
Machine
● Hydraulic oil
temp: Within
operational
range
● Engine
running at
high idle
Control circuit
● Self 3.9 ± 0.2 3.7 ～ 4.1
source
pressure {40 ± 2} {37 ～ 41}
pressure
reducing
valve output
pressure with
all control
levers in
NEUTRAL
position

Applicable Models SY500H

Standard
Measurement Value for Permissi-
Category Item Unit
Condition New ble Value
Machine
●Hydraulic oil temp:
Within operational
range
● Engine running at
high idle
● Working mode: H
º Max.100 Max. 130
Swing brake angle ● Swing circle
（mm） （—） （—）
misalignment amount
Swing when stopping after
one turn
● For measuring
posture see “Swing 1”
on page 3-11.
● 90° s 3.5 ± 0.3 Max. 4.0
Time taken to start Hydraulic
swing oil temp: 180° s 4.8 ± 0.4 Max. 5.5
Within
5-8 Shop Manual-June 2016
SY500H Hydraulic Excavator Standard Values

Applicable Models SY500H

Standard
Measurement Value for Permissi-
Category Item Unit
Condition New ble Value
Machine
operation
al range
● Engine
running at
high idle
● Working
mode: H
● Time
required
for
passing
points 90°
and 180°
from
starting
point
● For
measur
ing
posture
see“
Swing 1”
on page
3-11.
● Hydraulic oil temp:
Within operational
range
● Engine running at
high idle
● Working mode: H
Time taken to swing s 38±3 Max. 34
● Time required for 5
turns after making
initial one turn
● For measuring
posture see “Swing 1”
on page 3-11.
● Hydraulic oil temp:
Hydraulic drift Within operational mm 0 0
range

Shop Manual-June 2016 5-9

Standard Values SY500H Hydraulic Excavator

Applicable Models SY500H

Standard
Measurement Value for Permissi-
Category Item Unit
Condition New ble Value
Machine
● Engine stopped
● Keeping the upper
structure transverse
on a grade of 15º. For
more information see
“Swing 2” on page 3-
11.
● Notching a mating
mark on inner and
outer races of the
swing circle
●Mating mark
misalignment amount
during 5 minutes.
● Hydraulic oil temp:
Within operational
range
● Engine running at
high idle
Motor leakage ml/min Max. 5 Max.10
● Swing lockout
switch: ON
● Leakage amount for
one minute during
swing relief
● Lo
Hydraulic
oil temp:
Within
operation
al range
● Engine
Travel speed running at
Travel s 48 ± 5 43～53
(unloaded) high idle Hi
● Working
mode: H
● Time
required
for track
shoes to
make 5
5-10 Shop Manual-June 2016
SY500H Hydraulic Excavator Standard Values

Applicable Models SY500H

Standard
Measurement Value for Permissi-
Category Item Unit
Condition New ble Value
Machine
turns after
making
one initial
idle turn
● For
more
informa
tion on
measur
ing
posture
see
“Travel 1”
on page
3-12.
● Lo
Hydraulic
oil temp:
Within
operation
al range
● Engine
running at
high idle
● Working
mode: H
● Level
Travel speed (Actual 16± 2.5
ground s 18.25~28
run) Hi 25.5± 2.5
● Time
required
for
traveling
10 m after
10 m trial
run
● For
measur
ing
posture
see“

Shop Manual-June 2016 5-11

Standard Values SY500H Hydraulic Excavator

Applicable Models SY500H

Standard
Measurement Value for Permissi-
Category Item Unit
Condition New ble Value
Machine
Swing
2“on page
3-11.
● Hydraulic oil temp:
Within operational
range
● Engine running at
high idle
● Working mode: H
● Travel Speed: Low
● Hard level ground
Deviation mm Max. 600 Max. 800
● Amount of deviation
(χ) while traveling 20
m after initial 10 m trial
run
● For measuring
posture see “Travel 2”
and “Travel 3” on page
3-12.
● Hydraulic oil temp:
Within operational
range
● Engine stopped
● Park the machine on
a grade of 12°, with
Hydraulic drift the sprocket in the mm 0 0
downhill direction
● Measure the sliding
distance for 5 minutes
● For measuring
posture see “Travel 4”
on page 3-13.
● Hydraulic oil temp:
Within operational
range
Leakage amount of
● Engine running at mm 13.6 27.2
travel motor
high idle
● Traveling with the
sprocket locked

5-12 Shop Manual-June 2016

SY500H Hydraulic Excavator Standard Values

Applicable Models SY500H

Standard
Measurement Value for Permissi-
Category Item Unit
Condition New ble Value
Machine
● Oil leakage amount
for one minute with
traveling in relief
condition
Bucket ● Hydraulic oil temp:
mm Max. 600 Max. 900
tips Within operational
Boom range
● Flat and level mm Max. 20 Max. 27
cylinder
ground
Arm ● Bucket full of earth mm Max. 160 Max. 200
cylinder or with rated load
● Boom horizontal,
arm fully retracted and
bucket cylinder fully
extended
● Engine stopped
● Work equipment
control lever in neutral
position
● Measure total
Work amount of falling for
Hydraulic
Equip 15 minutes by
drift
ment measuring the falling
every 5 minutes
Bucket immediately after
mm Max. 35 Max. 40
cylinder initial setting
● Bucket tip lower
distance
● Boom cylinder:
Cylinder retracting
distance
● Arm cylinder:
cylinder extending
distance
● Bucket cylinder:
cylinder retracting
distance
● For measuring
posture see “Work

Shop Manual-June 2016 5-13

Standard Values SY500H Hydraulic Excavator

Applicable Models SY500H

Standard
Measurement Value for Permissi-
Category Item Unit
Condition New ble Value
Machine
Equipment 1” on page
3-13.
●
Hydraulic
oil temp:
Within
operation
al range
● Engine
running at
high idle
● Working
mode: H
● Time
required
for the
Boom bucket to UP s 3.9± 0.4 4.3
raise from
the
Work ground to
Equip its stroke
ment end
Speed ● For
measur
ing
posture
see “Work
Equip
ment 2”
on page
3-13.
● IN s 3.4± 0.4 3.8
Hydraulic
oil temp:
Within
Arm operation
al range OUT s 3.6± 0.4 4.0
● Engine
running at
high idle

5-14 Shop Manual-June 2016

SY500H Hydraulic Excavator Standard Values

Applicable Models SY500H

Standard
Measurement Value for Permissi-
Category Item Unit
Condition New ble Value
Machine
● Working
mode: H
● Time
required
from
dumping
stroke
end to
digging
stroke
end
● For
measur
ing
posture
see “Work
Equip
ment 3”
on page
3-14.
● DIG s 3.7± 0.4 4.1
Hydraulic
oil temp:
Within
operation
al range
● Engine
running at
high idle
● Working
Bucket
mode: H DUMP s 2.3± 0.4 2.7
● Time
required
from
dumping
stroke
end to
digging
stroke
end

Shop Manual-June 2016 5-15

Standard Values SY500H Hydraulic Excavator

Applicable Models SY500H

Standard
Measurement Value for Permissi-
Category Item Unit
Condition New ble Value
Machine
● For
measur
ing
posture
see “Work
Equip
ment 4”
on page
3-14.

Applicable Models SY500H

Standard
Judge-
Cate- Value for
Item Measurement Condition Unit ment
gory New
Criteria
Machine
● Hydraulic oil temp: Within
operational range
● Engine running at low idle
● Working mode: H
● Time required from maneuvering
Boo the joystick to the moment that the Max.
s Max. 1.0
m bucket reaches the ground and 1.2
begins to push the machine
upward, within 50 mm off the
ground
Time ● For measuring posture see“
Work
De Work Equipment 5” on page 3-14.
Equip
ment lay ● Hydraulic oil temp: Within
operational range
● Engine running at low idle
● Working mode: H
Max.
Arm ● Average time required for s Max. 2.0
2.8
operating the control lever back
and forth till the arm starts to move
● For measuring posture see“
Work Equipment 6” on page 3-15.
Buc ● Hydraulic oil temp: Within Max.
s Max. 1.0
ket operational range 3.6

5-16 Shop Manual-June 2016

SY500H Hydraulic Excavator Standard Values

Applicable Models SY500H

Standard
Judge-
Cate- Value for
Item Measurement Condition Unit ment
gory New
Criteria
Machine
● Engine running at low idle
● Working mode: H
● Average time required for
operating the control lever back
and forth till the arm starts to move
● For measuring posture see“
Work Equipment 7” on page 3-15.
Cyl
in ● Hydraulic oil temp: Within 10 30
Inter ders operational range
nal Cen ● Engine running at high idle
ml/min
Leak tral ● Leakage amount for one minute
age Swiv with cylinder or travel measured at 20 50
el relief condition
Joint
● Hydraulic oil temp: Within
Per Amount of operational range
for deviation in ● Engine running at high idle
mance simultane ● Working mode: H
in ous ● Travel Speed: Low Max.
mm Max. 200
Com operation of ● Amount of deviation measured 220
bined work for 20 m after traveling about 10 m
Opera equipment on a hard level ground
tions and travel ● For measuring posture see
“Travel 2” on page 3-12.

Shop Manual-June 2016 5-17

Standard Values SY500H Hydraulic Excavator

Applicable Models SY500H

Standard
Value for Permissi
Category Item Measurement Condition Unit
New ble Value
Machine

Perform
ance of
Hydraulic
● Pump speed: The pump's solenoid valve current value is 650 mA when the
Pump
pump runs at 2,000 rpm.
Pump Other Pump Judgement
Average
Output Output Standard Criteria
Check Pressure
Pressure Pressure Flow Q Lower
Point （MPa {kg/
（MPa {kg/ （MPa {kg/ （l/min） Limit Q
cm2}）
cm2}） cm2}） （l/min）
（P1＋P2）/ See the See the
Any P1 P2
2 graph graph
★ When measuring, bring the pump output pressure P1 and P2 as close as
possible to the average pressure.
★ When measuring with the pump mounted on the machine, if it is impossible to
set the engine speed to the specific speed with the fuel control dial, take the pump
output value and engine speed at the point of measurement, and use these values
as a base to calculate the pump output value at specific speed.

Machine attitudes applicable to performance test and testing procedure of all machine
models

5-18 Shop Manual-June 2016

 SY500H Hydraulic Excavator Standard Values

Control valve: Spool stroke

Fig.5-1

Swing 1: Swing brake angle, time taken to

start swing and time taken to swing

Fig.5-2

Swing 2: Hydraulic drift of swing

Fig.5-3

Shop Manual-June 2016 5-19

 Standard Values SY500H Hydraulic Excavator

Travel 1: Travel speed (without load)

Fig.5-4

Travel 2: Travel speed (actual run), Travel

deviation

Fig.5-5

Travel 3: Travel deviation

Fig.5-6

5-20 Shop Manual-June 2016

 SY500H Hydraulic Excavator Standard Values

Travel 4: Hydraulic drift of travel

Fig.5-7

Work equipment 1: Hydraulic drift of work

equipment

Fig.5-8

Work equipment 2: Boom speed

Fig.5-9

Shop Manual-June 2016 5-21

Standard Values SY500H Hydraulic Excavator

Work equipment 3: Arm speed

Fig.5-10

Work equipment 4: Bucket speed

Fig.5-11

Work equipment 5: Boom delay

Fig.5-12

5-22 Shop Manual-June 2016

SY500H Hydraulic Excavator Standard Values

Work equipment 6: Arm delay

Fig.5-13

Work equipment 7: Bucket delay

Fig.5-14

Shop Manual-June 2016 5-23

Standard Values SY500H Hydraulic Excavator

5-24 Shop Manual-June 2016

 SY500H Hydraulic Excavator Testing and Adjusting

Testing and Adjusting

6 Testing and Adjusting ..................................................................................................6-1

6.1 Exhaust Gas Color - Test .....................................................................................................6-3
6.2 Valve Clearance - Adjust......................................................................................................6-4
6.3 Compression Force - Test....................................................................................................6-6
6.4 Fuel Injection Timing - Test and Adjust ..............................................................................6-8
6.5 Engine Oil Pressure - Test ...................................................................................................6-9
6.6 Engine Speed Sensor - Adjust ..........................................................................................6-11
6.7 A/C Compressor Belt Tension - Check and Adjust.........................................................6-11
6.8 Swing Bearing Clearance - Check................................................................................... 6-12
6.9 Track Tensioning device - Check and Adjust ................................................................. 6-14
6.10 Oil in hydraulic circuits - Test and Adjust ...................................................................... 6-15
6.11 Control Oil Circuit Pressure - Check and Adjust.......................................................... 6-19
6.12 Solenoid Valve Output Pressure - Test ......................................................................... 6-20
6.13 Pilot Valve Output Pressure - Test................................................................................. 6-22
6.14 Work Equipment and Swing PPC Valves - Adjust....................................................... 6-24
6.15 Hydraulic Drift of Work Equipment - Test...................................................................... 6-24
6.16 Remaining Pressure in Hydraulic Lines - Relieve....................................................... 6-26
6.17 Oil Leakage Amount - Test ............................................................................................. 6-27
6.18 Air in Each Component - Purge ..................................................................................... 6-31
6.19 Sensors - Test................................................................................................................... 6-33
6.19.1 Coolant temperature sensor................................................................................. 6-33
6.19.2 Checking engine spe............................................................................................. 6-34
6.19.3 Pressure sensor ..................................................................................................... 6-34
6.19.4 Fuel level sensor .................................................................................................... 6-35

Shop Manual-June 2016 6-1

Testing and Adjusting SY500H Hydraulic Excavator

WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.

6-2 Shop Manual-June 2016

 SY500H Hydraulic Excavator Testing and Adjusting

6.Testing and Adjusting

6.1 Exhaust Gas Color - Test
Testing tools

ID Model Part Name

Smoke
1 YDJ-2006
meter
2 SV-2TY Opacimeter

CAUTION
• Hot part can cause burns. Do not touch
any hot parts when you install or remove a
testing tool.

1. Testing with smoke meter

A. Put the filter paper in the smoke meter.

B. Insert the waste gas intake pipe into the ex-

haust pipe.

C. Start the engine and keep the engine run-

ning until engine coolant temperature is within
the operational range.

D. When engine speed increases suddenly or

is kept at high idle, direct exhaust gas through
smoke meter to the filter paper. Fig.6-1
E. Remove the filter paper from the smoke
meter. Read the smoke value through the ap-
paratus provided.

F. Remove the testing tools after testing.

Make sure the machine goes back to its nor-
mal state.

Shop Manual-June 2016 6-3

 Testing and Adjusting SY500H Hydraulic Excavator

2. Measuring with opacimeter

A. Mount the opacimeter onto the exhaust

pipe by clamping it to the pipe outlet.

Fig.6-2

B. Open the opacimeter and preheat it for

about 15 minutes.

C. Start the engine and keep the engine run-

ning until engine coolant temperature is within
the operational range.

D. When engine speed increases suddenly or

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

E. Remove the test i n g tools a fter measur-

ing. Make sure the machine goes back to its
normal state. Fig.6-3

6.2 Valve Clearance - Adjust

Service standard (unit: mm)

Standard Correction
Location Service Item Limits
Value Method
Valve Intake 0.4 — Adjust
— clearance
(engine cold) Exhaust 0.4 — Adjust

Special tool

Location Tool name and shape Part number Application

Adjusting valve
— MH061359
clearance

6-4 Shop Manual-June 2016

 SY500H Hydraulic Excavator Testing and Adjusting

Check and adjust the valve clearance in cold

state according the to the following method:

Checking

1. Remove the rocker arm cover.

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

the top dead center of compression stroke by
following the procedure below.
• Turn the engine until the mark 16 on the fly-
wheel aligns with the pointer on sight glass
of the flywheel housing.
• Turn the No.1 piston or the No.6 piston to
the top dead center of compression stroke.

NOTICE
When the rocker arm at the intake side and
rocker arm at the exhaust side cannot be
turned with hands, it is indicated that the pis-
Fig.6-4
ton has reached the top dead center of com-
pression stroke. Turning the engine by one
more turn, the top dead center of compres-
sion stroke of No.1 piston and No.6 piston
interchanges.

3. Adjust the valve clearance in the underside

sheet. The assembly marked by a dot ( ○ )
can be adjusted.

Adjustment sheet
Cylinder 1 2 3 4 5 6
Valve IN EX IN EX IN EX IN EX IN EX IN EX
When the No.1
piston is at the
○ ○ ○ ○ ○ ○
top dead
center
When the No.6
piston is at the
○ ○ ○ ○ ○ ○
top dead
center

Shop Manual-June 2016 6-5

 Testing and Adjusting SY500H Hydraulic Excavator

A. When a feeler gauge is used for such

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

B. If the feeler gauge moves easily in the

clearance, it is impossible to obtain accurate
result.

4. If the measured value is out of specification,

readjustment shall be performed according to
the following method.

Fig.6-5

Adjusting

1. In adjustment of valve clearance, loosen

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

Fig.6-6

2. After adjustment, stop the turning motion of

the adjusting screw with a screwdriver, and
tighten the locknut.

Locknut: 78Nm {8 kgm}

3. Go on with the next step until all valve

clearances marked with a black dot have
been adjusted.

4. Check the clearances again with the feeler

gauge. Readjustment should be made if the
value is out of specification.
Fig.6-7

6.3 Compression Force - Test

Service Standard

6-6 Shop Manual-June 2016

 SY500H Hydraulic Excavator Testing and Adjusting

Standard Correction
Location Service Item Limits
Value Methods
Each cylinder 2940kPa 2260 kPa
Test
(at 200 rpm) {30kgf/cm2} {23kgf/cm2}
Compression Differential
—
force pressure 196 kPa { ≤
— Test
between 4kgf/cm2 }
cylinders

Special Tool

Symbol Tool Name and Shape Part Number Application

Measuring
1-8531-7019-0
compression force

Note: Before testing, make sure that the en-

gine oil, start motor and battery are in normal
condition.

1. Disconnect the ground cable of battery.

CAUTION
If you turn the ignition switch to the closed
(OFF), please do not make the battery cable
disconnected for a minute.

2. Remove the admission line.

Fig.6-8
3. Remove the exhaust gas recirculation
cooler.

4. Remove the glow plug from the cylinder.

NOTICE
Remove all glow plugs from the cylinders.

5. Remove the injector harness connector

from the lower cover.

6. Install the special tool to the cylinder

assembly.

Shop Manual-June 2016 6-7

 Testing and Adjusting SY500H Hydraulic Excavator

NOTICE
Insert the connector of pressure gauge into
the glow plug hole, and then install the pres-
sure gauge.

7. Measure the compression pressure.

NOTICE
Start the engine, and then read compression
pressure from the pressure gauge when the
engine is at the speed of about 200r/min.

8. Measure the compression pressure of all

cylinders

NOTICE
You should measure the compression pres-
sure when the engine is refrigerant

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

6.4 Fuel Injection Timing - Test and Adjust

Service standard

Correction
Location Service Item Standard Value Limits
Method
Fuel injection
— 0° — Adjust
timing (BTDC)

Tightening torque

Symbol Parts Tightened Tightening Torque Remark

– Timing adjusting bolt 31 (3.2) —

6-8 Shop Manual-June 2016

 SY500H Hydraulic Excavator Testing and Adjusting

Testing

1. Reverse the crankshaft once to make it to

90 degrees before top dead center position.
Rotate the crankshaft forward to make fly-
wheel engraved lines P-P align with timing
pointer. Therefore, check the No. 1 cylinder to
make sure it in the vicinity of compression top
dead center.

Fig.6-9

2. If the groove is inconsistent, loosen the two

coupling bolts. Rotate the coupling to make
fuel supply pump align with the couplingside
groove, and then tighten coupling.

1） Coupling bolts

2）Coupling-side groove

3） Pump-side groove

4） Bolt with pin

Tightening torque:
Fig.6-10
Common fuel tank side：54N.m{5.5kgf.m}

Supply pump side: 44N.m{4.5kgf.m}

6.5 Engine Oil Pressure - Test

Service Standard

Standard Correction
Location Service Item Limits
Value Method
Engine oil
Max. speed, 540kPa｛6kg 49kPa (0.5kgf/
— pressure at Adjust
unloaded f/cm2｝ cm2)
70~90℃
Tightening torque

Shop Manual-June 2016 6-9

 Testing and Adjusting SY500H Hydraulic Excavator

Unit: N·m (kgf·m)

Location Part Tightened Tightening Torque Remark
Engine oil pressure Check when engine is
1 18{1.8}
switch cold.
2 sleeve

1. Remove the engine oil pressure sense (1).

2. Mount the adaptor (2) to where the engine

oil pressure switch has been removed. Mount
an engine oil pressure gauge to the adaptor.

3. Preheat the engine until engine oil tempera-

ture reaches 70-90℃ .

4. Measure respectively the unloaded engine

oil pressure at minimum speed and maximum
speed. If the measured value is lower than the Fig.6-11

specified standard value, check the entire lu-

brication system.

5. Reinstall pressure sense (1) after measure-

ment. Tighten the pressure sense (1) to the
specific torque.

• The engine must be cold when installing the

pressure switch (1).

Fig.6-12

6-10 Shop Manual-June 2016

 SY500H Hydraulic Excavator Testing and Adjusting

6.6 Engine Speed Sensor - Adjust

★ Disconnect accumulator ground wire、
connector for transitional harness of crank
shaft location sensor. And then remove crank
shaft location sensor.

★ Remove the engine speed sensor (1) be-

fore adjusting. Check for presence of metal
chips and for damaged top. Restore the
sensor.

1. Screw on the sensor (1) until its end con- Fig.6-13

tacts with the flywheel housing (2).

2. Tighten the sensor (1) with the nut.

Nut: 10N•m {1.0kgfm}

3. Install crank shaft location sensor and accu-

mulator ground wire.

4. Make sure that the engine speed is dis-

played correctly on the monitor after
adjustmen

6.7 A/C Compressor Belt Tension - Check and Adjust

Checking

Press the intermediate point of the belt be-

tween the drive pulley and the compressor
belt pulley with a finger force of about 58.8 N
(6kgf), and measure deflection (A) of the belt,
which shall be 5~8 mm (0.20 in~0.31in).

Fig.6-14

Shop Manual-June 2016 6-11

 Testing and Adjusting SY500H Hydraulic Excavator

Adjusting

★ If the belt deflection is abnormal, adjust it

according to the following procedure.

1. Loosen the bolts (1) and (2).

2. Move the compressor (3) and the bracket

(4) together to adjust belt tension.

3. After positioning the compressor (3), tighten

the bolts (1) and (2).

4. Recheck belt tension after adjustment. Fig.6-15

Reference

Use a tensiometer to check the compressor

belt tension.
New Belt Used Belt
637±108 N 441±88.2 N
{65±11 kgf} {45±9 kgf}

NOTICE
• Check each belt for damage. Check the V-
groove and the V-belt for wear. In addition,
it is especially important to keep the V-belt
free from friction with bottom of the V-
groove.
• Contact local Sany dealer and replace the
belt in case of the following conditions.

– The fan belt has been stretched and lit-

tle margin is left for adjustment.

– Cuts or cracks are found in the belt.

– Abnormal sliding or noise.

• When a new belt is mounted, readjust the

belt tension after one hour operation.

6.8 Swing Bearing Clearance - Check

Measuring tool

6-12 Shop Manual-June 2016

 SY500H Hydraulic Excavator Testing and Adjusting

Symbol Part Number Part Name

H 60033930 Dial gauge

★ Follow the steps below when you are

checking the clearance of swing bearing.

CAUTION
• Park your machine on a level ground. Low-
er the work equipment to the ground.
• Do not put your hands or feet under the
undercarriage during testing.

1. Fix the dial gauge (H) to the track frame

and make the pointer point the lower end of
the outer race.

Fig.6-16

2. Place the work equipment to the maximum

reach position. Raise the bucket to a height
that the bucket tips and the swing frame bot-
tom are on the same level.

★ At the moment, the front of upper structure

lowers while the rear rises.

Fig.6-17

Shop Manual-June 2016 6-13

 Testing and Adjusting SY500H Hydraulic Excavator

3. Reset the dial gauge (H) to zero.

4. Set the arm almost perpendicular to the

ground and lower the boom until the front
track shoe tilts.

★ At the moment, the front of upper structure

rises while the rear lowers.

5. Read the dial gauge (H).

★ The value indicated by the dial gauge (H) is

the clearance of the bearing.
Fig.6-18
★ For more information on standard values
see “Swing bearing” on page 4-12.

6. Restore the machine to the condition of

step 2. Check the dial gauge (H) to see if it
reads zero.

★ Repeat step 3 through step 5 if the dial

gauge (H) reads a value other than zero.

6.9 Track Tensioning device - Check and Adjust

Checking

1. Move your machine forward at a distance

that is equal to the length of track on the
ground. Keep running the engine at low idle.
Park your machine slowly.

2. Place a straight edge on top of the track

grousers between the idler (1) and the front
carrier roller (2).
★ A straight edge of angle steel is recom-
mended for this purpose as angle steel bends
Fig.6-19
little. In addition, an L-shaped beam has good
performance against bending.

3. Measure the maximum clearance (a) be-

tween the upper surface of track and the bot-
tom of straight edge.
• Max. clearance (a): 10~30 mm(0.4~1.2 in)

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 SY500H Hydraulic Excavator Testing and Adjusting

Adjusting

★ If the track tension is incorrect, adjustment

is to be made in the following way.

1. Decreasing the tension

A. Loosen the valve (1) to discharge grease.
Tighten the valve after discharging.

WARNING
• Never loosen the valve more than one turn.
If it is loosened too much, the highly-pres-
Fig.6-20
surized grease behind the valve can cause
it to eject.

B. Recheck the track tension as per the above

method after adjustment.

2. Increasing the tension

A. Add grease through the grease fitting (2)
with a grease gun.
B. Recheck the track tension as per the above
method after adjustment.

★ Add grease until the gap (b) between the id-

ler guide and the track frame end becomes
zero. If the tension is till low, it indicates that
the pins and bushings are seriously worn. Re-
place the pins and bushings, or remove a
track shoe.

Fig.6-21

6.10 Oil in hydraulic circuits - Test and Adjust

Testing and adjusting tools

ID Part Number Part Name

Hydraulic
— 60038932
Tester

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 Testing and Adjusting SY500H Hydraulic Excavator

B210770000
Adaptor
084

★ The hydraulic pressure in work equipment,

swing and travel (hydraulic pump output pres-
sure) circuits can be viewed on the monitor.

Testing

1. Preparatory work before measuring

Lower the work equipment to the ground and

stop the engine. After the engine is stopped,
operate the control levers for several times in
order to release the remaining pressure in hy-
draulic circuits. Open the butterfly nut on the
breather valve. Press the relief button to re-
lease pressure in the hydraulic tank.

A. Remove the plug (1) and plug (2) for testing

the hydraulic pressure.

• Plug (1): For oil circuit of back hydraulic

pump Fig.6-22
• Plug (2): For oil circuit of front hydraulic
pump

B. Install the priming adaptor and connect it to

the hydraulic tester.

★ Use an oil pressure gauge with a capacity

of 40 MPa {408 kg/cm2}.

C. Start the engine and keep it running until

the hydraulic pressure rises to a point within
the operational range.

2. Testing the unloading pressure

A. Start the engine.

B. Test the hydraulic pressure when the en-

gine is running at high idle and all control lev-
ers are in neutral position.

★ The hydraulic pressure indicated is the

pressure when the unloading valve unloads.

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 SY500H Hydraulic Excavator Testing and Adjusting

3. Testing the relief pressure of work

equipment

A. Start the engine and move the cylinder to

be measured to its stroke end.

B. Test the hydraulic pressure when the en-

gine is running at high idle and the cylinder is
in relief condition.

★ The hydraulic pressure indicated is the

pressure when the main relief valve is in relief
condition.

4. Testing the swing relief pressure

A. Start the engine. Reach out the work equip-

ment as far as possible. Lower the work
equipment on the ground in order to restrict
swinging.

B. Test the hydraulic pressure when the en-

gine is running at high idle and the swing cir-
cuit is in relief condition.

★ The hydraulic pressure indicated is the

pressure when the swing motor relief valve is
in relief condition.

★ The relief pressure of swing motor is lower

than the main relief pressure.

5. Testing the relief pressure of travel circuit

A. Start the engine and lock the travel

mechanism.

Place pin (1) between the sprocket and the

track frame in order to block the travel
mechanism.

B. Test the hydraulic pressure when the en-

gine is running at high idle and the travel cir-
cuit is in relief condition.

★ The hydraulic pressure indicated is the

Fig.6-23
pressure when the main relief valve is in relief
condition. When the travel circuit is in relief

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 Testing and Adjusting SY500H Hydraulic Excavator

condition, the pressure indicated is always the

pressure at high relief.

Adjusting

★ The boom unloading valve and safety valve

are not adjustable.

1. Adjusting the main relief pressure (at the

high pressure setting side)

★ If the high relief pressure in work equipment

and travel circuits is abnormal, adjust the high
pressure setting side of the main relief valve
(3) according to the following procedure.

Fig.6-24

A. Disconnect the pilot hose.

B. Loosen the locknut (4). Turn the adjusting

screw (5) to adjust the pressure.

★ The pressure increases as the retainer is

turned right.

The pressure decreases as the retainer is

turned left.

★ Each turn of the retainer approximates:

12.5 MPa {128 kg/cm2}
Fig.6-25
Locknut: 49±6 Nm

C. Check the pressure again after adjustment.

Test the pressure according to the procedure
described above.

★ Connect the pilot hose before testing the

pressure.

★ Adjustment of the high pressure setting side

will affect the low pressure setting side. The
low pressure setting side is, therefore, to be
adjusted too.

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 SY500H Hydraulic Excavator Testing and Adjusting

2. Adjusting the swing relief pressure

★ If the swing relief pressure is abnormal, ad-

just the swing motor relief valve (6) according
to the following procedure.

Fig.6-26

A. Loosen the locknut (7). Turn the adjusting

screw (8) to adjust the pressure.

★ The pressure increases as the retainer is

turned right. The pressure decreases as the
retainer is turned left.

★ Each turn of the retainer approximates:

6.71 MPa { 68.4 kg/cm2}

Locknut: 78-103 Nm{8.0-10.5 kgm}

B. Check the pressure again after adjustment.

Test the pressure according to the procedure Fig.6-27
described above.

6.11 Control Oil Circuit Pressure - Check and Adjust

Checking and adjusting tools

ID Part Number Part Name

Hydraulic
21008760
Tester
—
B210770000
Adaptor
084

Testing

Lower the work equipment to the ground and

stop the engine. After the engine is stopped,
operate the control levers for several times in
order to release the remaining pressure in hy-
draulic circuits. Open the butterfly nut on the

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 Testing and Adjusting SY500H Hydraulic Excavator

breather valve. Press the relief button to re-

lease pressure in the hydraulic tank.

1. Remove the plug (1) for testing the hydraul-

ic pressure.

2. Install the priming adaptor and connect it to

the hydraulic tester.
★ Use an oil pressure gauge with a capacity
of 6 MPa {60 kg/cm2}

3. Start the engine and keep it running until

the hydraulic pressure rises to the operational
range.
Fig.6-28
4. Test the oil pressure with the engine run-
ning at high idle and all control levers in neu-
tral position.

5. Remove all measuring tools after measure-

ment. Make sure that the machine returns to
its normal condition.
★ Unloading valve and safety valve are not
adjustablet.

6.12 Solenoid Valve Output Pressure - Test

Testing tools

ID Part Number Part Name

Hydraulic
21008760
Tester
—
B210770000
Adaptor
084

★ Make sure that the initial pressure of control

oil circuit is normal before testing the output
pressure of solenoid valve.

● Lower the work equipment to the ground

and stop the engine. After the engine is
stopped, operate the control levers for several
times in order to release the remaining pres-
sure in hydraulic circuits. Open the butterfly

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 SY500H Hydraulic Excavator Testing and Adjusting

nut on the breather valve. Press the relief but-

ton to release pressure in the hydraulic tank.

1. Disconnect the hose of solenoid valve in or-

der to test the pressure at the outlet.

No. Solenoid valves to be tested

1
2
3
4

2. Install a tee to location (A) on each solenoid

valve and connect the hose. Fig.6-29

3. Mount the adaptor onto the tee and connect

it to the hydraulic tester.

★ Use a hydraulic tester with a capacity of 6

MPa {61 kg/cm2} .

4. Start the engine and keep it running until

the hydraulic oil temperature rises to the op-
erational range.

5. Run the engine at full speed. Operate the

control levers to open or close each solenoid
valve, and measure the pressure.

★ The function of each solenoid valve can be

checked through the monitor's monitoring
function. (This is a special function of the
monitor.)

★ When each output pressure reads the fol-

lowing values, the solenoid valve is normal.

Table 1: Travel high speed、 Boom Priority

to swing

Solenoid Valve Output Pressure

OFF (de-
0{0}
energized)
3.9~4.1MPa{39~41kgf/
ON (energized)
cm2}

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 Testing and Adjusting SY500H Hydraulic Excavator

Table 2: Boom 2 confluence、 Boom Priority

to bucket

Solenoid valve Output pressure

OFF (de-
0{0}
energized)
3.0~3.9MPa{30~39kgf/
ON (energized)
cm2}

Table 3:PPC lock solenoid valve

Functional state Function
Hyd lockout Lock OFF
control Unlock ON

6. Remove all measuring tools after measure-

ment. Make sure that the machine returns to
its normal condition.

6.13 Pilot Valve Output Pressure - Test

Testing tools

ID Part Number Part Name

21008760 Hydraulic Tester
—
B210770000084 Adaptor

★ Make sure that the initial pressure of control

oil circuit is normal before testing the output
pressure of pilot valve.

1. Remove the pilot oil pressure switch.

Fig.6-30

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 SY500H Hydraulic Excavator Testing and Adjusting

Oil circuit Oil circuit

No. No.
tested tested
Boom Left
1 7
UP swing
Boom Right
2 8
DOWN swing
Bucket Left
3 9
DIG travel
Bucket Right
4 10
DUMP travel
Arm
5
OUT
6 Arm IN

2. Install the adaptor and connect it to the hy-

draulic tester.

★ Use a hydraulic tester with a capacity of 6

MPa{61 kg/cm2}.

3. Start the engine and keep it running until

the hydraulic oil temperature rises to the op-
erational range.

4. Measure the output pressure when the en-

gine is running at high idle and all control lev-
ers of the tested circuit are in neutral position.

★ When the measured output pressure reads

the following values, the pilot valve is normal.

Control lever Hydraulic pressure

Neutral position 0{0}
Close to the average
initial pressure of oil
Full stroke control circuit
(See Table of
Standard Values)

5. Remove all the tools after testing. Make

sure that the machine returns to its normal
condition.

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 Testing and Adjusting SY500H Hydraulic Excavator

6.14 Work Equipment and Swing PPC Valves - Adjust

★ If the play of work equipment or swing con-
trol lever is too big, adjustment can be made
through the following steps.

1. Remove the work equipment and swing pi-

lot valve assembly.

2. Remove the bellows (1).

3. Loosen the locknut (2). Screw on the disc

(3) until it contacts with the four heads of
plunger (4).

★ Do not move the plunger.

4. When the disc (3) is fixed, tighten the lock-

nut (2) to the specified torque.

Locknut: 98~127 Nm {10~13 kgm}

Fig.6-31
5. Restore the bellows (1).

6. Restore the work equipment and swing pilot

valve assembly.

6.15 Hydraulic Drift of Work Equipment - Test

★ If hydraulic drift occurs to the work equip-
ment (cylinder), check it according to the fol-
lowing procedure. It is to determine whether
the failure is caused by cylinder seal or control
valve.

1. Check the boom and bucket cylinders.

A. Park your machine in an attitude as shown

in the illustration on the right, and stop the
engine.

★ Load the bucket fully with soil or apply rated

load to the bucket.

B. Operate the control levers in order to keep

the boom in the UP position and the bucket in
the DIG position.

● If the lowering speed increases, it is failure Fig.6-32

of the cylinder seal.

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 SY500H Hydraulic Excavator Testing and Adjusting

● If nothing changes, it is failure of the control

valve.

★ Operate the control levers with engine start

switch in the ON position.

★ If the pressure in accumulator drops,

charge the accumulator again by running the
engine for about 10 seconds.

2. Check the arm cylinder.

A. Park your machine in an attitude as shown

in the illustration on the right. The distance be-
tween the arm cylinder and the digging stroke
end is 100 mm. Stop the engine.

B. Operate the control levers in order to place

the arm in the digging position.

● If the lowering speed increases, it is failure

of the cylinder seal.

● If nothing changes, it is failure of the control Fig.6-33

valve.

★ Operate the control levers with engine start

switch in the ON position.

★ If the pressure in accumulator drops,

charge the accumulator again by running the
engine for about 10 seconds.

[Ref.] If the hydraulic drift is caused by failure

of the cylinder seal, the reason for increase of
lowering speed during the above operation is
described below:

A. If the machine is set in the above position

(where the holding pressure is applied to the
head end), the oil leaks from the head end to
the rod end. The pressure in the rod end is in-
creased as a result.

B. As the pressure in the rod end decreases,

the pressure in the head end increases in or-
der to keep it balanced. This process is

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 Testing and Adjusting SY500H Hydraulic Excavator

repeated until balance is reached at a certain

level depending on the amount of leakage.

C. When the pressure is balanced, the lower-

ing speed decreases. If the control levers are
operated according to the above procedure,
the oil circuit in the rod end opens to the drain
circuit (while the head end is closed by a
check valve), and the oil flows to the drain cir-
cuit from the rod end. As a result, the lowering
speed increases.

3. Check the pilot valve.

Test the hydraulic drift respectively while the

accumulator is pressurized and the hydraulic
lockout control in the LOCK/FREE position.

★ Operate the control levers with engine start

switch in the ON position.

★ If the pressure in accumulator drops,

charge the accumulator again by running the
engine for about 10 seconds

★ If there is a difference in hydraulic drift be-

tween the LOCK position and the FREE posi-
tion, it is the failure (internal fault) of the pilot
valve.

6.16 Remaining Pressure in Hydraulic Lines - Relieve

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

★ Even if there is no pressure remaining in the swing motor line and the travel motor line, they will
be influenced by the internal pressure of hydraulic tank. The breather valve must therefore be
opened to release pressure prior to operation.

1. Stop the engine, loosen the butterfly nut on the breather valve, and press the release button to
release the pressure in hydraulic tank.

2. Turn the engine start switch to the ON position and operate the control levers for several times.
★ The pilot lock valve must be energized. Operate the control levers with the engine start switch in
the ON position.
★ Operate the control levers 2 or 3 times to release the pressure in the accumulator.

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 SY500H Hydraulic Excavator Testing and Adjusting

3. Start the engine and keep the engine running at low idle for about 10 seconds in order to in-
crease the pressure in accumulator. And then stop the engine.

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

6.17 Oil Leakage Amount - Test

1. Testing the oil leakage amount of boom
cylinder

A. Start the engine and keep the engine run-

ning until the hydraulic oil temperature
reaches the operational range. And then fully
extend the boom cylinder.

Release the pressure remaining in the cir-

cuits. “Air in Each Component - Purge” on
page 6-34.

B. Disconnect the hose (1) on the cylinder rod

end and plug the hose opening. Fig.6-34

Take care not to disconnect the hose on the

cylinder head end.

C. Start the engine and apply relief pressure

to the head end of the cylinder while the en-
gine is running at high idle.

D. Hold this state for 30 seconds and then test

the amount of oil leakage for one minute.

E. Make sure that the machine returns to its

normal condition after testing.

2. Testing the oil leakage amount of arm

cylinder

A. Start the engine and keep the engine run-

ning until the hydraulic oil temperature
reaches a point within the operational range.
Fully extend the arm cylinder.

Release the pressure remaining in the cir-

cuits. “Remaining Pressure in Hydraulic Lines
- Relieve” on page 6-29.

B. Disconnect the hose (2) on the cylinder

head end and blind the hose end with a cap. Fig.6-35

Shop Manual-June 2016 6-27

 Testing and Adjusting SY500H Hydraulic Excavator

Take care not to disconnect the hose on the

cylinder head end.

C. Start the engine and apply relief pressure

to the head end of the cylinder while the en-
gine is running at high idle.

D. Hold this state for 30 seconds. Test the

amount of oil leakage for one minute.

E. Make sure that the machine returns to its

normal condition after testing.

3. Testing the oil leakage amount of bucket

cylinder

A. Start the engine and keep the engine run-

ning until the hydraulic oil temperature
reaches the operational range. Fully extend
the bucket cylinder.

Release the pressure remaining in the cir-

cuits. “Remaining Pressure in Hydraulic Lines
- Relieve” on page 6-29.

B. Disconnect the hose (3) on the cylinder rod

end and blind the hose end with a cap.

Take care not to disconnect the hose on the

cylinder head end. Fig.6-36

C. Start the engine and apply relief pressure

to the head end of the cylinder while the en-
gine is running at high idle.

D. Hold this condition for 30 seconds and

them test the amount of oil leakage for one
minute.

E. Make sure that the machine returns to its

normal condition after testing.

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 SY500H Hydraulic Excavator Testing and Adjusting

4. Testing the oil leakage amount of swing

motor

A. Fully extend the work equipment. Lower

the bucket on the ground and raise the ma-
chine slightly. Stop the engine.

B. Disconnect the drain hoses (4) . Blind the

hose ends with caps.

C. Start the engine and apply relief pressure

to the head end of the cylinder while the en-
gine is running at high idle. Measure the
amount of oil leakage under this condition.

★ Hold the condition described in step 3) for Fig.6-37

30 seconds. Measure the amount of oil leak-
age for one minute.

★ After the first testing, turn the upper struc-

ture 180 ° and measure the leakage again in
the same way.

D. Make sure that the machine returns to its

normal condition after testing.

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 Testing and Adjusting SY500H Hydraulic Excavator

5. Testing the oil leakage amount of the travel

motor

A. Remove the cover of the travel motor.

B. Start the engine and lock the travel.

Insert the pin (1) between the sprocket and

the track frame in order to prevent traveling.

C. Disconnect the drain hose (6) of the travel

motor. Blind the hose end with a cap.

D. Start the engine and apply relief pressure

Fig.6-38
to the head end of the cylinder while the en-
gine is running at high idle. Measure the
amount of oil leakage under this condition.

During testing, misoperation of the control lev-

ers can cause serious accidents. Make sure
that all signals are correct.

★ Hold the condition described in step 4) for

30 seconds. Test the amount of oil leakage for
one minute.

★ Rotate the motor slightly. Swap the posi-

tions of the oil distributor and the cylinder and
Fig.6-39
of the cylinder and piston. Repeat the testing
several times.

E. Make sure that the machine returns to its

normal condition after testing.

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 SY500H Hydraulic Excavator Testing and Adjusting

6.18 Air in Each Component - Purge

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

1. Purging air from hydraulic pump

A. Loosen the air bleeder (1) and check that

oil oozes out through the air bleeder.

B. Tighten the air bleeder (1) if oil is seen.

Bleeder: 7.8~9.8 Nm{0.8~1.0 kgm}

★ Engine starting precautions

Run the engine at low idle for 10 minutes after

purging the air according to the above
procedure.
Fig.6-40
2. Purging air from hydraulic cylinder

A. Start the engine and keep the engine run-

ning at low idle for 5 minutes.

B. Raise or lower the boom 4 or 5 times with

the engine running at low idle.

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 Testing and Adjusting SY500H Hydraulic Excavator

★ Be careful not to apply relief pressure. Stop

the piston when the piston rod is about 100
mm ahead its stroke end.

C. Repeat step 2) with the engine running at

high idle.

D. While running the engine at low idle, move

the piston rod to the stroke end and apply re-
lief pressure.

E. Purge the air from the arm cylinder and

bucket cylinder by performing step 2) through
step 4).

★ When a new cylinder is installed for re-

placement, purge the air from the new cylin-
der before mounting it to the work equipment.
Especially the boom cylinder, once mounted
to the work equipment, its piston rod is unable
to reach its stroke end in lowering operation.
Therefore, the air must be purged from the
boom cylinder before it is mounted to the work
equipment.

3. Purging air from swing motor

A. Start the engine and run the engine at low

idle.

B. Purge the air from the swing motor by turn-

ing the upper structure slowly.

4. Purging air from travel motor

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 SY500H Hydraulic Excavator Testing and Adjusting

A. Start the engine and run the engine at low

idle.

B. Loosen the drain pipe (2) and check that oil

oozes out through the air bleeder.

C. Tighten the air drain pipe (2) if oil is seen.

27.5~35.3 Nm {2.8~3.6 kgm}

Fig.6-41

6.19 Sensors - Test

6.19.1 Coolant temperature sensor

• Put the sensor into a container filled with or-

ganic oil.
• Heat the oil to specified level and stir the oil
at the same time.
• Check the resistance value between termi-
nal 1 and body.

50℃ 867.2Ω
60℃ 586.5Ω
Standard 80℃ 322.2Ω
values 100℃ 188.4Ω
106℃ 168.4Ω Fig.6-42
120℃ 116.3Ω

• If measured value exceeds the standard

value given, replace the sensor.

Shop Manual-June 2016 6-33

Testing and Adjusting SY500H Hydraulic Excavator

6.19.2 Checking engine spe

• Check the resistance between terminals 1

and 2.

Standard value at
2.3±0.2kΩ
25°C

• If measured value exceeds the standard

value given, replace the sensor.

If engine speed sensor is not tightened

enough, it probably cause sensor output
signal failure. The engine speed sensor
must be tightened to specified torque.
Fig.6-43

6.19.3 Pressure sensor

• Input voltage: 4.75 - 5.25 VDC

• Output voltage: 0.5 - 4.5
• Range of testing pressure: 0-50 Bar

Fig.6-44

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SY500H Hydraulic Excavator Testing and Adjusting

6.19.4 Fuel level sensor

• Swing the float up and down to check the

angle of rotation of effective radius, which
should be 105°.
• Swing the float up and down to check the
vertical distance between the upper position
and lower position of the float, which should
be 500 mm.
• Move the float to top end. Use a multimeter
to check the resistance between sensor ter-
minal R and ground. The resistance value
(Ru) should be not more than 9.6 Ω.
• Move the float to the lower end. Check the
resistance between sensor terminal R and Fig.6-45
ground. The resistance value (Rd) should
be not lower than 86 Ω.

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Testing and Adjusting SY500H Hydraulic Excavator

6-36 Shop Manual-June 2016

 SY500H Hydraulic Excavator Troubleshooting

Troubleshooting

7 Troubleshooting ..............................................................................................................7-1
7.1 General ...................................................................................................................................7-3
7.2 Checks before Troubleshooting ..........................................................................................7-4
7.3 Troubleshooting Types and Steps ......................................................................................7-5
7.3.1 Troubleshooting types ................................................................................................7-5
7.3.2 Troubleshooting steps ................................................................................................7-5
7.4 Connectors.............................................................................................................................7-7
7.4.1 List of connectors ........................................................................................................7-7
7.4.2 Connector locations ..................................................................................................7-11
7.4.3 SWP connectors....................................................................................................... 7-13
7.4.4 A/AMP connectors ................................................................................................... 7-14
7.4.5 DT connectors........................................................................................................... 7-14
7.5 Troubleshooting with an Event Code .............................................................................. 7-16
7.6 Troubleshooting the Electrical System (E-Mode).......................................................... 7-23
7.7 Troubleshooting the Hydraulic and Mechanical System (H-Mode) ............................ 7-47

Shop Manual-June 2016 7-1

Troubleshooting SY500H Hydraulic Excavator

WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.

7-2 Shop Manual-June 2016

 SY500H Hydraulic Excavator Troubleshooting

7.Troubleshooting
7.1 General

WARNING
• Stop the machine on a level ground, and check that lock pins, blocks, and parking brake are
effective.
• When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
• If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
• Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
• When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
• When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure fi rst. When installing measuring equipment, be sure to
connect it properly.

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

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

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

1. When carrying out troubleshooting, do not hurry to disassemble the components. If components
are disassembled immediately any fault occurs:
• Parts that have no connection with the fault or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the fault.
It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior in-
vestigation and to carry out troubleshooting in accordance with the fi xed procedure.

2. Points to ask user or operator:

A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the fault occurred?
C. Did the fault occur suddenly, or were there problems with the machine condition before this?
D. Under what conditions did the fault occur?
E. Had any repairs been carried out before the fault? When were these repairs carried out?
F. Has the same kind of fault occurred before?

3. Check before troubleshooting

A. Check the oil level.

Shop Manual-June 2016 7-3

 Troubleshooting SY500H Hydraulic Excavator

B. Check for any external leakage of oil from the piping or hydraulic equipment.
C. Check the travel of the control levers.
D. Check the stroke of the control valve spool.
E. Other maintenance items can be checked externally, so check any item that is considered to be
necessary.

4. Confirming fault
Confirm the extent of the fault yourself, and judge whether to handle it as a real fault or as a prob-
lem with the method of operation, etc.
When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.

5. Troubleshooting
Use the results of the investigation and inspection in Items 2 – 4 to narrow down the causes of
fault, then use the troubleshooting flowchart to locate the position of the fault exactly.
● The basic procedure for troubleshooting is as follows.
A. Start from the simple points.
B. Start from the most likely points.
C. Investigate other related parts or information.

6. Measures to remove root cause of fault

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

7.2 Checks before Troubleshooting

Item Criterion Remedy

1. Check fuel level and type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
4. Check hydraulic oil strainer — Clean, drain
Lubricat
5. Check swing drive oil level — Add oil
ing oil,
coolant 6. Check engine oil level (in oil pan) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
Electri 1. Check for looseness, corrosion of battery Tighten or
—
cal terminal and wiring replace
equip 2. Check for looseness, corrosion of alternator Tighten or
—
ment terminal and wiring replace

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 SY500H Hydraulic Excavator Troubleshooting

3. Check for looseness, corrosion of start motor Tighten or

—
terminal and wiring replace
Hydraul 1. Check for abnormal noise and smell — Repair
ic, 2. Check for oil leakage — Repair
mechan
ical
equip 3. Bleeding air — Bleed air
ment
1. Check battery voltage (with engine stopped) 20-30V Replace
2. Check electrolyte level — Add or replace
3. Check for discolored, burnt, exposed wiring — Replace
4. Check for missing wiring clips and hanging
— Repair
wiring
Elec
trics, Disconnect
5. Check for wet wires (esp. wet connectors or
electri — connector and
terminals)
cal dry
equip 6. Check for blown or corroded fuses — Replace
ment
After running
7. Check alternator voltage (with engine speed at for several
Replace
middle or higher) minutes:
27.5~ 29.5V
8. Check operating sound of battery relay (when
— Replace
start switch is turned ON or OFF)

7.3 Troubleshooting Types and Steps

7.3.1 Troubleshooting types

Mode Content
Troubleshooting when Service Code (electrical system) and Failure
Code display
Code (mechanical system) are displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems

7.3.2 Troubleshooting steps

If some phenomenon occurs on a machine that looks like a failure, identify the corresponding trou-
bleshooting No. and proceed to the explanations for diagnosis.

Follow six steps listed below to diagnose and analyze for troubleshooting, and find the causes and
work out the corresponding methods.

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 Troubleshooting SY500H Hydraulic Excavator

1. Read related technical manuals in detail. Have a knowledge of related system, principle of oper-
ation, and structure, function and technical specification of parts.

2. Ask operator
Before checking, ask related person, i.e. the operator for all information about the failure.
A. Current working condition of machine (Whether machine is operated properly).
B. When troubles are found and what kind of operation does machine perform at that time?
C. Development of troubles (Whether troubles are becoming severer or occur for the first time.)
D. What kind of trouble did machine have before? For example, which parts have been repaired or
replaced?
E. What has been done after troubles take place and how about the reaction?
F. Will the trouble reoccur? Does the trouble occur regularly?

3. Check before starting

Before starting troubleshooting, check the operator's records on operation, maintenance and serv-
ice of the machine. Understand whether related personnel has done wrong in operation, mainte-
nance and service. Check for wrong operation and maintenance at the same time.
Check each part of the machine for abnormalities, such as insufficiency or leakage of oil or water,
looseness and disconnection of pipe line and circuit, and breakage, etc.
Meanwhile, check the electrical system. For example, check the voltage of battery; check for loose
or burnt posts of the power lines; check for blown fuses. Use a multimeter to check the fuse.

4. Operate machine by yourself (trial run)

Confirming that the third item above is normal, run startup check on the machine in order to deter-
mine the cause of failure. If the failure cannot be determined, turn off the engine and get more in-
formation from the operator.

5. Perform troubleshooting
Conduct deep analysis and determine the cause of trouble according to the symptoms of the ma-
chine and the information displayed on the monitor.
Remark:
• Never disconnect harness and hydraulic lines when the engine is running. Oil and water under
high pressure and high temperature may squirt and cause personal injuries. Shut off then engine
when disconnecting the harness and hydraulic lines.
• Failure codes may not indicate machine trouble. Temporary electrical failure can occur in con-
troller memory, such as low battery output voltage, or open circuit in switch or sensor. Therefore,
make repeated trials to erase the accumulated failure codes from the controller memory and
confirm whether the failure codes are displayed after repeated trials. That is to say, "reoccur-
rence" of this trouble is possible.

6. Find out possible causes

Before making a conclusion, check the most possible causes again and try to determine the root
causes of troubles. Make a feasible repair scheme according to your conclusion.

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7.4 Connectors
7.4.1 List of connectors

Number of
Connector No. Category Component Name
Pins
CN-109M Connector 2 To Horn Button
CN-112M Connector 7 To Radio
CN-113F Connector 2 To Pilot Lock
CN-116F Connector 12 To HVAC.
CN-118M Connector 2 To Stop Switch
CN-119M Connector 3 Intermediate connector
CN-115M Connector 8 Intermediate connector
CN-110F Connector 12 Intermediate connector
CN-111F Connector 12 Intermediate connector
CN-117M Connector 6 To Wiper Controller
CN-431F Connector 40 Intermediate connector
CN-161M Connector 8 To Dome Lamp Switch
CN-162M Connector 8 To Washer Switch
CN-163M Connector 8 To Wiper Switch
CN-164M Connector 8 To Working Lamp Switch
CN-165M Connector 3 To Throttle knob
CN-166M Connector 6 To Lgntion Key Switch
F-167 Indicator light 1 To Charge Indicator Yellow Lamp +
F-168 Indicator light 1 To Charge Indicator Yellow Lamp -
F-169 Indicator light 1 To Diagnosis Indicator Red Lamp +
F-170 Indicator light 1 To Diagnosis Indicator Red Lamp -
CN-459F Connector 12 Intermediate connector
CN-458M Connector 9 Intermediate connector
CN-457M Connector 4 Intermediate connector
CN-210F Connector 3 To Fuel Filter Pump
CN-211F Connector 2 To Fuel Add Pump
CN-212F Connector 2 To Diode
CN-222F Connector 2 To Diode
T-214 Terminal 1 To Fuel Level Sensor GND
CN-213M Connector 1 To Fuel Level Sensor
T-228 Terminal 1 To Battery Relay Contact Input
T-229 Terminal 1 To Battery Relay Contact Output

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T-208 Terminal 1 To Battery Relay solenoid +

T-209 Terminal 1 To Battery Relay solenoid -
CN-220F Connector 2 To Diode
CN-207M Connector 2 To Start Relay solenoid
CN-472M Connector 2 To Start Relay Contact
CN-221F Connector 2 To Diode
CN-206M Connector 2 To Glow Relay solenoid
CN-223M Connector 1 To Glow Relay Contact Input
CN-224M Connector 1 To Glow Relay Contact Output
T-201 Terminal 1 To Electric Circuit Fuse Fuse Input
T-202 Terminal 1 To Electric Circuit Fuse Fuse Output
T-225 Terminal 1 To Glow Fuse Output
T-226 Terminal 1 To Main Circuit Fuse Input
T-227 Terminal 1 To Main Circuit Fuse Output
T-230 Terminal 1 To Start Relay Fuse Output
CN-205F Connector 2 To Fuel Add Pump Switch
T-216 Terminal 1 To Body GND
T-217 Terminal 1 To Body GND
CN-219F Connector 2 To Body Lamp
CN-305M Connector 3 To Pump 1 Pressure Sensor
CN-306M Connector 3 To Pump 2 Pressure Sensor
To Cooling Pump Proportional
CN-307M Connector 2
Solenoid
CN-308M Connector 2 To Pump 1 Proportional Solenoid
CN-309M Connector 2 To Pump 2 Proportional Solenoid
CN-310M Connector 2 To Hydraulic Oil Temp. Sensor
CN-311F Connector 3 To O-W Separator Water Level Sensor
CN-401M Connector 12 Intermediate Connector
CN-439M Connector 94 To ECM 94pin Socket
CN-438M Connector 60 To ECM 60pin Socket
CN-436M Connector 40 To Main Controller 40pin Socket
CN-437M Connector 81 To Main Controller 81pin Socket
CN-435M Connector 14 S/R Message Port
CN-106F Connector 3 Intermediate Connector
CN-105M Connector 12 Intermediate Connector

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CN-433M Connector 16 Engine DIAG. Port

CN-100M Connector 2 Engine Memary Clear Port
CN-408M Connector 3 To BARO. Sensor
CN-409M Connector 2 To INTAKE AIR TEMP. Sensor
CN-410M Connector 2 To Air Filtration Switch
CN-411F Connector 3 To Arm In Pilot Pressure Sensor
CN-412F Connector 3 To Arm Out Pilot Pressure Sensor
CN-413F Connector 2 To Pilot Lock Solenoid
CN-414F Connector 2 To Travel Speed Sw Solenoid
To Boom Priority For Swing
CN-415F Connector 2
Proportional Solenoid
CN-416F Connector 2 To Spare Solenoid
CN-417F Connector 2 To Boom 2 Confluence Cut Solenoid
To Boom Priority For Bucker
CN-418F Connector 2
Proportional Solenoid
CN-419F Connector 3 To Cooling Pump Pressure Sensor
CN-420F Connector 3 To Boom Up Pilot Pressure Sensor
CN-421F Connector 3 To Boom Down Pilot Pressure Sensor
CN-422F Connector 3 To Bucker In Pilot Pressure Sensor
CN-423F Connector 3 To Bucker Out Pilot Pressure Sensor
CN-424F Connector 3 To Swing Pilot Pressure Sensor
CN-425F Connector 3 To Travel L Pilot Pressure Sensor
CN-426F Connector 3 To Travel R Pilot Pressure Sensor
T-480 Terminal 1 To Generator E Terminal
T-479 Terminal 1 To Generator B Terminal
T-481 Terminal 1 To Body GND
CN-407M Connector 2 To Generator
CN-406M Connector 1 To Hvac Compressor
CN-301F Connector 5 To Cam
CN-427F Connector 2 To Fule Pump
CN-303F Connector 2 To Fule Pump Switch
CN-482F Connector 1 To Engine Connector H
CN-405F Connector 16 To Engine Connector B
CN-404F Connector 20 To Engine Connector D
CN-403F Connector 32 To Engine Connector A
T-486 Terminal 1 To Starter S Terminal

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T-485 Terminal 1 To Starter B Terminal

CN-401M Connector 12 Intermediate Connector
CN-456F Connector 3 To Boom Head Pressure Sensor
CN-454F Connector 2 To Horn
CN-453F Connector 2 Intermediate Connector
CN-455F Connector 2 To Horn
CN-416F Connector 2 To Diode
CN-119M Connector 2 To Washer Motor
CN-463F Connector 2 To Diode
CN-462F Connector 2 To Diode
To Electrical Power Center 5S
T-125 Terminal 1
Terminal
To Electrical Power Center 6S
T-126 Terminal 1
Terminal
To Electrical Power Center 7S
T-127 Terminal 1
Terminal
To Electrical Power Center 8S
T-128 Terminal 1
Terminal
T-134 Terminal 1 To Repair Lamp Socket -
T-135 Terminal 1 To Repair Lamp Socket +
CN-450F Connector 5 To Ecm Power Relay
CN-451F Connector 5 To Start Cut Relay
To Electrical Power Center Gray
CN-121M Connector 8
Socket
To Electrical Power Center Red
CN-122M Connector 8
Socket
To Electrical Power Center Black
CN-123M Connector 8
Socket
To Electrical Power Center Orange
CN-124M Connector 8
Socket
To Electrical Power Center Blue
CN-129M Connector 8
Socket
To Electrical Power Center Yellow
CN-130M Connector 8
Socket
To Electrical Power Center Green
CN-131M Connector 8
Socket
To Electrical Power Center Brown
CN-132M Connector 8
Socket
CN-501F Connector 2 To Boom Left Working Lamp
CN-502F Connector 2 To Boom Right Working Lamp
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 SY500H Hydraulic Excavator Troubleshooting

CN-101M Connector 34 To Monitor

CN-107M Connector 2 Monitor Reset Port
CN-103M Connector 2 To Pyrheliometers
CN-104M Connector 2 To Cigarette Socket

7.4.2 Connector locations

Fig.7-1

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Fig.7-2

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 SY500H Hydraulic Excavator Troubleshooting

7.4.3 SWP connectors

Fig.7-3

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7.4.4 A/AMP connectors

Fig.7-4

7.4.5 DT connectors

Fig.7-5

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Fig.7-6

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Troubleshooting SY500H Hydraulic Excavator

7.5 Troubleshooting with an Event Code

Information contained in troubleshooting table

Failure code Code The monitor displays

failure information
Failure description
Displayed on monitor E101/ corresponding tot he
code.
Failure alarm
RAM/EEPROM failure；Inspect Task pause
condition
Controller reaction Alarm output
Machine symptom ——

Standard value in normal

Causes condition Reference value in
troubleshooting
Possible
To stop driveing the motor and
causes and
the solenoid. The engine rotate
standard
speed to soon be as low as idle.
value under 1 RAM/EEPROM failure
In the normal status, Pass to
normal
connect the power instauration
condition
again.
Keep on running，Only send
2 Inspect Task pause
failure code

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3
4
5
Related circuit diagram

This is part of the circuit diagram which shows the portion where the failure occurred.

Failure code E102 Controller inside temp. abnormal

Failure code Code Controller inside

Failure description
Displayed on monitor E102/ temp. abnormal

Failure alarm
Controller inside temp. >110℃ or <-40℃ and continuance 10Sec
condition
Controller reaction Alarm output
Machine symptom Keep on running

Standard value in normal

Causes condition Reference value in
troubleshooting
Possible
causes and Controller inside high temp. Controller inside temp. >110℃
1
standard abnormal and continuance 10Ses
value under Controller inside low temp. Controller inside temp. < -40℃
2
normal abnormal and continuance 10Ses
condition 3
4
5

Failure code E103 Sensor power abnormal

Failure code Code Sensor power

Failure description
Displayed on monitor E103/ abnormal
Failure alarm
Sensor power output abnormal and continuance 1Sec
condition
Controller reaction Alarm output
Machine symptom Keep on running

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Standard value in normal

Causes condition Reference value in
troubleshooting
Possible
causes and DC24V Supply power voltage DC24V Supply power voltage
1
standard abnormal abnormal and continuance 1Sec
value under Sensor power output abnormal
2 Sensor power abnormal
normal and continuance 1Sec
condition 3
4
5

Failure code E104 Memory failure

Failure code Code

Failure description Memory failure
Displayed on monitor E104/
Failure alarm
GPS lock memory failure
condition
Controller reaction Alarm output
Machine symptom Keep on running

Standard value in normal

Possible Causes condition Reference value in
causes and troubleshooting
standard Memory failure GPS lock memory failure
1
value under
normal 2
condition 3
4

Failure code E105 CPU failure

Failure code Code

Failure description CPU failure
Displayed on monitor E105/
When the CPU processing to detect the abnormal; Detect the storage
Failure alarm confirmation can’t fix mistakes; To detect the I2C communication to a
condition halt; The procedure writes in an abnormality; The parameter writes in
an abnormality
Alarm output
Stop the motor, proportional solenoid valve coil driver
Controller reaction
Engine speed reduced to automatic idle speed
In normal status, by again to restore power supply is connected
Machine symptom Normal action is slow , speed for automatic idle speed

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Standard value in normal

Causes condition Reference value in
troubleshooting
When the CPU processing to
1 CPU error
Possible detect the abnormal
causes and Detect the storage confirmation
standard 2 Memory errors
can’t fix mistakes
value under
To detect the I2C communication
normal 3 I2C communication abnormal
to a halt
condition
Written procedures/parameters The procedure writes in an
4
abnormality abnormality
The parameter writes in an
5 The controller internal fault
abnormality

Failure code E201 Voltage low

Failure code Code

Failure description Voltage low
Displayed on monitor E201/
Failure alarm
Power supply voltage is less than 18V and lasts 10 sec.
condition
Controller reaction Alarm output
Machine symptom Normal action is slow

Standard value in normal

Causes condition Reference value in
troubleshooting
Turn the start key switch to OFF
position to prepare and keep the
Possible switch in the OFF position for
causes and 1 The Power supply failure
fault diagnosis.
standard Check the battery voltage: about
value under 25V.
normal
Start the engine, measurement of
condition
2 The generator abnormal generator voltage between B
terminals and GND: about 28V.
3
4
5

Failure code E202 Voltage high

Failure code Code Failure description Voltage high

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Troubleshooting SY500H Hydraulic Excavator

Displayed on monitor E202/

Failure alarm
Power supply voltage is greater than 32V and lasts 10 sec.
condition
Controller reaction Alarm output
Machine symptom ——

Standard value in normal

Causes condition Reference value in
troubleshooting
Possible
causes and Start the engine, measurement of
standard 1 The generator abnormal generator voltage between B
value under terminals and GND: about 28V.
normal 2
condition 3
4
5

Failure code H402 Hyd oil temp. high

Failure code Code

Failure description Hyd oil temp. high
Displayed on monitor H402/
Failure alarm
The hydraulic oil temperature higher than 90℃
condition
Controller reaction Alarm output
Machine symptom Normal action is slow.

Standard value in normal

Causes condition Reference value in
troubleshooting
Possible
Cooling pump output Check the cooling pump output
causes and 1
abnormalities pressure:9MPa above
standard
value under Check the cooling fan speed:
2 Cooling fan speed
normal more than 1700rpm
condition 3
4
5

Failure code P101 Engine oil pressure low

Engine oil pressure

Failure code Code Failure description
low
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SY500H Hydraulic Excavator Troubleshooting

Displayed on monitor P101/

Failure alarm
The ECM send low oil pressure alarm signal
condition
Controller reaction Alarm output. Engine is forced to run at low idle.
Machine symptom Engine speed decreases to low idle.

Standard value in normal

Causes condition Reference value in
Possible troubleshooting
causes and Stop engine, check the gngine oil
standard 1 Lack of oil
level.
value under
2
normal
condition 3
4
5

Failure code P301 Coolant temp. high

Failure code Code

Failure description Coolant temp. high
Displayed on monitor P301
Failure alarm
Coolant temperature greater than 105℃
condition
Controller reaction Alarm output, Engine speed forced to reduce to idle
Machine symptom Engine speed reduce to idle

Standard value in normal

Causes condition Reference value in
troubleshooting
Check that the thermostat is
Possible 1 Thermostat is not open
open
causes and
standard Check whether the fan belt
2 Fan belt loose
value under tension
normal Check the cooling fan for
condition 3 Fan fault
damage
Check whether the lack of
4 A lack of coolant
coolant
5

Failure code P401 Fuel level low

Failure code Code Failure description Fuel level low

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Troubleshooting SY500H Hydraulic Excavator

Displayed on monitor P401/

Failure alarm
Fuel level less than 10% and the delay time for 10 sec.
condition
Controller reaction Alarm output
Machine symptom ——

Standard value in normal

Causes condition Reference value in
Possible
troubleshooting
causes and
standard 1 Fuel level less than 10% Please add fuel.
value under 2
normal 3
condition
4
5

Failure code P501 Air filter blockage

Failure code Code

Failure description Air filter blockage
Displayed on monitor P501/
Failure alarm
Blocked air filter pressure switch is closed, lead to report to the alarm
condition
Controller reaction Alarm output
Machine symptom ——

Standard value in normal

Causes condition Reference value in
Possible troubleshooting
causes and Check the air filter to remove
standard 1 Air filter blockage
dust, clean filter strainer
value under
2
normal
condition 3
4
5

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Failure code P601 Water separator abnormal

Failure code Code Water separator

Failure description
Displayed on monitor P601/ abnormal
Failure alarm
RAM/EEPROM failure；Inspect Task pause
condition
Controller reaction Alarm output
Machine symptom The oil-water separator water level to exceed warnning line

Standard value in normal

Causes condition Reference value in
Possible troubleshooting
causes and Oil-water separator water level is Open the oil-water separator
standard 1
too high drain switch, draining water
value under
2
normal
condition 3
4
5

7.6 Troubleshooting the Electrical System (E-Mode)

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 Troubleshooting SY500H Hydraulic Excavator

Table of Electrical Power Center connections

★ This table contains information on power supply devices and rated current of each fuse box
power source.

★ If the power supply is normal, check the fuse box and fuses when troubleshooting the electrical
system.

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Electrical Power Center

Fuse NO./Relay NO. Rated Value System
F1 20A Start Circuit
F2 15A Key ON Sign
F3 10A Start Sign
F4 5A Extinction
F5 10A Charge Indicator
F6 20A Controller Power
F7 10A Monitor Power
F8 15A Manual/AUTO
F9 10A Radio
F10 5A Alarm Lamp（Light）
F11 10A Fuel Filter Pump
F12 10A Cigarette Lighter
F13 10A +24v Power
F14 20A Working Lamp
F15 20A Dome Lamp
F16 5A Alarm Lamp（Sound）
F17 5A Wiper/Washer
F18 20A Hvac.
F19 5A Gps Power
F20 30A Ecm Power
F21 15A Pvc Power
F22 10A Fuel Pump
F23 15A Horn
F24 5A Cab Lamp
F25 5A Repair Lamp
F26 10A Fuel Add Pump
F27 10A Spare
F28 30A Spare
K2 24V,20A 5-PIN MICRO Controller Power Relay
K3 24V,20A 5-PIN MICRO Working Lamp Relay
K4 24V,20A 5-PIN MICRO Dome Light Relay
K5 24V,20A 5-PIN MICRO Alarm Lamp（Sound）Relay
K8 24V,20A 5-PIN MICRO Fuel Pump Relay

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Troubleshooting SY500H Hydraulic Excavator

K9 24V,20A 5-PIN MICRO Horn Relay

K10 24V,20A 5-PIN MICRO Fuel Filter Pump Relay
K11 24V,20A 5-PIN MICRO Alarm Lamp（Light）Relay
K12 24V,20A 5-PIN MICRO Extinction Relay
K15 24V,20A 5-PIN MICRO Fuel Add Pump Relay
K16 24V,20A 5-PIN MICRO Start Cut Relay
K17 24V,20A 5-PIN MICRO ECM Power Relay

Information contained in troubleshooting table

Failure information Machine symptom

Failure occurred and troubleshooting
Related information
information

Standard value in normal condition

Causes
Reference value in troubleshooting
< Contents>
● A standard value under normal condition
can be used to judge a possible cause.
Possible ● A reference value can be used to
causes and The possible causes of approve/disapprove the above judgement.
standard failure are to be < Failure of wiring harness>
value under discussed. (Instead of ● Open circuit
normal 1
priority, the sequential Improper contact with connector or open
condition numbers are just used circuit of wiring harness
for easy identification.) ● Faulty grounding
A non-grounding wire is grounded.
● Short circuit
A wire has mistaken contact with a 24 V
electric circuit.

E-1 Engine does not start

Failure information Engine misfires (engine does not crank).

Related information

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Standard value in normal condition Reference value in

Causes
troubleshooting
★ Turn the engine start switch to the OFF position before
Lower power of troubleshooting. Keep the switch in the OFF position while
1 troubleshooting is performed.
battery
Battery voltage Volts ≥ 24V
★ Turn the engine start switch to the OFF position before
troubleshooting. Keep the switch in the OFF position while
Internal failure troubleshooting is performed.
2 of engine start OFF: Between lines 22# and
Resist ≥ 1M
switch 11#
ance
ON: Between lines 22# and
value ≤1Ω
11#
★ Turn the engine start switch to the OFF position before
Possi
troubleshooting. Keep the switch in the OFF position while
ble
troubleshooting is performed.
caus
es Hydraulic lockout control
Failure of pilot
and 3 FREE: Between lines 105 # ≤ 1M Ω
switch Resist
stand and 0#
ance
ard Hydraulic lockout control
value
value LOCKED: Between lines 105 # ≥1Ω
un and 0#
der ★ Turn the engine start switch to the OFF position. Keep the
nor engine running during troubleshooting. (If all power supplies,
mal grounding, generated signals and engine inputs, except engine
condi output, are normal, it should be the failure of engine start
tion motor.)
Failure of start Start
4 Engine start motor Volts
motor switch
Power supply: terminal B and
20—30V
ground
Start
Between engine input S and
20—30V
ground
★ Turn the engine start switch to the OFF position before
troubleshooting. Keep the switch in the OFF position while
troubleshooting is performed.
Open circuit of
5 Between start switch line 22#
wiring harness Resist ≤1Ω
and start motor terminal B
ance
Between start switch line 11#
value ≤1Ω
and start relay terminal SW

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Troubleshooting SY500H Hydraulic Excavator

Between battery terminal "+" Resist

Failure of fuse
6 (line 20#) and control dial line ance ≤1Ω
F1
22#. value
★ Turn the engine start switch to the OFF position before
troubleshooting. Keep the switch in the OFF position while
Short circuit of troubleshooting is performed.
wiring harness
7 Between start relay terminal
(grounding Resist ≥1MΩ
SW and ground
failure) ance
Between engine input s and
value ≥1MΩ
ground
★ Turn the engine start switch to the OFF position before
troubleshooting. Turn the switch to the ON position and keep it
Internal failure in the ON position while troubleshooting is performed.
8
of alternator
Between engine terminal P
Volts ≤ 1V
and ground

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Fig.7-7

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E-2 Engine runs rough

Failure information Engine runs rough.

Engine speed reading is displayed on the
Related information
monitor.

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Turn the engine start switch to the OFF position before
troubleshooting. Keep the switch in the OFF position while
troubleshooting is performed.
Open circuit of
1 Unplug the controller
wiring harness Resist
Possi connector and check the
ance 2.3±0.2 K Ω
ble resistance between controller
value
caus pins 38 and 19.
es ★ Turn the engine start switch to the OFF position before
and troubleshooting. Keep the switch in the OFF position while
stand troubleshooting is performed.
Internal failure
ard 2
of sensor Unplug the connector and Resist
value
un check the resistance between ance 2.3±0.2 K Ω
der CN-448M A and B. value
nor ★ Turn the engine start switch to the OFF position before
mal troubleshooting. Keep the switch in the OFF position while
condi Short circuit of troubleshooting is performed.
3
tion wiring harness Resist
Between CN-448M A and
ance ≥ 1M Ω
ground
value
No troubleshooting can be done since it is an internal failure. (If
Internal failure
4 a failure is not caused by the above factors, it should be the
of controller
failure of controller.)
5

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 SY500H Hydraulic Excavator Troubleshooting

Fig.7-8

E-3 Engine does not stop

Failure information Engine runs rough.

The engine shuts down without power-cut
Related information delay when engine start switch is turned to the
OFF position.

Standard value in normal condition Reference value in

Causes
troubleshooting
Possi
The battery is good if a click of battery relay contact can be
ble Failure of
1 heard when the engine start switch is operated. The start switch
caus battery relay
is turned ON-START-ON.
es
and ★ Turn the engine start switch to the OFF position before
stand troubleshooting. Keep the switch in the OFF position while
Short circuit
ard troubleshooting is performed.
2 (breakdown) of
value flywheel diode Resist
Between battery relay lines
un ance ≥ 1M Ω
20# and 21#.
der value
nor No troubleshooting can be done since it is an internal failure. (If
mal Internal failure
3 a failure is not caused by the above factors, it should be the
condi of controller
failure of controller or program.)
tion
4
5

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 Troubleshooting SY500H Hydraulic Excavator

Fig.7-9

E-4 Auto deceleration fails

Failure information Engine fails to run at auto deceleration.

Under the mode of auto deceleration, engine
Related information speed does not drop when the joystick is in the
neutral position.

Standard value in normal condition Reference value in

Causes
troubleshooting
Possi
ble ★ Turn the engine start switch to the OFF position before
caus troubleshooting. Restart the engine and keep the engine
es running while troubleshooting is performed.
and 1 Sensor failure Pressure signal is sent with the
stand 0 KG
control lever in neutral position. Pressure
ard
Pressure signal is sent with the value
value 0～37 KG
control lever operated.
un
der Failure of
2 Check the state of pressure switch.
nor pressure switch
mal ● No troubleshooting can be done since it is an internal failure.
condi Controller
3 (If a failure is not caused by the above factors, it should be the
tion failure
failure of controller or program.)
4

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SY500H Hydraulic Excavator Troubleshooting

E-5 Preheating function fails

Failure information Engine preheating function fails.

Related information

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Turn the engine start switch to the OFF position before
troubleshooting. Keep the switch in the OFF position while
Failure of troubleshooting is performed.
1
preheat fuse Resist
Between line 21# and preheat
Possi ance ≤1Ω
relay pin (contact) 3#
ble value
caus When the preheating function is activated, the preheat relay is
Failure of
es 2 normal if a click of preheat relay is heard. The preheat switch is
preheat relay
and turned OFF-ON-OFF.
stand ★ Turn the engine start switch to the OFF position before
ard troubleshooting. Keep the switch in the OFF position while
value troubleshooting is performed.
un Failure of
der 3 Between lines 16# and 17#,
preheat switch Resist ≥ 1M Ω
nor with preheat switch off
ance
mal Between lines 16# and 17#,
value ≤1Ω
condi with preheat switch on
tion ★ Turn the engine start switch to the OFF position before
troubleshooting. Keep the switch in the OFF position while
Short circuit of troubleshooting is performed.
4
lead (grounded) Resist
Between preheat relay pin
ance ≥ 1M Ω
(contact) 3# and ground
value
5

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Troubleshooting SY500H Hydraulic Excavator

Fig.7-10

E-6 All equipment do not work

No operation can be made after the machine is

Failure information
started.
Related information

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Turn the engine start switch to the OFF position before
troubleshooting. Restart the engine and keep the engine
running while troubleshooting is performed.
Possi Failure of safety
1 Lockout
ble lockout switch Item checked Resistance value
control
caus
es LOCK ≤1Ω
Between lines 105# and 41#
and FREE ≥ 1M Ω
stand ★ Turn the engine start switch to the OFF position before
ard troubleshooting. Keep the switch in the OFF position while
value Short circuit of troubleshooting is performed.
un 2
lead (grounded) Resist
der
Between 105# and ground ance ≥ 1M Ω
nor
value
mal
condi ★ Turn the engine start switch to the OFF position before
tion Failure of troubleshooting. Keep the switch in the OFF position while
internal coil troubleshooting is performed.
3
(pilot lockout Resist
solenoid valve) Between 1 and 2 of solenoid
ance About 34 Ω
valve
value
4

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 SY500H Hydraulic Excavator Troubleshooting

Fig.7-11

E-7 Boom-up operation slow and weak

Boom motion is slow and weak during

Failure information
operation of machine.
Pressure signal reads on the monitor during
Related information
boom operation.

Standard value in normal condition

Causes
Reference value in troubleshooting
★ Turn the engine start switch to the OFF
position before troubleshooting. Restart the
engine and keep the engine running while
troubleshooting is performed.
Possible 1 Sensor failure
Pilot pressure is 0 kg when the joystick is in
causes and neutral position.
standard
Pilot pressure is 0-37 kg when the joystick
value under
is in operated.
normal
condition Check engine speed and the ampere of
2 Engine speed abnormal proportional solenoid valve. Calibrate
engine speed if it is too low.
No troubleshooting can be done since it is
an internal failure. (If a failure is not caused
3 Controller failure
by the above factors, it should be the failure
of controller.)

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Troubleshooting SY500H Hydraulic Excavator

Fig.7-12

E-8 Arm operation slow and weak

Arm motion is slow and weak during operation

Failure information
of machine.
Pressure signal reads on the monitor during
Related information
arm operation.

Standard value in normal condition

Causes
Reference value in troubleshooting
★ Turn the engine start switch to the OFF
position before troubleshooting. Restart the
engine and keep the engine running while
troubleshooting is performed.
Possible 1 Sensor failure
Pilot pressure is 0 kg when the joystick is in
causes and neutral position.
standard
Pilot pressure is 0-37 kg when the joystick
value under
is in operated.
normal
condition Check engine speed and the ampere of
2 Engine speed abnormal proportional solenoid valve. Calibrate
engine speed if it is too low.
No troubleshooting can be done since it is
an internal failure. (If a failure is not caused
3 Controller failure
by the above factors, it should be the failure
of controller.)

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SY500H Hydraulic Excavator Troubleshooting

Fig.7-13

E-9 Bucket operation slow and weak

Bucket motion is slow and weak during

Failure information
operation of machine.
Pressure signal reads on the monitor during
Related information
bucket operation.

Standard value in normal condition

Causes
Reference value in troubleshooting
★ Turn the engine start switch to the OFF
position before troubleshooting. Restart the
engine and keep the engine running while
troubleshooting is performed.
Possible 1 Sensor failure
Pilot pressure is 0 kg when the joystick is in
causes and neutral position.
standard
Pilot pressure is 0-37 kg when the joystick
value under
is in operated.
normal
condition Check the engine speed and the ampere of
2 Engine speed abnormal proportional solenoid valve. Calibrate
engine speed if it is too low.
No troubleshooting can be done since it is
an internal failure. (If a failure is not caused
3 Controller failure
by the above factors, it should be the failure
of controller.)

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Troubleshooting SY500H Hydraulic Excavator

Fig.7-14

E-10 Travel operation slow and weak

Travel motion is slow and weak during

Failure information
operation of machine.
Pilot pressure signal reads on the monitor
Related information
during travel operation.

Standard value in normal condition

Causes
Reference value in troubleshooting
★ Turn the engine start switch to the OFF
position before troubleshooting. Restart the
engine and keep the engine running while
troubleshooting is performed.
Possible 1 Sensor failure
Pilot pressure is 0 kg when the joystick is in
causes and neutral position.
standard
Pilot pressure is 0-37 kg when the joystick
value under
is in operated.
normal
condition Check the engine speed and the ampere of
2 Engine speed abnormal proportional solenoid valve. Calibrate
engine speed if it is too low.
No troubleshooting can be done since it is
an internal failure. (If a failure is not caused
3 Failure of controller
by the above factors, it should be the failure
of controller.)

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SY500H Hydraulic Excavator Troubleshooting

Fig.7-15

E-11 Monitor blank

Monitor is blank when the excavator is

Failure information
powered on.
Related information

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Turn the engine start switch to the OFF position before
Possi troubleshooting. Turn the switch to the ON position and keep it
ble in the ON position while troubleshooting is performed.
1 Failure of fuse
caus Between line 21# and ground About 24V
es Volts
Between line 29# and ground About 24V
and
stand ★ Turn the engine start switch to the OFF position before
ard troubleshooting. Keep the switch in the OFF position while
value troubleshooting is performed.
un Between CN-400F pin 60,
Breakage of
der 2 DT06-3S pin A and CN-401F ≤1Ω
lead Resist
nor 77
mal ance
Between CN-400F pin 78,
condi value
DT06-3S pin B and CN-401F ≤1Ω
tion 58
★ Turn the engine start switch to the OFF position before
Short circuit of
3 troubleshooting. Keep the switch in the OFF position while
lead
troubleshooting is performed.

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Troubleshooting SY500H Hydraulic Excavator

Between CN-400F pin 60 and

≥ 1M Ω
CN-401F pin 58 Resist
Between CN-400F pin 78, ance
DT06-3S pin A and CN- 401F value ≥ 1M Ω
77
No troubleshooting can be done since it is an internal failure. (If
4 Monitor failure a failure is not caused by the above factors, it should be the
failure of monitor.)

Fig.7-16

E-12 Monitor displays nothing

When the machine is powered on, the monitor

Failure information
illuminates but displays nothing.
Related information

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SY500H Hydraulic Excavator Troubleshooting

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Turn the engine start switch to the OFF position before
troubleshooting. Keep the switch in the OFF position while
Failure of troubleshooting is performed.
1
resistance Resist
Between 1 and 2 of M09 ance 120 Ω
value
Possi
★ Turn the engine start switch to the OFF position before
ble
troubleshooting. Keep the switch in the OFF position while
caus
troubleshooting is performed.
es
and Between CN-400F pin 60,
Breakage of
stand 2 DT06-3S pin A and CN-401F ≤1Ω
lead Resist
ard 77
ance
value Between CN-400F pin 78,
value
un DT06-3S pin B and CN-401F ≤1Ω
der 58
nor ★ Turn the engine start switch to the OFF position before
mal troubleshooting. Keep the switch in the OFF position while
condi troubleshooting is performed.
tion
Short circuit of Between CN-400F pin 60 and
3 ≥ 1M Ω
lead CN-401F pin 58 Resist
Between CN-400F pin 78, ance
DT06-3S pin A and CN-401F value ≥ 1M Ω
77
Failure of No troubleshooting can be done since it is an internal failure. (If
4 monitor or a failure is not caused by the above factors, it should be the
controller failure of monitor or controller.)

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Troubleshooting SY500H Hydraulic Excavator

Fig.7-17

E-13 Double speed travel fails

Machine always travels at low speed during

Failure information
operation. High speed travel fails.
High/Low travel speed shifts by pressing the
Related information
Hi/Lo travel button on the monitor.

Standard value in normal condition Reference value in

Causes
troubleshooting
Possi ★ Turn the engine start switch to the OFF position before
ble Failure of troubleshooting. Keep the switch in the OFF position while
caus doublespeed troubleshooting is performed.
es 1
travel solenoid Resist
and valve Between CN451F 607 and 0 ance About 34 Ω
stand value
ard
★ Turn the engine start switch to the OFF position before
value
troubleshooting. Keep the switch in the OFF position while
un
troubleshooting is performed.
der
nor Between CN451F 609 and
Breakage of
mal 2 controller SEHC-281AJ2 signal ≤1Ω
lead Resist
condi collecting port pin 82
tion ance
Between CN451F 0 and
value
controller SEHC-281A-J2 ≤1Ω
signal collecting port pin 114

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SY500H Hydraulic Excavator Troubleshooting

★ Turn the engine start switch to the OFF position before

troubleshooting. Keep the switch in the OFF position while
Short circuit of troubleshooting is performed.
3
lead Resist
Between CN451F 607 and
ance ≥ 1M Ω
ground
value
4

Fig.7-18

E-14 Engine coolant temperature reading incorrect

Engine coolant temperature sensor is unable

Failure information
to correctly reflect current temperature
Related information Coolant temperature reads on the monitor

Standard value in normal condition Reference value in

Possi Causes
troubleshooting
ble
caus Standard reference values of engine coolant temperature
es sensor are shown below
and 50℃ 80 Ω
Failure of
stand 60℃ 56.3 Ω
coolant
ard 1
temperature 80℃ 29.5 Ω
value
sensor 100℃ 16.5 Ω
un
der 106℃ 14.3 Ω
nor 120℃ 10 Ω
mal
★ Turn the engine start switch to the OFF position before
condi Breakage of
2 troubleshooting. Keep the switch in the OFF position while
tion lead
troubleshooting is performed.

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Troubleshooting SY500H Hydraulic Excavator

Resist
Between line 510# and
ance ≤1Ω
controller pin 30
value
★ Turn the engine start switch to the OFF position before
troubleshooting. Keep the switch in the OFF position while
Short circuit of troubleshooting is performed.
3
lead (grounded) Resist
Between line 510# and ground ance ≥ 1M Ω
value

Fig.7-19

E-15 Fuel level reading incorrect

Engine fuel level sensor is unable to correctly

Failure information
reflect current fuel level.
Related information Fuel level reads on the monitor

Standard value in normal condition Reference value in

Possi Causes
troubleshooting
ble
★ Turn the engine start switch to the OFF position before
caus
troubleshooting. Keep the switch in the OFF position while
es
troubleshooting is performed.
and
stand Pin Fuel level Resistance value
Fuel level
ard 1 Full (upper
sensor failure About 10 Ω
value limit)
un Between line 509# and ground Empty
der
(lower 85-95 Ω
nor
limit)
mal
condi ★ Turn the engine start switch to the OFF position before
Breakage of
tion 2 troubleshooting. Keep the switch in the OFF position while
lead
troubleshooting is performed.
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SY500H Hydraulic Excavator Troubleshooting

Resist
Between line 509# and
ance ≤1Ω
controller pin 11
value
★ Turn the engine start switch to the OFF position before
troubleshooting. Keep the switch in the OFF position while
Short circuit of troubleshooting is performed.
3
lead (grounded) Resist
Between line 509# and ground ance ≥ 1M Ω
value

Fig.7-20

E-16 Wiper does not work

Failure information Wiper operation fails

Related information

Standard value in normal condition Reference value in

Possi Causes
troubleshooting
ble
caus ★ Turn the engine start switch to the OFF position before
es troubleshooting. Keep the switch in the OFF position while
and Internal failure troubleshooting is performed.
1
stand of wiper motor Resist
Between wiper line 25# and
ard ance >10 Ω
ground
value value
un ★ Turn the engine start switch to the OFF position before
der troubleshooting. Keep the switch in the OFF position while
nor troubleshooting is performed
Breakage of
mal 2
lead Resist
condi Between F6 25 and CN-107M
tion ance ≤1Ω
2
value

Shop Manual-June 2016 7-45

Troubleshooting SY500H Hydraulic Excavator

Between wiper switch line

≤1Ω
35L# and CN-107M 5
Between wiper switch line
≤1Ω
35H# and CN-107M 4
★ Turn the engine start switch to the OFF position before
troubleshooting. Keep the switch in the OFF position while
Short circuit troubleshooting is performed.
3 oflead
(grounded) Between the harness Resist
connecting F6 25 with CN- ance ≥ 1M Ω
107M 2 and the ground value

Fig.7-21

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SY500H Hydraulic Excavator Troubleshooting

7.7 Troubleshooting the Hydraulic and Mechanical System (H-Mode)

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 Troubleshooting SY500H Hydraulic Excavator

A Schematic of hydraulic and mechanical systems

Fig.7-22

Information contained in troubleshooting table

★ The following information is contained in the troubleshooting table and related electric circuit dia-
grams. Deeply understand these information before carrying out troubleshooting.

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SY500H Hydraulic Excavator Troubleshooting

Failure information Machine symptom

Related information and troubleshooting of
Related information
failure that has occurred.

Standard value in normal condition

Causes
Possible Reference value in troubleshooting
causes and 1 Possible causes < Contents>
standard
2 (Instead of priority, the ● A standard value under normal condition
value under
3 sequential numbers are can be used to judge a possible cause.
normal
4 just used for easy ● A reference value can be used to
condition
identification.) approve/disapprove the above judgement.
5

H-1 Work equipment speed slow, or swing and travel speeds slow

● Work equipment speed is slow or the travel

Failure information
and swing speeds are slow.
● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition Reference value in

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

Defective Control levers Main relief pressure

Possi adjustment or 31.4~33 MPa
1 Arm DIG
ble malfunction of {320~337 kg/cm2}
causes main relief valve
If normal pressure cannot be restored after adjustment, it is
and possible the failure of main relief valve or its internal defect.
stand Check the valve directly.
ard
value ★ Stop the engine. Perform troubleshooting while the
under engine is running at high idle.
Malfunction of
normal 2 Control levers Pilot control pressure
pilot relief valve
condi
3.9~4.1 MPa
tion All levers NEUTRAL
{40~42 kg/cm2}
Malfunction of The regulator possibly fails. Check the servo mechanism of
3
regulator the regulator.
If the trouble is caused by other factors, it might be the main
Malfunction of
4 pump that has performance deterioration, malfunction or
main pump
internal defect.

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Troubleshooting SY500H Hydraulic Excavator

H-2 Engine speed drops sharply or engine stalls

Failure information ● Engine speed drops sharply or engine stalls.

Related information ● Information concerned

Standard value in normal condition

Causes
Reference value in troubleshooting
Injection pump may be defective. Check it
1 Failure of injection pump
directly.
Regulator may have malfunction. Check its
2 Malfunction of regulator
servo mechanism.
Possible
causes and Clogging of oil filter Oil filter element may be clogged. Check
3
standard element the element directly.
value under Carbon buildup at fuel Carbon may be built up at fuel injection
4
normal injection nozzle nozzle. Check it directly
condition
Air cleaner may be clogged. Check it
5 Clogging of air cleaner
directly.
Abnormal wear of Engine may be worn abnormally. Check it
6
engine directly.
Oil pump may be defective. Check it
7 Failure of oil pump
directly.

H-3 Work equipment, swing, and travel systems do not work

● Whole work equipment, swing, and travel

Failure information
systems do not work.
● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition Reference value in

Causes
Possi troubleshooting
ble ★ Stop the engine before troubleshooting. Perform
causes troubleshooting while the engine is running at high idle.
and Malfunction of Pilot lockout control Pilot relief pressure
stand 1 pilot relief
ard LOCKED 0 {0}
solenoid valve
value 3.9~4.1 MPa
under FREE
{40~42 kg/cm2}
normal
condi Failure of relief ★ Stop the engine before troubleshooting. Perform
tion 2 valve (pilot troubleshooting while the engine is running at high idle.
pump) Control lever Pilot relief pressure
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SY500H Hydraulic Excavator Troubleshooting

All levers in NEUTRAL 3.9~4.1 MPa

{40~42 kg/cm2}
The main pump may have malfunction or internal defect.
Check it by following method.
Failure of
3 ● Remove the oil pressure measurement plug and start the
hydraulic pump
engine. If oil flows out of the opening, the main pump is in
good condition.
Internal failure of the coupling can stop rotation of the pump
Failure of shaft. Check the coupling.
4
coupling ● Loosen the oil delivery line of the pilot pump. If no oil is
seen, it is probably the failure of coupling.

H-4 Abnormal noise in hydraulic pump

● Abnormal noise is heard around the

Failure information
hydraulic pump
Related information ―

Standard value in normal condition

Causes
Reference value in troubleshooting
1 Low level of hydraulic oil Make a visual check.
Hydraulic oil probably contains air. Make a
2 Inferior hydraulic oil
visual check.
Possible It is probably the clogging of the vent on top
causes and of the hydraulic tank that causes negative
standard Clogging of vent on top pressure in the hydraulic tank. Press the
value under 3
of hydraulic tank release button of the breather valve to
normal eliminate air. Check again if the noise
condition disappears.
It is probably the clogging of hydraulic tank
Clogging of hydraulic
4 strainer that causes negative pressure in
tank strainer
the oil suction line. Make a visual check.
The main pump may have internal defect.
5 Failure of main pump
Check the main pump.

H-5 Auto deceleration not functioning

Failure information ● Auto-deceleration is not functioning.

● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

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Troubleshooting SY500H Hydraulic Excavator

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Stop the engine before troubleshooting. Perform
Possi troubleshooting while the engine is running at high idle.
ble Malfunction of Control levers Pilot valve output pressure
causes 1
pressure relay NEUTRAL 0 {0}
and
stand 3.5~4.1MPa
OPERATION
ard {36~42 kg/cm2}
value ★ Stop the engine before troubleshooting. Perform
under troubleshooting while the engine is running at high idle.
normal
Malfunction of Control levers Pilot valve output pressure
condi 2
tion pilot valve NEUTRAL 0 {0}
3.5~4.1MPa
OPERATION
{36~42 kg/cm2}
3 Controller failure Controller may be defective. Check it directly.

H-6 Boom speed slow

Failure information ● The boom moves slowly.

● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Stop the engine before troubleshooting. Perform
troubleshooting while the engine is running at high idle.
Possi
Malfunction of Boom control lever Pilot valve output pressure
ble
1 right pilot valve
causes NEUTRAL 0 {0}
(boom circuit)
and
Boom RAISE ≥ 3.5MPa
stand
Boom LOWER {36 kg/cm2}
ard
value ★ Stop the engine before troubleshooting. Perform
Failure of troubleshooting while the engine is running at high idle.
under 2
pressure relay
normal Check the pressure sensor by replacing it with a new one.
condi
Malfunction of
tion Spool of boom control valve may have malfunction. Check it
3 boom control
directly.
valve (spool)
Malfunction of Retaining valve of boom control valve may have
4
boom control malfunction. Check the valve directly.

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SY500H Hydraulic Excavator Troubleshooting

valve (retaining
valve)
Malfunction or
defective seal of
The relief valve and makeup valve in boom control valve
boom control
5 may have malfunction or defective seal. Check the valves
valve (relief
directly.
valve and
makeup valve)
★ Stop the engine before troubleshooting. Perform
troubleshooting while the engine is running at high idle.
Charge the bucket with a load of approximate 2260 kg. Cut
Failure of boom off the oil passage to the high-pressure side of the cylinder.
6 Disconnect the cylinder from the main valve. Measure the
cylinder
displacement of piston for 15 minutes after the cylinder
becomes stable. If the measured value is greater than 10
mm, it is deemed that cylinder has a defective seal. For
more information on the testing procedure.

H-7 Arm speed slow

Failure information ● The arm moves slowly.

● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Stop the engine before troubleshooting. Perform
troubleshooting while the engine is running at high idle.
Possi
Malfunction of Arm control lever Pilot valve output pressure
ble
1 left pilot valve
causes NEUTRAL 0 {0}
(arm circuit)
and
≥ 3.5MPa
stand DIG or DUMP
{36 kg/cm2}
ard
value ★ Stop the engine before troubleshooting. Perform
Failure of troubleshooting while the engine is running at high idle.
under 2
pressure relay
normal Check the pressure sensor by replacing it with a new one.
condi
Malfunction of
tion Spool of arm control valve may have malfunction. Check it
3 arm control
directly.
valve (spool)
Malfunction of Regeneration valve of arm control valve may have
4
arm control malfunction. Check it directly.

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Troubleshooting SY500H Hydraulic Excavator

valve
(regeneration
valve)
Malfunction or
defective seal of
The safety valve or makeup valve inside the arm control
arm control
5 valve may have malfunction or defective seal. Check the
valve (safety
valves directly.
valve and
makeup valve)
★ Stop the engine before troubleshooting. Perform
troubleshooting while the engine is running at high idle.
Cut off the oil passage to the high-pressure side of the
Failure of arm cylinder. Disconnect the cylinder from the main valve.
6
cylinder Measure the displacement of piston for 15 minutes after the
cylinder becomes stable. If the measured value is greater
than 10 mm, it is deemed that cylinder has a defective seal.
For more information on the testing procedure.

H-8 Bucket speed slow

Failure information ● The bucket moves slowly.

● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Stop the engine before troubleshooting. Perform
Possi
troubleshooting while the engine is running at high idle.
ble
Malfunction of Bucket control lever Pilot valve output pressure
causes
1 right pilot valve
and NEUTRAL 0 {0}
(bucket circuit)
stand
≥ 3.5MPa
ard Bucket DIG or DUMP
{36 kg/cm2}
value
under ★ Stop the engine before troubleshooting. Perform
normal Failure of troubleshooting while the engine is running at high idle.
2
condi pressure relay
Check the pressure sensor by replacing it with a new one.
tion
Malfunction of
Spool of bucket control valve may have malfunction. Check
3 bucket control
it directly
valve (spool)

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SY500H Hydraulic Excavator Troubleshooting

Malfunction or
defective seal of
Safety valve and makeup valve in bucket control valve may
bucket control
4 have malfunction or defective seal. Check the valves
valve (safety
directly.
valve and
makeup valve)
★ Stop the engine before troubleshooting. Perform
troubleshooting while the engine is running at high idle.
Charge the bucket with a load of approximate 2260 kg. Cut
Failure of bucket off the oil passage to the high-pressure side of the cylinder.
5 Disconnect the cylinder from the main valve. Measure the
cylinder
displacement of piston for 15 minutes after the cylinder
becomes stable. If the measured value is greater than 10
mm, it is deemed that cylinder has a defective seal. For
more information on the testing procedure.

H-9 Work equipment cylinder fails in separate operation

● Boom cylinder fails in separate operation

Failure information ● Arm cylinder fails in separate operation
● Bucket cylinder fails in separate operation
● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Stop the engine before troubleshooting. Perform
troubleshooting while the engine is running at high idle.
Possi
ble Work equipment control Pilot valve output pressure
Malfunction of
causes 1 lever
pilot valve
and NEUTRAL 0 {0}
stand
≥ 3.5MPa
ard DIG or DUMP
{36 kg/cm2}
value
under ★ Stop the engine before troubleshooting. Perform
Failure of troubleshooting while the engine is running at high idle.
normal 2
pressure relay
condi Check the pressure sensor by replacing it with a new one.
tion
Malfunction of
work equipment Spool of work equipment control valve may have
3
control valve malfunction. Check it directly.
(spool)

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Troubleshooting SY500H Hydraulic Excavator

H-10 Work equipment cylinder drifts excessively

Failure information (1) ● The boom drifts at excessive speed.

● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition

Causes
Reference value in troubleshooting
★ Stop the engine before troubleshooting.
Perform troubleshooting while the engine is
running at high idle.
Charge the bucket with a load of
approximate 2260 kg. Cut off the oil
passage to the high-pressure side of the
1 Failure of boom cylinder cylinder. Disconnect the cylinder from the
Possible main valve. Measure the displacement of
causes and piston for 15 minutes after the cylinder
standard becomes stable. If the measured value is
value under greater than 10 mm, it is deemed that
normal cylinder has a defective seal. For more
condition information on the measuring procedure.
Failure of boom Boom retaining valve or pilot valve may be
2
retaining valve worn or sluggish. Check the valves.
Defective seal in boom
The safety valve and the makeup valve in
control valve (safety
3 the boom control valve may have a
valve and makeup
defective seal. Check the seals.
valve)
Failure of boom valve Spool of boom valve may be worn
4
spool excessively. Check the spool.

Failure information (2) ● The arm drifts excessively

● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting

Possible Standard value in normal condition

Causes
causes and Reference value in troubleshooting
standard
★ Stop the engine before troubleshooting.
value under
1 Failure of arm cylinder Perform troubleshooting while the engine is
normal
running at high idle.
condition

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SY500H Hydraulic Excavator Troubleshooting

Cut off the oil passage to the high-pressure

side of the cylinder. Disconnect the cylinder
from the main valve. Measure the
displacement of piston for 15 minutes after
the cylinder becomes stable. If the
measured value is greater than 10 mm, it is
deemed that cylinder has a defective seal.
For more information on the testing
procedure.
The safety valve and the makeup valve in
the arm control valve may have a defective
Defective seal in arm seal. Check the seals.
control valve (safety ★ The performance of seal can be judged
2
valve and makeup by replacing it with another relief valve or
valve) makeup valve. (Do not replace it with the
boom-down relief valve or makeup valve as
their pressures are set differently. )
Failure of arm retaining Arm retaining valve or pilot valve may be
3
valve worn or sluggish. Check the valves.
Failure of arm valve Arm valve (spool) may be worn excessively.
4
(spool) Check it directly.

Failure information (3) ● The bucket drifts excessively.

● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Stop the engine before troubleshooting. Perform
Possi troubleshooting while the engine is running at high idle.
ble Failure of bucket
1 Bucket control lever Leakage from bucket
causes cylinder
cylinder
and
stand DIG relief 20 ml/min
ard Seal of safety valve or makeup valve in bucket control lever
Defective seal in
value may be defective. Check it directly.
bucket control
under ★ The performance of seal can be judged by replacing it
2 valve (safety
normal with another relief valve or makeup valve. (Do not replace it
valve and
condi with the boom-down relief valve or makeup valve as their
makeup valve)
tion pressures are set differently. )
Defective seal in
Seal of bucket control valve spool may be defective. Check
3 bucket control
it directly.
valve (spool)
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Troubleshooting SY500H Hydraulic Excavator

H-11 Work equipment moves sluggishly

Failure information ● Work equipment moves sluggishly.

● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition

Causes
Reference value in troubleshooting
Malfunction of arm Regeneration valve of arm may have
1
regeneration valve malfunction. Check it directly.
Possible
causes and Safety valve or makeup valve in the control
standard valve may have malfunction. Check it
value under directly.
normal Malfunction of control ★ For arm and boom, malfunction of a valve
condition 2 valve (safety valve and can be judged by replacing it with another
makeup valve) relief valve or makeup valve.
(Do not replace it with the boom-lower relief
valve or makeup valve as their pressures
are set differently. )

H-12 Other work equipment moves while single oil circuit is relieved

● Other work equipment moves while single oil

Failure information
circuit of certain work equipment is relieved.
● Set the working mode to S before
Related information
troubleshooting.

Possible Standard value in normal condition

Causes
causes and Reference value in troubleshooting
standard
value under Defective seal of control Seal of control valve may be defective.
normal 1
valve Check it directly.
condition

H-13 Travel speed drops considerably during swing-plus-travel operation

● Travel speed drops considerably during

Failure information
swing-plus-travel operation.
● If the travel speed is low in only travel
Related information
operation, check first H-15.

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SY500H Hydraulic Excavator Troubleshooting

Possible Standard value in normal condition

Causes
causes and Reference value in troubleshooting
standard
The straight travel valve gives no response.
value under Failure of straight travel
1 Check the spool and the logic oil circuit
normal valve
drain port.
condition

H-14 Machine deviates during travel

Failure information ● Machine tends to deviate while travelling

● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Stop the engine before troubleshooting. Perform
troubleshooting while the engine is running at high idle.
Travel control lever Pilot valve output pressure
Malfunction of
1 Forward 3.5~3.9 MPa
travel pilot valve
Reverse { 36~40 kg/cm2}
Difference occurs between 0.4 MPa {4 kg/cm2}
Possi left and right output
ble
★ Stop the engine before troubleshooting. Perform
causes
troubleshooting while the engine is running at high idle.
and
stand Malfunction of Control circuit source
2 Control lever
ard pilot relief valve pressure
value 3.5~3.9 MPa
under All levers in NEUTRAL
{ 36~40 kg/cm2}
normal
condi Failure of Check the regulator by swapping the front and back
3
tion regulator regulators.
★ Stop the engine before troubleshooting. Perform
troubleshooting while the engine is running at high idle.
Sluggishness of
4 proportional Proportional valve output
Travel control lever
solenoid valve pressure
Operate both control levers ≤ 0.1 MPa
Sluggishness of
5 travel control Check the valve spool to see whether it works well.
valve (spool)

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Troubleshooting SY500H Hydraulic Excavator

Internal leakage
6 of central swivel Check it by swapping the lines.
joint
★ Stop the engine before troubleshooting. Perform
Malfunction of troubleshooting while the engine is running at high idle.
7
travel motor Travel control lever Leakage of travel motor
Travel relief 27.2 ml/min
Final drive may have internal defect. Check it directly.
Failure of final ★ Internal defect of the final drive can be determined
8
drive through abnormal noise, abnormal heat, and metal powder
or debris contained in the oil drained.
★ Stop the engine before troubleshooting. Perform
troubleshooting while the engine is running at high idle.
Travel control lever Pilot valve output pressure
Failure of travel
Forward Whether deceleration is
9 pilot pressure
Reverse cancelled
relay
Difference occurs between
0.4 MPa {4 kg/cm2}
left and right output
Check the sensor by swapping it with another one.

H-15 Travel speed is low

Failure information ● Machine travel speed is low.

● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting

Standard value in normal condition Reference value in

Possi Causes
troubleshooting
ble
★ Stop the engine before troubleshooting. Perform troubleshooting
caus
while the engine is running at high idle.
es
and Pilot valve output
Malfunction Travel control lever
stand pressure
1 of travel
ard Forward 3.5~3.9 MPa
pilot valve
value Reverse { 36~40 kg/cm2}
under
Difference occurs between left and right 0.4 MPa {4 kg/cm2}
nor
output
mal
condi Malfunction ★ Stop the engine before troubleshooting. Perform troubleshooting
tion 2 of pilot relief while the engine is running at high idle.
valve

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SY500H Hydraulic Excavator Troubleshooting

Control circuit source

Control lever
pressure
3.5~3.9 MPa
All levers in NEUTRAL
{ 36~40 kg/cm2}
★ Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
Indicator light on
Travel speed Travel control lever
Sensor monitor
3
failure Operated
Low ON/OFF
High Operated ON/OFF
Check the sensor by replacing it with another one.
Malfunction
of the
4 control Spool of travel control valve may have malfunction. Check it directly
valve
(spool)
Malfunction
of tra-vel
control The makeup valve in travel control valve may have malfunction.
5
valve Check it directly.
(makeup
valve)
★ Stop the engine before troubleshooting. Perform troubleshooting
while the engine is running at high idle.
Failure of
6 Oil leakage of travel
travel motor Travel control lever
motor
Travel relief 27.2 ml/min
Final drive may have internal defect. Check it directly.
Failure of ★ Internal defect of the final drive can be determined through
7
final drive abnormal noise, abnormal heat, and metal powder or debris
contained in the oil drained.

H-16 Machine is not steered well or steering power is low

● Machine is not steered well or steering

Failure information
power is low
● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting

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Troubleshooting SY500H Hydraulic Excavator

Standard value in normal condition Reference value in

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

Malfunction of Travel control lever Pilot valve output pressure

1
travel pilot valve Both sides in NEUTRAL 0 {0}
3.5~3.9 MPa
Either side operated
{ 36~40 kg/cm2}
★ Stop the engine before troubleshooting. Perform
troubleshooting while the engine is running at high idle.
Possi Solenoid valve output
Malfunction of Travel control lever
ble pressure
2 travel pilot
causes 3.5~3.9 MPa
pressure sensor Both sides operated
and { 36~40 kg/cm2}
stand
ard 3.5~3.9 MPa
Either side operated
value { 36~40 kg/cm2}
under Malfunction of
Spool of travel control valve may have malfunction. Check it
normal 3 travel control
directly.
condi valve (spool)
tion
Malfunction of
travel control The makeup valve in travel control valve may have
4
valve (makeup malfunction. Check it directly.
valve)
Seal of safety valve in travel motor may be defective. Check
Failure of travel
it directly.
5 motor (safety
★ The failure of seal can be determined by swapping the
valve)
front and back motors or the left and right motors.
Seal of check valve in travel motor may be defective. Check
Failure of travel
it directly.
6 motor (check
★ The failure of seal can be determined by swapping the
valve)
front and back motors or the left and right motors.

H-17 Travel speed cannot be changed

Failure information ● Travel speed cannot be changed.

● Set the working mode to S and the fuel control dial
Related information
in position 10 before troubleshooting.

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SY500H Hydraulic Excavator Troubleshooting

Standard value in normal condition Reference value in

Causes
Possi troubleshooting
ble
★ Stop the engine before troubleshooting. Perform troubleshooting
caus
Malfunction while the engine is running at high idle.
es
of travel Travel speed Travel control lever Solenoid valve output
and
speed pressure
stand 1
shifting
ard Low Operated 0 {0}
solenoid
value
valve 3.5~3.9 MPa
under High Operated
{ 36~40 kg/cm2}
nor
mal Failure of
condi travel motor Speed shifting assembly of travel motor may have malfunction.
2
tion (in speed Check it directly.
shift)

H-18 Travel system fails (only at one side)

Failure information ● One side of the tracks cannot make a turn.

● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition Reference value in

Causes
troubleshooting
Defective seat
of travel control Seat of makeup valve in travel control valve may have
1
valve (makeup malfunction. Check it directly.
Possi valve)
ble
Defective seat
causes Seat of safety valve in travel control valve may have
2 of travel motor
and malfunction. Check it directly.
(safety valve)
stand
ard Defective seat
value of travel motor Seat of check valve in travel motor valve may have
3
under valve (makeup malfunction. Check it directly.
normal valve)
condi ★ Stop the engine before troubleshooting. Perform
tion troubleshooting while the engine is running at high idle.
Speed of travel
4
motor drops. Travel control lever Leakage from travel motor
Travel relief 27.2 ml/min
Failure of final
5 Final drive may have internal defect. Check it directly.
drive

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Troubleshooting SY500H Hydraulic Excavator

★ Internal defect of final drive can be determined with

abnormal noise, overheat, and metal powder or debris
contained in the oil drained.
★ Stop the engine before troubleshooting. Perform
troubleshooting while the engine is running at high idle.
Travel control lever Pilot valve output pressure
Failure of pilot Forward 3.5~3.9MPa { 36~40 kg/
6
pressure sensor Reverse cm2}
Difference occurs between
0.4 MPa {4 kg/cm2}
left and right output
Check it with swapping method.

H-19 Swing operation fails

● Upper structure fails to swing in either

Failure information (1)
direction
● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition Reference value in

Causes
troubleshooting
Malfunction of
Parking brake of swing motor may have malfunction. Check
1 swing motor
it directly.
Possi (parking brake)
ble ★ Stop the engine before troubleshooting. Perform
causes troubleshooting while the engine is running at high idle.
and Improper Swing control lever Swing relief pressure
stand adjustment or
ard malfunction of 25.5~28.5 MPa
2 Swing relief
value swing motor {260~291 kg/cm2}
under (safety valve) If oil pressure does not become normal after adjustment,
normal swing motor safety valve may have malfunction or internal
condi defect. Check the safety valve directly.
tion
★ Stop the engine before troubleshooting. Perform
troubleshooting while the engine is running at high idle.
Failure of swing
3
motor Swing control lever Leakage from swing motor
Swing relief ≥ 10 ml/min

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SY500H Hydraulic Excavator Troubleshooting

Swing mechanism may have internal defect. Check it

directly.
Failure of swing
4 ★ Internal defect of swing mechanism can be determined
mechanism
with abnormal noise, overheat, and metal powder or debris
contained in the oil drained.

Failure information (2) ● Machine fails to swing in one direction

● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting

Standard value in normal condition Reference value in

Causes
troubleshooting

Possi ★ Stop the engine before troubleshooting. Perform

ble troubleshooting while the engine is running at high idle.
causes Malfunction of Pilot valve output pressure
1 Left control lever
and pilot valve
NEUTRAL 0 {0}
stand
ard Swing ≥ 3.5 MPa {36 kg/cm2}
value Malfunction of
under Spool of swing control valve may have malfunction. Check it
2 swing control
normal directly
valve (spool)
condi
Seal of makeup valve in swing motor may have defect.
tion Defective seal of
Check it directly.
3 swing motor
★ Failure of the seal can be determined by swapping the
(makeup valve)
right and left makeup valves and check for any changes.

H-20 Swing acceleration poor or swing speed low

● Swing acceleration is poor, or swing speed is

Failure information (1)
low.
● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting

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Troubleshooting SY500H Hydraulic Excavator

Standard value in normal condition Reference value in

Causes
troubleshooting
Malfunction of
Parking brake of swing motor may have malfunction. Check
1 swing motor
it directly.
(parking brake)
★ Stop the engine before troubleshooting. Perform
Possi
troubleshooting while the engine is running at high idle.
ble
Improper Swing control lever Swing relief valve
causes
adjustment or
and 28.5~30 MPa
stand 2 malfunction of Swing relief
swing motor {291~306 kg/cm2}
ard
value (safety valve) If oil pressure does not become normal after adjustment,
under swing motor safety valve may have malfunction or internal
normal defect. Check the safety valve directly.
condi ★ Stop the engine before troubleshooting. Perform
tion troubleshooting while the engine is running at high idle.
Failure of swing
3
motor Swing control lever Leakage from swing motor
Swing relief ≤ 10 ml/min
Clogging of
4 brake control Disassemble, clean and check.
lines

● Swing acceleration is only poor on one side,

Failure information (2)
or swing speed is low.
● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition Reference value in

Causes
troubleshooting
Possi
★ Stop the engine before troubleshooting. Perform
ble
troubleshooting while the engine is running at high idle.
causes
and Malfunction of Swing control lever Pilot valve output pressure
1
stand pilot valve NEUTRAL 0 {0}
ard
Left swing
value ≥ 3.5MPa {36 kg/cm2}
Right swing
under
normal Malfunction of
condi swing motor
Pressure compensation valve of swing motor may have
tion 2 (pressure
malfunction. Check it directly.
compensation
valve)

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SY500H Hydraulic Excavator Troubleshooting

Seal of makeup valve in swing motor may have defect.

Defective seal of
Check it directly.
3 swing motor
★ Swap the left and right makeup valves and observe the
(makeup valve)
result in order to determine whether the seal fails.
★ Stop the engine before troubleshooting. Perform
One-side troubleshooting while the engine is running at high idle.
leakage of Swing control lever Pilot valve output pressure
4 swing pilot
pressure sensor NEUTRAL 0 {0}
(shuttle valve) Left swing
3.5~3.9MPa {36~40 kg/cm2}
Right swing

H-21 Excessive swing distance upon swing stoppage

● Work equipment swings an extra distance

Failure information (1)
when swing operation is stopped.
● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Stop the engine before troubleshooting. Perform
Possi
troubleshooting while the engine is running at high idle.
ble
Improper Swing control lever Swing relief pressure
causes
adjustment or
and 28.5~30 MPa
1 malfunction of Swing relief
stand {291~306 kg/cm2}
swing motor
ard
(safety valve) If oil pressure does not become normal after adjustment,
value
swing motor safety valve may have malfunction or internal
under
defect. Check the safety valve directly.
normal
condi ★ Stop the engine before troubleshooting. Perform
tion troubleshooting while the engine is running at high idle.
Failure of swing
2
motor Control lever Leakage from swing motor
Swing relief ≤ 10 ml/min

● Swing acceleration is only poor on one side,

Failure information (2)
or swing speed is low.
● Set the working mode at gear (10) of power
Related information
mode (S) to perform troubleshooting.

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Troubleshooting SY500H Hydraulic Excavator

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Stop the engine before troubleshooting. Perform
Possi troubleshooting while the engine is running at high idle.
ble
Malfunction of Swing control lever Pilot valve output pressure
causes
1
and pilot valve NEUTRAL 0 {0}
stand
Left swing
ard ≥ 3.5MPa { ≥ 36 kg/cm2}
Right swing
value
under Malfunction of
Spool of swing control valve may have malfunction. Check it
normal 2 swing control
directly.
condi valve (spool)
tion Seal of makeup valve in swing motor may be defective.
Defective seal of
Check it directly.
3 swing motor
★ Swap the left and right makeup valves and observe the
(makeup valve)
result in order to determine whether the seal fails.

H-22 large shock is produced when upper structure stops swinging

● Large shock is produced when upper

Failure information
structure stops swinging.
● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting.

Standard value in normal condition Reference value in

Causes
troubleshooting
★ Stop the engine before troubleshooting. Perform
Possi troubleshooting while the engine is running at high idle.
ble
causes Malfunction of Swing control lever Pilot valve output pressure
1
and swing pilot valve NEUTRAL 0 {0}
stand
Left swing ≥ 3.5 MPa {36 kg/cm2}
ard
Right swing
value
under Reverse prevention valve of swing motor may have
Malfunction of
normal malfunction. Check it directly
2 swing reverse
condi ★ Replace the valve with a new on in order to determine
prevention valve
tion whether the valve fails
Malfunction of
3 swing relief Swing relief valve may be worn or sluggish
valve

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SY500H Hydraulic Excavator Troubleshooting

H-23 High abnormal noise upon swing stoppage

● High abnormal noise is produced when

Failure information
swing stops.
● Set the working mode to S and the fuel
Related information control dial in position 10 before
troubleshooting

Standard value in normal condition

Causes
Reference value in troubleshooting
Malfunction of back Back pressure valve may have malfunction.
1
pressure valve Check it directly.
Malfunction of swing Safety valve of swing motor may have
2
motor (safety valve) malfunction. Check it directly.
Possible
Seal of makeup valve in swing motor may
causes and
be defective. Check it directly.
standard Malfunction of swing
3 ★ Swap the left and right makeup valves
value under motor (makeup valve)
and observe the result in order to determine
normal
whether the seal fails.
condition
The swing mechanism is suspected of an
internal failure. Check the inside of the
mechanism.
Failure of swing
4 ★ Internal defect of swing mechanism can
mechanism
be determined with abnormal noise,
overheat, and metal powder or debris
contained in the oil drained.

H-24 Excessive swing drift

● Hydraulic drift of swing is excessive (when

Failure information (1)
the parking brake is activated).
● When the swing and parking brakes are
Related information activated, the swing will be held by a disc
brake.

Standard value in normal condition

Causes
Reference value in troubleshooting
Possible
causes and Swing brake control lines and brake pilot
Failure of swing brake
standard 1 valve may be defective. Check them
control lines
value under directly.
normal Parking brake of swing motor may have
condition Malfunction of swing
2 malfunction or internal defect. Check it
motor (parking brake)
directly.

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Troubleshooting SY500H Hydraulic Excavator

● Hydraulic drift of swing is large (when swing

Failure information (2)
holding brake is released).
● When swing holding brake release switch is
in release position, swing holding brake is
Related information
released and upper structure is secured by
only hydraulic pressure.

Standard value in normal condition

Causes
Reference value in troubleshooting
Possible
causes and Malfunction of swing The spool in swing control valve may have
1
standard control valve (spool) a defective seal. Check it directly.
value under Failure of swing motor Seal of relief valve in swing motor may be
normal 2
(relief valve) defective. Check it directly.
condition
Failure of swing motor Seal of makeup valve in swing motor may
3
(makeup valve) be defective. Check it directly.

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 SY500H Hydraulic Excavator Disassembly and Assembly

Disassembly and Assembly

8 Disassembly and Assembly......................................................................................8-1

8.1 Operating Precautions..........................................................................................................8-7
8.2 Start Motor AS .......................................................................................................................8-9
8.2.1 Removing sequence...................................................................................................8-9
8.2.2 Installing sequence .................................................................................................. 8-10
8.3 Fuel Injection Pump AS..................................................................................................... 8-10
8.3.1 Removal .................................................................................................................... 8-10
8.4 Engine Rear Oil Seal ......................................................................................................... 8-16
8.4.1 Removal .................................................................................................................... 8-16
8.4.2 Installation ................................................................................................................. 8-17
8.5 Cylinder Head AS............................................................................................................... 8-17
8.5.1 Removal .................................................................................................................... 8-17
8.5.2 Installation ................................................................................................................. 8-20
8.6 Engine Rear Oil Seal ......................................................................................................... 8-22
8.6.1 Removal .................................................................................................................... 8-22
8.6.2 Installation ................................................................................................................. 8-23
8.7 Cylinder Head AS............................................................................................................... 8-26
8.7.1 Removal .................................................................................................................... 8-26
8.7.2 Insallation .................................................................................................................. 8-28
8.8 Radiator AS......................................................................................................................... 8-40
8.9 Engine and Hydraulic Pump AS....................................................................................... 8-44
8.9.1 Removal .................................................................................................................... 8-44
8.9.2 Installation ................................................................................................................. 8-50
8.10 Radiator AS....................................................................................................................... 8-51
8.11 Engine and Hydraulic Pump AS..................................................................................... 8-56
8.11.1 Removal .................................................................................................................. 8-56
8.11.2 Installation ............................................................................................................... 8-62
8.12 Final Drive AS................................................................................................................... 8-62
8.12.1 Removal .................................................................................................................. 8-62
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 Disassembly and Assembly SY500H Hydraulic Excavator

8.12.2 Installation............................................................................................................... 8-63

8.13 Final Drive AS................................................................................................................... 8-64
8.13.1 Disassembly ........................................................................................................... 8-64
8.13.2 Assembly................................................................................................................. 8-67
8.14 Swing Motor and Swing Drive AS.................................................................................. 8-72
8.14.1 Removal .................................................................................................................. 8-72
8.14.2 Installation............................................................................................................... 8-73
8.14.3 Disassembly ........................................................................................................... 8-74
8.14.4 Assembly................................................................................................................. 8-79
8.15 Idler AS.............................................................................................................................. 8-84
8.15.1 Disassembly ........................................................................................................... 8-84
8.15.2 Assembly................................................................................................................. 8-85
8.16 Sprocket ............................................................................................................................ 8-88
8.16.1 Removal .................................................................................................................. 8-88
8.16.2 Installation............................................................................................................... 8-88
8.17 Track AS............................................................................................................................ 8-88
8.17.1 Removal .................................................................................................................. 8-88
8.17.2 Installation............................................................................................................... 8-90
8.18 Swing Bearing AS ............................................................................................................ 8-91
8.18.1 Removal .................................................................................................................. 8-91
8.18.2 Installation............................................................................................................... 8-91
8.19 Swing frame AS................................................................................................................ 8-92
8.19.1 Removal .................................................................................................................. 8-92
8.19.2 Installation............................................................................................................... 8-95
8.20 Swivel Joint AS................................................................................................................. 8-96
8.20.1 Removal .................................................................................................................. 8-96
8.20.2 Installation............................................................................................................... 8-98
8.21 Central Swivel Joint AS................................................................................................... 8-99
8.21.1 Disassembly ........................................................................................................... 8-99
8.21.2 Assembly............................................................................................................... 8-100
8.22 Hydraulic Tank AS.......................................................................................................... 8-100
8.22.1 Removal ................................................................................................................ 8-100
8.22.2 Installation............................................................................................................. 8-102
8.23 Control Valve AS ............................................................................................................ 8-103
8.23.1 Removal ................................................................................................................ 8-103
8.23.2 Installation............................................................................................................. 8-106
8.24 Hydraulic Pump AS........................................................................................................ 8-107
8.24.1 Removal ................................................................................................................ 8-107
8.24.2 Installation............................................................................................................. 8-109
8.25 Middle Oil Seal (Hydraulic Pump Input Shaft) ............................................................8-110
8.25.1 Removal .................................................................................................................8-110
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 SY500H Hydraulic Excavator Disassembly and Assembly

8.25.2 Installation..............................................................................................................8-111
8.26 Independent Radiator AS ..............................................................................................8-111
8.26.1 .................................................................................................................................8-111
8.26.2 Installation..............................................................................................................8-111
8.27 Work Equipment Pilot Valve AS....................................................................................8-111
8.27.1 Assembly................................................................................................................8-111
8.28 Travel Pilot Valve AS ......................................................................................................8-113
8.28.1 Assembly................................................................................................................8-113
8.29 Hydraulic Cylinder AS ....................................................................................................8-113
8.29.1 Disassembly ..........................................................................................................8-113
8.29.2 Assembly............................................................................................................... 8-120
8.30 Work Equipment AS ...................................................................................................... 8-125
8.30.1 Removal ................................................................................................................ 8-125
8.30.2 Installation............................................................................................................. 8-126
8.31 Air Conditioner AS ......................................................................................................... 8-127
8.31.1 Removal ................................................................................................................ 8-127
8.31.2 Installation............................................................................................................. 8-131
8.32 Counterweight AS.......................................................................................................... 8-131
8.32.1 Removal ................................................................................................................ 8-131
8.32.2 Installation............................................................................................................. 8-132
8.33 Cab AS ............................................................................................................................ 8-133
8.33.1 Removal ................................................................................................................ 8-133
8.33.2 ................................................................................................................................ 8-136
8.34 Monitor............................................................................................................................. 8-137
8.34.1 Removal ................................................................................................................ 8-137
8.34.2 Installation............................................................................................................. 8-137
8.35 Controller AS .................................................................................................................. 8-137
8.35.1 Removal ................................................................................................................ 8-137
8.35.2 Installation............................................................................................................. 8-138
8.36 Radio................................................................................................................................ 8-138
8.36.1 Structure................................................................................................................ 8-138
8.36.2 Removal ................................................................................................................ 8-139
8.36.3 Installation............................................................................................................. 8-140
8.36.4 Connector model and wiring............................................................................... 8-141
8.37 Battery ............................................................................................................................. 8-141
8.37.1 Structure................................................................................................................ 8-141
8.38 Battery ............................................................................................................................. 8-142
8.38.1 Installation and Removal .................................................................................... 8-142
8.38.2 Installation............................................................................................................. 8-142
8.38.3 Replacement ........................................................................................................ 8-143
8.39 Start Switch..................................................................................................................... 8-144
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 Disassembly and Assembly SY500H Hydraulic Excavator

8.39.1 Structure................................................................................................................ 8-144

8.39.2 Removal ................................................................................................................ 8-145
8.39.3 Installation............................................................................................................. 8-146
8.39.4 Working principle and wiring .............................................................................. 8-146
8.40 Electrical Power Center ................................................................................................ 8-147
8.40.1 Installation and Removal .................................................................................... 8-147
8.40.2 Installation............................................................................................................. 8-148
8.41 Wiper................................................................................................................................ 8-148
8.41.1 Structure................................................................................................................ 8-148
8.41.2 Working principle ................................................................................................. 8-149
8.41.3 Removal ................................................................................................................ 8-149
8.41.4 Installation............................................................................................................. 8-150
8.41.5 Wiper arm angle adjustment .............................................................................. 8-151
8.42 Relays.............................................................................................................................. 8-151
8.42.1 Engine relays........................................................................................................ 8-151
8.42.2 Other load relays.................................................................................................. 8-152
8.43 Connector Terminals ..................................................................................................... 8-154
8.43.1 Insertion................................................................................................................. 8-154
8.43.2 Removal ................................................................................................................ 8-155

8-4 Shop Manual-June 2016

Disassembly and Assembly SY500H Hydraulic Excavator

8-5 Shop Manual-June 2016

Disassembly and Assembly SY500H Hydraulic Excavator

WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.

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 SY500H Hydraulic Excavator Disassembly and Assembly

8.Disassembly and Assembly

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

1. Precautions to be observed prior to removal operation

• Dispose the engine coolant properly if antifreeze is used in the engine coolant.
• After disconnecting a hose or tube, seal the openings to prevent invasion of dirt or dust.
• Use a suitable container to contain oil drained.
• Matching mark must be made at where is necessary before removing a part in order to avoid
mistake during reinstallation.
• Do not pull the wire and avoid the wire coming off its contact. To avoid excessive force imposing
on the wire, hold the connector when disconnecting a wire.
• Tag the wires and the hoses in order to ensure their connecting positions. By doing so, mistakes
can be avoided during reinstallation.
• Count and check the number and thickness of the shims, and keep them in a safe place.
• When raising or lifting a component, be sure to use a proper lifting equipment of ample strength.
• When forcing screws are used to remove any components, tighten the screws evenly in turn.
• The surrounding area must be cleaned before removing a component. Cover the component
after removal in order to prevent invasion of dirt or dust.
★ Precautions to be observed when disassembling the lines
The lines disassembled must be blinded with plugs.
A. Thread-connected hoses

Inner Diameter (mm) Code Description

Light Thread Connection
6 B210780001189 Plug
8 B210780001190 Plug
10 B210780000077 Plug
12 B210780000078 Plug
15 B210780000883 Plug
20 B210780000079 Plug
22 60056667 Plug
Heavy Thread Connection
12 B210780001142 Plug
16 60002397 Plug
20 B210780000080 Plug
25 B210780000081 Plug

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 Disassembly and Assembly SY500H Hydraulic Excavator

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

Inner Dia.(mm) Code Description Code Description

Light Thread Connection
6 B210780000903 Cone Plug 23002925 Nut
8 B210780001146 Plug B210770000011 Nut
10 B210780000088 Plug B210334000011 Nut
12 B210780000089 Plug B210334000012 Nut
15 B210780000882 Plug B210334000004 Nut
20 B210780000090 Plug B210334000010 Nut
22 B210780000091 Plug B210780000112 Nut
Heavy Thread Connection
12 B210780001143 Plug B210780000406 Nut
16 A820205001523 Plug B210780000405 Nut
20 B210780000902 Plug B210780000904 Nut
25 B210780001172 Plug B210334000006 Nut

2. Precautions to be observed prior to installation operation

• Tighten all the screws and nuts (sleeve nuts) to specified torques
• Install the hoses without twisting or interference.
• Replace the gaskets, O-rings, cotter pins and lock plates with new ones
• Bend the cotter pin or lock plate securely.
• Before applying the adhesive, clean the parts of oil and dust. Apply 2 or 3 drops of adhesive to
the threaded portion
• Before applying the sealant to the gasket, clean the gasket surface of oil and dust. Check the
gasket for contamination or damage. Apply the gasket sealant evenly.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Apply engine oil to the moving parts.
• Before installing a snap ring, make sure that the snap ring is mounted properly in the circular
groove.
• Before connecting the wiring connector, clean the wiring connector of oil, dirt or water. Make
sure that the wiring connector is connected securely.
• Before using an eyebolt, check the eyebolt for deformation or deterioration. Screw on the eye-
bolt as far as possible and align it to the direction of the hook.
• Before tightening the half flanges, tighten it evenly in turn in order to prevent over tightening on
one side.
★ After reassembling the hydraulic cylinder, main pump or other hydraulic equipment that has
been disassembled and repaired, it is necessary to purge the air from the hydraulic cylinder prior
to initial operation of the cylinder. The purging procedure is performed as the following:

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 SY500H Hydraulic Excavator Disassembly and Assembly

• Start the engine and run the engine at low idle.

• Operate the work equipment control lever in order to cycle the movement of the hydraulic cylin-
der 4 or 5 times. Hold the cylinder at where it is 100 mm from its stroke end.
• Go on operating the hydraulic cylinder 3 or 4 times to its stroke end.
• You can run the engine at normal speed after this operation.
★ This procedure is to be performed before using your machine for the first time after repair or long
storage.

3. Precautions to be observed upon completion of the operations

• Completely discharge the engine coolant, tighten the drain valve, and add coolant to the speci-
fied level. Run the engine to circulate the coolant through the system. Check the coolant level
again.
• Add hydraulic oil to the specified level after disassembly and reinstallation of a hydraulic unit.
Run the engine to circulate the hydraulic oil through the system. Check the oil level again.
• Purge the air from the system after removing and repairing the lines or hydraulic unit and reas-
sembling the parts.
★ To purge the air, see related information in "Testing and Adjusting".
• Add the specified amount of grease (MoS2) to the work equipment related parts.

8.2 Start Motor AS

8.2.1 Removing sequence

(1) Nut

(2) Nut

(3) Starter relay

(4) Bolt

(5) Nut

(6) Starter

*a Flywheel housing

B: Terminal B

S: Terminal S

Fig.8-1

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 Disassembly and Assembly SY500H Hydraulic Excavator

CAUTION
• Before removing the starter (6), first dis-
connect the negative post of battery, and
then wrap it with insulation tape.
• It is dangerous to keep the negative post
of battery connected because every termi-
nal B is under voltage.

8.2.2 Installing sequence

• Installation is performed in the reverse or-

der of removal.

8.3 Fuel Injection Pump AS

8.3.1 Removal

Disconnect the negative (-) post of battery.

1. Open the engine hood at the side of

counterweight.

Fig.8-2

2. Disconnect the air intake hose (1).

Fig.8-3

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 SY500H Hydraulic Excavator Disassembly and Assembly

3. Remove the fuel return tube (2).

Fig.8-4

4. Remove the line (4).

Fig.8-5

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 Disassembly and Assembly SY500H Hydraulic Excavator

5. Remove the fuel return tube (4).

Fig.8-6

6. Remove the fuel tube (5) (supply pump –

community tank).

Fig.8-7

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SY500H Hydraulic Excavator Disassembly and Assembly

7. Remove pipe clamp, and then remove

NO.1 injector tube (6)、 NO.2 injector tube
(7)、 NO.3 injector tube (8)、 NO.4 injector
tube (9)、 NO.5 injector tube (10)、 NO.6 in-
jector tube (11).

Fig.8-8

8. Remove the bearer boards of tube clamps

(12)、(13)、(14) and the community tank(15).

Fig.8-9

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 Disassembly and Assembly SY500H Hydraulic Excavator

9. Remove the fuel Inlet pipe(17) and the fuel

return tube(18) of the fuel pump(16).

Fig.8-10

10. Turn the engine crankshaft to position

No.1 cylinder at the fuel injection starting
point. Make The flywheel punch mark aligned
with the pointer.

Fig.8-11

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SY500H Hydraulic Excavator Disassembly and Assembly

11. Remove the bolt of the coupling, and the

remove the fuel pump.

Fig.8-12

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 Disassembly and Assembly SY500H Hydraulic Excavator

8.4 Engine Rear Oil Seal

8.4.1 Removal

Fig.8-13

1. Remove the hydraulic pump assembly. See

Hydraulic Pump AS in this section.

2. Remove bolt (1), flywheel AS (2), elastic re-

tainer (3) and guide bearing (4).

3. Remove bolt (8) and oil seal assembly (9).

4. The oil seal assembly will be disassembled

into retainer (10) and oil seal (11).

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 SY500H Hydraulic Excavator Disassembly and Assembly

8.4.2 Installation

• Installation is performed in the reverse or-

der of removal.
• The rear oil seal will be installed in the fol-
lowing way:
Uniformly press fitting the periphery of oil
seal (11) until surface A is seated tightly on
the retainer (10).

Fig.8-14

8.5 Cylinder Head AS

8.5.1 Removal

1. Remove the hood (1) and beam (2).

Fig.8-15

2. Remove six fuel delivery lines (3) and one

fuel return line.

Fig.8-16

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 Disassembly and Assembly SY500H Hydraulic Excavator

3. Removing the cylinder head

● Disassembling sequence

(1) Bolt

(2) Fuel injector

(3) O-ring seal

(4) Top gasket (fuel injector)

(5) Bolt

(6) Bushing

(7) Insulation ring

(8) Gasket (rocker cover)

(9) Rocker cover

(10) Bolt

(11) Long bolt (cylinder head)

(12) Rocker arm & Seat AS

(13) O-ring seal

Fig.8-17
(14) Short bolt (cylinder head)

(15) Cylinder head & valve AS

(16) Gasket (cylinder head)

★ : Crankcase

A: Dowel pin

Part that shall never be reused.

• Be careful not to bruise the cylinder head &

valve assembly (15) and the crankcase ★
when removing the cylinder head gasket
(16).

● Assembling sequence

Assembling operation is to be performed in

the reverse order of disassembling operation.

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 SY500H Hydraulic Excavator Disassembly and Assembly

• Cylinder head bolts (13) and (14) are tight-

ened plastically. Any such bolts that have
been tightened thrice must be replaced.
Tightening torques

Unit: N·m｛kgf·m｝
Locations Part tightened Tightening torque Remark
1 Bolt (for mounting fuel injector) 15-20｛1.5-20｝ —
5 Bolt (for mounting rocker arm) 49｛0.5｝ —
10 Cylinder head bolt (M14) 59｛6.0｝ —
Cylinder head bolt (only used for
180｛18｝+
11 tightening cylinder head with rocker ● Wet
90°+20°0
arm and rocker shaft seat assembly) ● Can be reused
Cylinder head bolt (only used for 180｛18｝+ thrice
14
tightening cylinder head assembly) 90°+20°0

Lubricant

Locations Part tightened Lubricant specified Quantity

Threads and bearing surface of
11, 14 Engine oil As required
cylinder head bolt
13 O-ring seal Engine oil As required
17 Both end faces of pushrod Engine oil As required
19 Outer surface of tappet Engine oil As required

Special tools

Locations Tool & Shape Part No. Application

Bolt used for

11, 14 MH061540 tightening cylinder
head
Socket wrench

Shop Manual-June 2016 8-19

 Disassembly and Assembly SY500H Hydraulic Excavator

• Loosen and remove the cylinder head bolts

(11) and (14) in a sequence as shown.
Loosen each bolt of the cylinder head a bit
each time.

① - ⑥ : Bolt (11)

⑦ : Bolt (14)

Fig.8-18

8.5.2 Installation

• The punching prints must be confirmed be-

fore using the bolts (11) and (14). Any such
bolts with more than two punching prints
must be discarded.
• The punching prints indicate the times that
the bolt has been tightened plastically. Any
such bolts with more than two punching
prints must be replaced.

Fig.8-19

• Tighten the cylinder head bolts (11) and

(14) to the specified torque (180N·m
｛18kgf. m｝) in a sequence as shown.
Make sure that the bolts ① , ② and ③ have
been tightened to 180N·m ｛18kgf. m｝.
(Tighten them again if the specified torque
is not met.) After that, turn each bolt by the
following method.

E: Bolt (14)

(Tighten the rocker arm and rocker shaft seat

assembly (12) at the same tim.) Fig.8-20

8-20 Shop Manual-June 2016

 SY500H Hydraulic Excavator Disassembly and Assembly

• Turn the socket seat F in the shown direc-

tion to tension internal spring before tighten-
ing the bolts of cylinder head with the
socket wrench.

G: Socket

H: Lever

J: Lever (extension)

Fig.8-21

Cylinder head and air valve mechanism AS

Removal

• Before loosening the cylinder head bolts

(11) and (14), the air valve spring must be
set free by adjusting the screw C on the
rocker arm A so as to avoid the compres-
sion of spring B by pushrod (17).
• Set the force of the spring in socket so that
the lever H could be intimate against the
rocker arm and shaft assembly (11).
• Align the mark on socket seat F with any Fig.8-22
mark on the socket G. (This point is used as
the benchmark zero.)
• Starting from the above benchmark, turn
the socket G about 90° +20° 0 as shown
(one segment on scale L stands for 10° .)
• After plastically tightening the bolts (13) and
(14), punch a mark on head of each bolt to
indicate the times that the bolt has been
used.

• Since the cylinder head bolts are tightened

plastically, no further tightening is required Fig.8-23
after tightening them in a diagonal manner.

Shop Manual-June 2016 8-21

Disassembly and Assembly SY500H Hydraulic Excavator

8.6 Engine Rear Oil Seal

8.6.1 Removal

Fig.8-24

1. NE sensor 5. flywheel housing support

2.gasket 6. flywheel housing
3.flywheel 7. Oil Seal
4.Oil Seal

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 SY500H Hydraulic Excavator Disassembly and Assembly

1. Remove the hydraulic pump assembly. See

Hydraulic Pump AS in this section.

2. Remove the NE sensor(1).

3. Remove the gasket(2).

4. Remove the flywheel(3).

5. Remove the flywheel housing support(5).

6. Remove the flywheel housing(6).

7. Remove the oil seal (4).Note: When remov-

ing seals, be careful not to damage or scratch
Fig.8-25
the flywheel housing seal pressure mounting
surface. At the same time, When replacing
seals, always replace the oil ring together.

8. Remove the slinger with the dedicated

stripper.

Fig.8-26

8.6.2 Installation

1. Install the flywheel housing.

Note: Tighten the bolts closed sthrust plunger.
Apply sufficient liquid sealant on the junction

Shop Manual-June 2016 8-23

 Disassembly and Assembly SY500H Hydraulic Excavator

surface between the cylinder and the crank-

case. Be sure not to let the liquid sealant into
the bolt holes.

2. Install the flywheel housing support.

3. Install the oil seal

1) Apply new oil on the inner peripheral of the

seal

2) Install the oil seal and retaining ring useing

the dedicated installer.

3) Tighten the center bolt until the sleeve con-

tacts the joint.

4) After pressing the parts, clean all traces of

oil.

5) After installing the oil seal, measure dimen-

sions from the top of the crankshaft to the sur-
face of the seal (2). Fig.8-27
Basic size: 7.0±0.3mm

4. Install the flywheel.

5. Install washer and tighten the bolts.

Apply molybdenum disulfide on the surface of

bearing and bolt thread. And the tighten the
bolts according to the tag sequence shown in
FIG.

6. Install the NE sensor on the flywheel

housing.

Note: Always install the sensor after assembly

flywheel.
Tightening torque

8-24 Shop Manual-June 2016

SY500H Hydraulic Excavator Disassembly and Assembly

Fig.8-28

Shop Manual-June 2016 8-25

 Disassembly and Assembly SY500H Hydraulic Excavator

8.7 Cylinder Head AS

8.7.1 Removal

Fig.8-29

1. cylinder head cover 8. rocker arm assembly

2. cylinder head cover gasket 9. camshaft
3. injector Harness 10. wishbone
4. tube of fuel spray nozzle 11. injector and clamp
5. the following cover of cylinder head 12. cylinder head assembly
6. wiring harness connector 13. cylinder head gasket
7. the following cover gasket of cylinder head 14. idler wheel C

1. Remove the breather hose, and the remove

the cylinder head cover (1). Remove six fuel
delivery lines (3) and one fuel return line.

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 SY500H Hydraulic Excavator Disassembly and Assembly

2. Remove the cylinder head cover gasket (2).

3. Remove the Injector Harness (3).

4. Remove the tube of fuel spray nozzle (4).

5. Remove the wiring harness connector (6).

6. Remove the following cover of cylinder

head (5).

7. Remove the following cover gasket of cylin-

der head (7).

8. When you maintain the rocker arm assem-

bly (8) balance, Loosen and remove the fas-
tening screws from the sides of the rocker arm
assembly bracket.

9. Remove the wishbone (10).

Note: Attach a label on each cylinder.

10.Remove the camshaft (9).

Before removing the camshaft, measure the

axial clearance of camshafts.

The axial clearance of cam shafts (mm)

standard limit
0.085~0.170 0.25

Measure the interval between the camshaft

journal and the bracket.

The interval between the camshaft journal

and the bracket (mm)

reference point limit

0.065~0.125 0.15

Shop Manual-June 2016 8-27

 Disassembly and Assembly SY500H Hydraulic Excavator

11. Remove the Injector and clamp (11).

12. Remove the cylinder head assembly (12),

and the Remove the fixing bolt (27)、 (28).
Remove the bolts according to the tag se-
quence shown in FIG.

13. Remove the cylinder head gasket.

Fig.8-30

8.7.2 Insallation

• Assembling operation is to be performed in

the reverse order of disassembling
operation.
• Install the cylinder head cover according to
the tag sequence shown in FIG.

Fig.8-31

Tightening torque

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SY500H Hydraulic Excavator Disassembly and Assembly

Fig.8-32

The Removal and Installation of Cylinder Head AS

Shop Manual-June 2016 8-29

Disassembly and Assembly SY500H Hydraulic Excavator

Fig.8-33

1. Spacer sleeve 13. O-ring

2. Seal ring 14. Valve seat pad
3. Seal ring 15. Valve
4. Exhaust pipe support 16. Glow plug
5. Exhaust manifold assembly 17. Glow plug connector
6. Split washers 18. Thermal sensor
7. Spring housing (upper) 19. Intake manifold
8. Valve spring 20. Idler shaft C
9. Valve stem seals 21. Idler
10. Spring housing (under) 22. Gearbox
11. Valve Guide 23. O-ring
12. Gas nozzle sleeve 24. Wishbone catheter

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 SY500H Hydraulic Excavator Disassembly and Assembly

1. Remove the glow plug connector (17).

2. Remove the glow plug (16).

3. Remove the thermal sensor (18).

4. Remove the gearbox (22).

Before removing the gear, measure the axial
clearance of Idler shaft C.

axial clearance （mm）

standard limit
0.05~0.14 0.25

5. Remove the O-ring of gearbox (23).

6. Remove the Idler shaft C (20).

7. Remove the Idler C (21).

Note：Be careful not to damage the multi-axis
liner.

8. Remove the Intake manifold (19).

9. Remove the exhaust pipe support (4).

10.Remove the engine bracket.

11.Remove the exhaust manifold assembly

(5).
Note：Do not reuse the lock bolt.

12.Remove the spring housing (7).

13.Remove the valve spring (8).

14.Remove the spring housing (10).

15.Remove the valve (15).

16.Remove the valve stem seals (9).

17.Remove the valve Guide (11).

18.Remove the wishbone catheter (24).

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 Disassembly and Assembly SY500H Hydraulic Excavator

Note: Do not remove the arm catheter, unless

he has been worn.

19.Remove the valve seat pad (14).

20.Remove the gas nozzle sleeve (12).

21.Remove the O-ring of

Installation

1. Smear oil on the O-rings, and then insert it

into the sleeve.

2. Apply sealant on the surface of nozzle di-

ameter sleeve and the bearing, and then en-
ergize it with a cylinder head.

Note: When you Insert O-rings, make the red

park upward, and the black park downward.

Fig.8-34

3.Clean the surface of valve gasket, and then

press Valve seat pad.

Fig.8-35

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4. Install wishbone catheter to the cylinder

head.

Apply oil on the surface of catheter. Press the

wishbone into the cylinder head using special
tool. Make the catheter 49mm above the sur-
face of cylinder head.

Fig.8-36

5. Install the valve guide sleeve

Apply engine oil on the entire periphery of

valve guide sleeve. Press the valve guide
sleeve using puller， make the distance be-
tween the valve guide sleeve and the cylinder
head as standard height.

The distance from the intake to the surface of

the cylinder as the standard height: 27mm

The distance from the exhaust to the surface

of the cylinder as the standard height: 29mm

Fig.8-37

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6. Install the valve sleeve to valve stem using

the installer.

Fig.8-38

7. Install the valve

Fig.8-39

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8. Install the spring housing (upper)

9. Install the valve spring.

10. Install the spring housing (under)

Fig.8-40

11.Install the split washers.

Fig.8-41

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 Disassembly and Assembly SY500H Hydraulic Excavator

12.Install the seal ring to exhaust manifold.

Fig.8-42

13. Clamp the gasket, and then install the

manifold to the cylinder head. Tighten the
bolts according to the tag sequence shown in
FIG. When you tighten the Flange, Start from
the bottom side of the flange, and tighten it
clockwise.

Fig.8-43

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14. Install the exhaust pipe support.

Fig.8-44

15. Install the engine bracket.

16 .Install the intake manifold.

Fig.8-45

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 Disassembly and Assembly SY500H Hydraulic Excavator

17. Apply oil on the surface of idler. And then

insert it into the idler shaft.

18. Idler is Installed in the idler shaft. And then

install the cylinder head.

Fig.8-46

19. Install the O-rings to the gearbox.

20. The gear box is mounted to the cylinder

head and tighten bolts.

Fig.8-47

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21. The thermal sensor is installed in the cylin-

der head.

Fig.8-48

22. Preheated plug is fitted to the cylinder

head.

23. Insert the glow connector between the

glow nut and the flat washer and tighten the
nuts.

Fig.8-49

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Disassembly and Assembly SY500H Hydraulic Excavator

8.8 Radiator AS
Pay attention to the following items before
disassembling:

• To avoid burn, the coolant must be cooled

enough before draining.
• If the pressure cap (2) is opened when the
coolant is still hot, the coolant could squirt
out and cause injury.
Cover the pressure cap (2) with a rag be-
fore opening the cap. Loosen the pressure
cap (1) slowly to release pressure before
fully opening the cap.
Fig.8-50

1. Remove the engine hood (1) and beam (2).

Fig.8-51

2. Remove the beam (4).

Fig.8-52

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3. Open the pressure cap (2) and discharge

engine coolant through the drain valve be-
neath the coolant tank.

Coolant: About 47 L

Fig.8-53

4. Remove the air inlet pipe (4) of the inter-

cooler .

Fig.8-54

5. Remove the air outlet pipe (5) o f

intercooler.

Fig.8-55

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 Disassembly and Assembly SY500H Hydraulic Excavator

6. Remove the drainpipe of EGR (6)、 Water

complement tube (7) and diesel engine dis-
charging tube(8).

Fig.8-56

7. Remove the coolant tank hose (9).

Fig.8-57

8. Clear up refrigerant, and then unscrew the

four bolts (11) and the two bolts (10) on the ra-
diator of air conditioner. Remove the radiator
and place it in a proper place. Remove inlet
pipe (12) and outlet pipe (13) of fuel cooler.

Fig.8-58

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9. Remove the pedal (14).

Fig.8-59

10. Remove the radiator fan guard (15).

Fig.8-60

11. Remove the four bolts (16) fixing the radia-

tor assembly.

12. Lift the radiator assembly with a lifting

device.

Fig.8-61

13. Remove the radiator assembly.

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 Disassembly and Assembly SY500H Hydraulic Excavator

Fig.8-62

Removing sequence

1. Pressure cap 5. Guard

2. Fan guard 6. Intercooler
3. Fuel cooler 7. Radiator
4. Expansion Water Tank

Installing sequence

Installation is performed in the reverse order of removal.

8.9 Engine and Hydraulic Pump AS

8.9.1 Removal

Lower the work equipment to the ground in order to ensure safety. Stop the engine. Disconnect the
cable from the battery negative (-) post.

Loosen the butterfly nut on the breather valve and press the relief button to release internal
pressure.

★ Mark the lines to avoid mistakes during reinstallation.

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1. Remove the hydraulic tank suction filter

and block the opening.

2. Discharge engine coolant.

Coolant: About 47 L

3. Open the engine hood.

Fig.8-63

4. Disconnect lines (1), (2) ,(3)and (4).

Fig.8-64

5. Disconnect lines (5) ,(6),(7),(8),(9)and (10).

6. Remove the sensors A,B and C.

Fig.8-65

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7. Remove the clamps , pipe and the cable.

Fig.8-66

8. Unscrew the connection bolt (12) of the

electronic shutdown device.

9. Disconnect the external cable from the

starter (13).

Fig.8-67

10. Disconnect the cables (14) and (15) as

well as the tubes (16) and (17) from the
compressor.

Fig.8-68

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11. Disconnect the hoses (18), (19), (20) and

(21) between the engine and the radiator.

Fig.8-69

12. Disconnect the air intake hose (22).

Fig.8-70

13. Cut off fuel ball value assembly. And then

remove fuel inlet pipes and fuel outlet pipes
(23)、(24)、(25)、(26).

Fig.8-71

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14. Disconnect engine ground wire.

Fig.8-72

15. Remove the engine cable clamps (28)、

(29)、(30).

Fig.8-73

16. Disconnect the cables (31)、(32)、(33) 、

(34)

Fig.8-74

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17. Remove the footplate(35).

Fig.8-75

18. Disconnect the engine oil inlet/outlet tube

(36) and tube (37).

Fig.8-76

19. Disconnect the engine breather tube (38).

ant temperature sensor.

Fig.8-77

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Disassembly and Assembly SY500H Hydraulic Excavator

20. Remove the fixing bolts (39) on each of

the four mounting plates of the damper. Lift
the engine and main pump assembly.

Engine and hydraulic pump AS:

1636kg

Fig.8-78

8.9.2 Installation

• Installation is performed in the reverse or-

der of removal.
• Open the cap of radiator tank to refill cool-
ant. Also add coolant to the coolant tank.
Engine coolant: About 47 L
• Refill the hydraulic tank with hydraulic oil.
Hydraulic tank: About 440 L
★ Start the engine to circulate the coolant in
order release the foams, and check the
coolant level again.
★ Start the engine to circulate the hydraulic
oil in the hydraulic system, and check the oil
level again.
• Release the air.

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8.10 Radiator AS
Pay attention to the following items before
disassembling:

• To avoid burn, the coolant must be cooled

enough before draining.
• If the pressure cap (1) is opened when the
coolant is still hot, the coolant could squirt
out and cause injury.

Cover the pressure cap (1) with a rag before

opening the cap. Loosen the pressure cap (1)
slowly to release pressure before fully open-
ing the cap. Fig.8-79

1. Remove the engine hood (2) and beam (3).

Fig.8-80

2. Remove the beam (4).

Fig.8-81

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3. Open the pressure cap (1) and discharge

engine coolant through the drain valve be-
neath the coolant tank.

Coolant: About 47 L

Fig.8-82

4. Remove the air inlet pipe (5) of the inter-

cooler .

Fig.8-83

5. Remove the air outlet pipe (6) of

intercooler.

Fig.8-84

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6. Remove the hydraulic oil cooler ports (7)

and (8), and plug the openings to prevent
leakage hydraulic oil from the system.

Capacity of hydraulic oil radiator: about

16.5 L

Fig.8-85

7. Remove the coolant tank hose (9).

Fig.8-86

8. Unscrew the four bolts (10) and the two

bolts (11) on the radiator of air conditioner.
Remove the radiator and place it in a proper
place.

Fig.8-87

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 Disassembly and Assembly SY500H Hydraulic Excavator

9. Remove the pedal (12).

Fig.8-88

10. Remove the radiator fan guard (13).

Fig.8-89

11. Remove the four bolts (14) fixing the radia-

tor assembly.

12. Lift the radiator assembly with a lifting

device.

Fig.8-90

13. Remove the radiator assembly.

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Fig.8-91

Removing sequence

(1) Pressure cap (6) Gasket

(2) Fan guard (7) Engine oil cooler
(3) Intercooler (8) Radiator
(4) Bracket (9) Frame
(5) Guard Part that shall never be reused.

Installing sequence

Installation is performed in the reverse order of removal.

Service standard

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Standard
Location Part tightened Limit Correction
value
49±9.8kPa
1 Pressure cap opening pressure ｛0.5±0.1kgf/ — Replace
cm2｝
Intercooler air leakage (air
3 pressure: 150 kPa｛1.5 kgf/ 0cm3｛0mL｝ — Replace
cm2｝
Engine oil cooler air leakage(air
7 pressure: 1.5 MPa｛15 kgf/ 0cm3｛0mL｝ — Replace
cm2｝
Radiator air leakage (air
8 pressure: 100 kPa｛1.0 kgf/ 0cm3｛0mL｝ — Replace
cm2｝

8.11 Engine and Hydraulic Pump AS

8.11.1 Removal

Lower the work equipment to the ground in order to ensure safety. Stop the engine. Disconnect the
cable from the battery negative (-) post.

Loosen the butterfly nut on the breather valve and press the relief button to release internal
pressure.

★ Mark the lines to avoid mistakes during reinstallation.

1. Remove the hydraulic tank suction filter

and block the opening.

2. Discharge engine coolant.

Coolant: About 47 L

3. Open the engine hood.

Fig.8-92

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4. Disconnect lines (1), (2) and (3).

Fig.8-93

5. Disconnect lines (4), (5) and (6).

6. Remove the sensors (7) and (8).

Fig.8-94

7. Remove the clamps (9), pipe (10) and the

cable (11).

Fig.8-95

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 Disassembly and Assembly SY500H Hydraulic Excavator

8. Unscrew the connection bolt (12) of the

electronic shutdown device.

9. Disconnect the external cable from the

starter (13).

Fig.8-96

10. Disconnect the cables (14) and (15) as

well as the tubes (16) and (17) from the
compressor.

Fig.8-97

11. Disconnect the hoses (18), (19), (20) and

(21) between the engine and the radiator.

Fig.8-98

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12. Disconnect the air intake hose (22).

Fig.8-99

13. Disconnect the external cable (23) of the

speed sensor.

14. Disconnect the external cable (24) of en-

gine oil pressure sensor.

Fig.8-100

15. Disconnect the engine oil inlet/outlet tube

(25) and tube (26).

16. Disconnect the wire (27) of engine oil

pressure switch.

Fig.8-101

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17. Disconnect the cables (28) and (29), and

remove the hose clamp (30).

Fig.8-102

18. Remove the hose clamp (31).

19. Disconnect the wire (32) of coolant tem-

perature sensor.

Fig.8-103

20. Disconnect the cables (33) and (34) of

coolant temperature switch.

Fig.8-104

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21. Disconnect the oil return hose (35).

Fig.8-105

22. Disconnect the engine breather tube (36).

Fig.8-106

23. Remove the fixing bolts (37) on each of

the four mounting plates of the damper. Lift
the engine and main pump assembly.

Engine and hydraulic pump AS: 1284 kg

Fig.8-107

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8.11.2 Installation

• Installation is performed in the reverse or-

der of removal.
• Open the cap of radiator tank to refill cool-
ant. Also add coolant to the coolant tank.
Engine coolant: About 47 L
• Refill the hydraulic tank with hydraulic oil.
Hydraulic tank: About 440 L
★ Start the engine to circulate the coolant in
order release the foams, and check the
coolant level again.
★ Start the engine to circulate the hydraulic
oil in the hydraulic system, and check the oil
level again.
• Release the air.
See “Air in Each Component - Purge” on
page 6-34.

8.12 Final Drive AS

8.12.1 Removal

1. Remove the sprocket. See “Sprocket” on

page 8-89.

Lower the work equipment to the ground in or-

der to ensure safety. Stop the engine. Operate
the breather valve to release internal
pressure.

2. Remove the motor coverplate (1).

Fig.8-108

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3. Disconnect the four hoses (2) of the travel

motor and the corresponding hose
connectors.

Fig.8-109

4. Remove the 40 mounting bolts from the fi-

nal drive assembly (3), and lift the assembly
for in order to disassemble it.

★ Be careful not to damage the surface of

mounting seal installed on the hose base.

★ Never use the threaded holes to lift the cov-

er when lifting the final drive.

Final Drive Assembly: 430 kg

Fig.8-110

8.12.2 Installation

• Installation is performed in the reverse or-

der of removal.

Mounting bolts (swing motor and

swing mechanism AS): 490~608 Nm
{50~62 kgm}
• Refill hydraulic oil.
Add hydraulic oil through the filler opening
to the specified level. Start the engine to cir-
culate oil in the hydraulic system, and check
the oil level again.
• Release the air.

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 Disassembly and Assembly SY500H Hydraulic Excavator

See “Air in Each Component - Purge” on

page 6-34.

8.13 Final Drive AS

8.13.1 Disassembly

1. Discharging the oil

Open the drain plug to discharge oil from the

final drive tank.

Final drive tank: About 9 L

2. Cover

Unscrew the mounting bolts. Remove the cov-

er (1) with the help of eyebolts ① .

Fig.8-111

3. Spacer

Remove the spacer (2).

Fig.8-112

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4. No. 1 planetary carrier assembly

A. Remove No.1 planetary carrier assembly

(3).

Fig.8-113

B. Disassembling No.1 planetary carrier

assembly.

a. Remove the pin (5). Remove the pin (4)

from the planetary carrier assembly (9).

b. Remove the thrust washer (6), gear (7),

bearing (9), and thrust washer (6).

Fig.8-114

5. No.1 sun gear shaft

Remove No.1 sun gear shaft (10).

Fig.8-115

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6. No.2 sun gear

Remove No.2 sun gear (11).

Fig.8-116

7. Disassembly of No.2 planetary carrier

assembly

A. Remove the pin (13). Remove the pin (18)

and the planetary gear (16) from the carrier
(12).

B. Remove thrust washer (17) and gear (16),

bearing (15) and thrust washer (14).

C. Remove the screw in order to take off the

planetary carrier (12) from the body.

Fig.8-117

8. Hub assembly

A. Remove the hub assembly (19) from the

travel motor with the help eyebolts ② .

Fig.8-118

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B. Disassemble the hub assembly through the

following steps.

a. Remove the floating seal (20).

b. Remove the bearing (22) and bearing (21)

from the hub (23).

★ Do not damage the bearing retainer when

removing the bearing (22).

Fig.8-119

C. Remove the floating seal (25) from the trav-

el motor (24).

Fig.8-120

8.13.2 Assembly

★ Clean all the parts. Make sure that these

parts are free from contamination or damage.
Apply some engine oil to the sliding surfaces
prior to installation.

1. Hub assembly

A. Install the bearing (22) and bearing (21) by

pressing them onto the hub (23).

Fig.8-121

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 Disassembly and Assembly SY500H Hydraulic Excavator

B. Install the floating seals (24).

★ Remove any oil or dust from the O-ring or

O-ring contact surfaces. Dry the parts before
installing the floating seals.

★ After installing the floating seal, check that

the angle of the floating seal is within 1 mm.

★ Apply a thin layer of engine oil to the sliding

surface after the floating seal has been Fig.8-122
installed.

C. Install the floating seal (25) on the travel

motor (24).

★ See the above step 2 for the installation

procedure.

Fig.8-123

D. Place the hub assembly (19) on the travel

motor with the help of eyebolts ② . Carefully
tap the bearing to pressfit it.

Fig.8-124

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2. Calculation of shim thickness

A. Measure the thickness (H) of the raised

part of No.2 planetary carrier (12).

Fig.8-125

B. Measurement of raised thickness

Apply 3000 Kg load to the bearing and meas-

ure the value (H) of the raised part of bearing.

★ Turn the hub 2-3 times before applying a

pushing force.

★ Do not use a spray gun to cushion the

bearing.

★ Do not push or strike the retaining valve.

C. Shim thickness calculation: C=H-h.

Fig.8-126

D. Place the shims on the body and insert the

dowel pin. Press the carrier assembly onto
the dowel pin and tighten it with screw (25).
Apply locking adhesive to the threads.

Screw-locking adhesive: (Kesaixin

1277)

★ Use a tensiometer to measure the tangen-

tial force of hub to motor case rotation.

● Tangential force: Max. 294N {30 kg}

Fig.8-127
● Maximum tangential force occurs when the
rotating direction begins to change.

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3. Assembly of No.2 planetary carrier

assembly

A. Assemble the No.2 planetary carrier as-

sembly through to the following steps.

★ Replace pin (13) with a new one.

a. Assemble the bearing (15) on the gear

(16). Assemble the top and bottom plates (14)
and (17), and place the gear assembly into
the planetary carrier (12).

b. Lock it with pin (18) and hammer in the pin Fig.8-128

(13).

★ Check the flexibility of gear (16) after as-

sembling the planetary carrier assembly.

4. No.2 sun gear

Install No.2 sun gear (11).

Fig.8-129

5. No.1 sun gear shaft

Install No.1 sun gear shaft (10).

Fig.8-130

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6. No.1 planetary carrier assembly

A. No.1 planetary carrier assembly will be as-

sembled through the following steps.

★ Replace pin (5) with a new one.

a. Assemble bearings (8) on gear (7). Assem-

ble the top and bottom washers (6). Place the
gear assembly in the carrier assembly (9).

b. Fix the gear assembly to the planetary car-

rier (9) with pin (4).
Fig.8-131

B. Install No.1 planetary carrier assembly (3).

Fig.8-132

7. Spacer

Install the spacer (2).

Fig.8-133

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8. Cover

Assemble the cover (1) with the help eyebolts

① . Use a torque wrench to tighten the bolts.

Bolts: 88.6±6.66 Nm {7±0.7 kgm}

9. Refilling of oil

Tighten the drain plug and refill engine oil

through a filler.

Final drive case: About 9 L

★ After the final drive has been successfully

installed to the chassis, check the oil to see if Fig.8-134
it has reached the specified level.

8.14 Swing Motor and Swing Drive AS

8.14.1 Removal

Release the remaining pressure in the hy-

draulic return circuit. See “Remaining Pres-
sure in Hydraulic Lines - Relieve” on page 6-
29.

Lower the work equipment to the ground in or-

der to ensure safety. Stop the engine. Press
the release button of the breather valve to re-
lease remaining pressure in the hydraulic
tank. Place the hydraulic lockout control in the
locked position.

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1. Disconnect the hose (1) through the hose

(9).

(1): Between main valve and swing motor

(port M)

(2): Between hydraulic tank and swing motor

(port Dr)

(3): Between left swing motor and right swing

motor (port DL)

(4): Between swing motor and main valve port

Px (port SH)

(5): Between swing motor and solenoid valve

block (port PG)
Fig.8-135
(6): Left swing motor and right swing motor
(port M)

(7): Connection of left swing motor SH with

right swing motor SH

(8): Connection of left swing motor PG with

right swing motor PG

2. Remove the 11 fixing bolts (9).

3. Lift the swing motor and swing mechanism

assembly (10) for disassembling.

★ Slowly lift the swing motor and swing mech-

anism assembly in order to avoid damaging
the hoses and other parts.

Swing motor and swing drive assembly:

280 kg

8.14.2 Installation

• Installation is performed in the reverse or-

der of removal.

Mounting bolts (swing motor and

swing mechanism AS): 490~608 Nm
{50~62 kgm}
• Refilling of hydraulic oil

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 Disassembly and Assembly SY500H Hydraulic Excavator

Refill hydraulic oil through the filler opening

to the specified level. Start the engine to cir-
culate oil in the hydraulic system, and check
the oil level again.
• Purging of air
See “Air in Each Component - Purge” on
page 6-34.

8.14.3 Disassembly

1. Draining of oil

Open the drain plug to drain the oil from the

swing mechanism.

Swing drive: About 4 L

2. Swing motor assembly

A. Place the swing motor and swing mecha-

nism assembly on a suitable cribbing. Be
careful not to damage the drive gear or let it
contact the ground.
Fig.8-136
B. Unscrew the 4 bolts in order to remove the
swing motor assembly (1).

Swing motor assembly: 70 kg

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3. No.1 sun gear

Remove No.1 sun gear (2).

Fig.8-137

4. No.1 planetary carrier assembly

A. Remove No.1 carrier assembly (3) and the

plate (4).

Fig.8-138

B. Disassemble No.1 carrier assembly.

Cut the rivets on the shaft (8) to remove the

shaft (8), and remove in turn the gear (6),
bearing (9) and plate (7).

Fig.8-139

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5. Gear ring

Unscrew the mounting bolts to remove the

gear ring (10).

Fig.8-140

6. No.2 sun gear

Remove No.2 sun gear (11).

Fig.8-141

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7. No.2 planetary carrier assembly

A. Remove No.2 carrier assembly (12).

Fig.8-142

B. Disassemble No.2 carrier assembly with

hands through the following steps.

a. Insert pin (13) and push the shaft (14) out

of the carrier assembly (19).

★ Pull out the pin (13) after removal of the

shaft.

b. Remove the thrust washer (16), gear (17)

Fig.8-143
and a second thrust washer (19).

c. Insert the pin (15) to remove the bearing

(18) from the shaft. Remove the pin (15).

8. Snap ring

Remove the snap ring (20).

Fig.8-144

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9. Disassembly of main shaft

A. Place the shaft housing assembly on a

press and push the shaft assembly (21) out of
the shaft housing assembly (22).

Fig.8-145

B. Disassemble the shaft assembly in the fol-

lowing procedure.

Remove the bearing (23) from the shaft (24).

Fig.8-146

10. Bearing

Remove the bearing (25) and the oil seal (26)

from the housing (27).

Fig.8-147

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8.14.4 Assembly

★ Clean all the parts and check for any con-

tamination or damage. Apply engine oil to the
sliding surfaces of the parts.

1. Bearing

Press the bearing (23) into the housing (27).

Fig.8-148

2. Oil seal

Press the oil seal (26) into the housing (27).

Oil seal mounting surface: gasket

sealant (Loctite 515)

Fig.8-149

3. Housing assembly

A. Position the plate (28) on the shaft (24).

B. Position the housing assembly (22) on the

shaft (24). Press fitting in the bearing.

Fig.8-150

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4. Bearing

Press in the bearing (25).

★ When press fitting the bearing, press the

bearing inner race and outer race simultane-
ously. Never press only the inner race.

★ After assembling the bearing, check if the

housing rotates freely.

Fig.8-151

5. No.2 Planetary carrier assembly

Reassemble No.2 carrier assembly through

the following steps.

A. Assemble the plate (16) in the carrier as-

sembly (19).

B. Assemble the gear (17) in the carrier as-

sembly (19). Put the bearing (18) on the shaft
Fig.8-152
(14). Slightly tap the pin (15) into the bore
after alignment. Use a rubber hammer to tap
the pin. Make sure that the pin (15) must not
be higher than the bearing (18).

C. Push the shaft assembly into the carrier as-

sembly (19). Be careful not to damage the
gear and the plate. Align the pin bore of the
shaft with that of the carrier assembly, and in-
stall the pin (13). Carefully tap the pin with a
rubber hammer during installation.

★ Installation of the shaft requires rotating the

planetary gear. Be careful not to damage the
thrust washer.

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6. Assemble in turn the snap ring (20), No.2

carrier assembly and No.2 sun gear (11).

Fig.8-153

7. Installation of gear ring

Apply sealant on the mating surface indicated

by (C) and tighten it with screws. Never get
the sealant onto the gear ring (10).

Mating surface: Sealant (Loctite 515)

Fig.8-154

8. No.1 planetary carrier assembly

A. No.1 carrier assembly is assembled as the

following.

a. Install the plate (7) on the carrier assembly

(5).

b. Install the gear (6) onto the plate after in- Fig.8-155
stalling the bearing (9) into the gear.

c. Press the shaft (8) into the gear (6) and the
carrier assembly (5). Rivet one end of the
shaft.

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 Disassembly and Assembly SY500H Hydraulic Excavator

★ Check if the gear rotates freely.

B. Install No.1 carrier assembly (3) and the

plate (4).

Fig.8-156

9. No.1 sun gear assembly

Install No.1 sun gear (2).

Fig.8-157

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10. Installation of swing motor assembly

Install the swing motor assembly after apply-

ing sealant to the mating surfaces of the gear
ring and the motor cover.

Mating surface: sealant (Loctite 515)

Swing motor assembly: 55 kg

Mounting bolts (swing motor): 156±5

Nm {16±0.5 kg}

★ The 14 bolt holes of the swing motor and

swing drive assembly are distributed nonuni-
formly. The mating direction of each hole is
exclusive, as shown in the illustration on the
right. The installation of swing motor requires
proper alignment of the bolt holes in order to
ensure the installation orientation.

11. Refilling of lubricant

Screw on the drain plug and refill lubricant

through the filler to the specified level (the
upper mark of oil stick).

Swing mechanism box: About 6.6 L

Fig.8-158

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8.15 Idler AS
8.15.1 Disassembly

1. Remove the dowel pin (1) and the support

(2).

2. Remove the floating seals (3) from the sup-

port (2) and the idler (4).

3. Remove the O-ring (11). Remove the idler

(4) from the shaft (5) and the support assem-
bly (7).

★ The idler contains 80 ml oil, which should

be drained completely before disassembling.
Spread a cloth on the floor to prevent smear-
ing of the floor by the oil.

Fig.8-159

4. Remove the floating seals (6) on the other

side from the idler (4), shaft (5) and support
assembly (7).

Fig.8-160

5. Remove the dowel pin (8) in order to re-

move the support (7) from the shaft (5).

6. Remove the bushings (9) and (10) from the

idler (4).

Fig.8-161

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8.15.2 Assembly

1. Install the bushings (9) and (10) in the idler

(4).

Fig.8-162

2. Assemble the O-ring. Use the dowel pin (8)

to install the support (7) on the shaft (5).

Fig.8-163

3. Install the floating seals (6) on the idler (4),

shaft (5) and support (7) assembly.

★ Floating seals

Completely remove the grease from the con-

tact surfaces (hatched area in the illustration
on the right) of O-ring and floating seal before
installing the floating seal. In addition, care
must be taken to keep the contact surface of Fig.8-164
floating seal free from dust.

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★ After installation of the floating seals, check

that the sealing inclination should be less than
1 mm and the seal protrusion be within a
range of 5-7 mm.

Fig.8-165

4. Install the shaft (5) and support (7) assem-

bly to the idler (4).

Fig.8-166

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5. Install the floating seal (3) to the idler (4)

and support (2).

★ Apply oil to the sliding surface of floating

seal. Care must be taken to keep the sliding
surface from any contaminants or dust.

★ Remove the oil and dust from the contact

surfaces of the O-ring and floating seal.

Fig.8-167

Fig.8-168

6. Install the O-ring. Use the dowel pin (1) to

install the support (2).

7. Refill oil and screw on the plug.

Oil: About 80 ml (No.18 hyperbola gear oil)

Plug: 205.8±49 Nm {21±5 kgm}

Fig.8-169

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8.16 Sprocket
8.16.1 Removal

1. Remove the track assembly. For more infor-

mation see "Track AS - Remove" on page in
this manual.

2. Swing the work equipment 90° and lift the

chassis with the help of the work equipment.
Place a block ① between the track frame and
the track shoe.

3. Remove the sprocket (1).

Sprocket: 106 kg
Fig.8-170

8.16.2 Installation

● Installation is performed in the reverse order

of removal.

Threads (bolt - sprocket): Thread seal-

ant (Kesaixin 1277).

Bolts (sprocket): 945 ±85 Nm {95 ±8

kgm}

8.17 Track AS
8.17.1 Removal

Special tools

Part Necessi
Mark Qty
Name ty
Manual/
electric
hydraulic
track
M ● 1
remov
ing/
installing
machine

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1. Choose a place that has enough space to

spread the track. Park the machine when the
master pin is between the idler and the carrier
roller.

2. Lower the work equipment. Loosen the

grease fitting (1) and release the track
tension.

WARNING
• The adjustment cylinder is under extremely
high pressure. Never loosen the grease fit-
Fig.8-171
ting by more than one turn. Move the ma-
chine back and forth if no grease is seen.

3. Pull out the master pin (2) with the tool (M).

Fig.8-172

4. Remove the tool (M). Move the machine

forward so that the temporary pin ② is in front
of the idler. Place the block ① .

5. Remove the temporary pin ② and the dust

seal. Move the machine backward to spread
the track (3).

Fig.8-173

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8.17.2 Installation

● Installation is performed in the reverse order

of removal.

★ See “Track Shoe Tensioner - Test and Ad-

just” on page “Track Tensioning device -
Check and Adjust” on page 6-16.

● Installation procedure of track shoe bolts

and nuts

A. Bring the R side of the track shoe nut (1) to

the link seat surface. Both seat surfaces
should be in close contact when assembling
the track shoe.

★ If the track shoe bolts are installed from the

other side, the corner of nut will interfere with
the link seat surface, causing the nut to raise
and the bolt to loosen.

B. Tighten the bolts of track shoe to the torque Fig.8-174

below.

Track shoe bolts: 1369±49 Nm {140±5

kgm}

★ Use the tool (M) to press the master pin.

Make sure that the protrusion of master pin
meets the size (a).

Master pin protrusion (a): 4.4±1 mm

★ Before installing the dust seal, apply grease

(G2-LI) to its contact surface with the bushing.

Fig.8-175

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8.18 Swing Bearing AS

8.18.1 Removal

1. Remove the swing frame assembly. For

more information see “Swing frame AS” on
page 8-95.

2. Remove the 40 bolts (1) to take off the

swing bearing assembly.

Fig.8-176

3. Hoist up the swing bearing assembly (2).

Swing bearing assembly: 800kg

Fig.8-177

8.18.2 Installation

● Installation is performed in the reverse order

of removal.

Threads (bolt - swing bearing): Thread

adhesive (Tianshan 1277)

Mounting bolts (swing bearing):

Step 1:

Use a pneumatic spanner to tighten the bolts.

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Step 2:

Tightened to: 900±50 Nm {92±3 kgm}

A. When a torque spanner is used to tighten

the bolts, tighten first the four corners and
then mark them.

B. Other bolts will be tightened clockwise or

counterclockwise. After one bolt is tightened,
tighten the next one on the diagonal position
and make a mark.

C. Tighten the rest bolts in the same way.

★ Let the S mark in the soft zone of the inner

race of the inner ring face the right side, as
shown in the photo, and install the swing bear-
ing to the track frame.

★ Apply grease to the inside of the gear ring

of the swing bearing.

● All gear teeth must be covered by grease.

Swing bearing: Grease (MoS2 G2-

LI):15 L

Fig.8-178

8.19 Swing frame AS

8.19.1 Removal

Fully extend the arm and the bucket. Lower

the work equipment to the ground and engage
the hydraulic lockout control.

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1. Disassemble the work equipment assem-

bly. See “Work Equipment AS” on page 8-
131.

2. Remove the counterweight assembly. See

“Counterweight AS” on page 8-138.

3. Remove the four hoses (1) of boom

cylinder.

★ Cork the hoses to stop oil flowing out.

Fig.8-179

4. Lift the boom cylinder assembly (2).

Fig.8-180

5. Remove the plate (3) and the pin (4). Lift

the boom cylinder assembly (2) in order to dis-
assemble it.

★ Remove the boom cylinder assembly on

the other side in the same way.

Boom cylinder AS: 415 kg

Fig.8-181

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6. Remove the plate (5).

★ Removal of the swing frame requires re-

moving other parts that interfere with the lifting
of swing frame.

Fig.8-182

7. Disconnect the six hoses over the rotary

joint assembly on the side of swivel joint.

(8): Central swivel joint (port A)- Left travel

control valve (port BTL)

(9): Central swivel joint (port C)- Left travel

control valve (port ATL)

(10): Central swivel joint (port F)- Solenoid

valve

(11): Central swivel joint (port G)- Swing motor

(port T)
Fig.8-183
(12): Central swivel joint (port D)- Right travel
control valve (port ATR)

(13): Central swivel joint (port B)- Right travel

control valve (port BTR)

8. Remove the bolt (14).

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9. Unscrew the 35 swing frame mounting bolts

in order to remove the swing frame assembly
(15). Lift the swing frame assembly off the
machine.

★ Remove the front and rear mounting bolts

of the platform. Use a lever block to adjust the
swing frame so that the platform can reach a
balance both longitudinally and laterally. Re-
move the last two bolts finally.

Be careful not to damage the central swivel

joint while removing the swing frame
assembly. Fig.8-184

Swing frame assembly (excluding

counterweight and work equipment):

Swing frame
Assembly
Only (Ref.)
SY500H 11552kg 8550 kg

8.19.2 Installation

• Installation is performed in the reverse order of removal.

Clamping screws (air intake hose): 5.4~6.4 Nm {0.55~0.65 kgm}

Mating surface (swing bearing): Flat surface sealant (Tianshan 1596)

Threads (bolt - swing frame): Thread adhesive: (Tianshan 1277)
Mounting bolts (swing frame):
Step 1: Tighten the bolts with a pneumatic spanner.
Step 2: tighten them again.
490~608 Nm {50~62 kgm}
• Refilling of hydraulic oil
Refill through the filler opening the hydraulic oil to the specified level. Start the engine to circu-
late oil in the hydraulic system, and check the oil level again.
• Purging the air
Purge the air from the travel motor. See “Air in Each Component - Purge” on page 6-34.

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 Disassembly and Assembly SY500H Hydraulic Excavator

8.20 Swivel Joint AS

8.20.1 Removal

Release remaining pressure in the hydraulic

return circuit. See “Remaining Pressure in Hy-
draulic Lines - Relieve” on page 6-29

★ Tag each line so as to ensure correct

reinstallation.

1. Disconnect the six hoses (1) through (6) on

the central swivel joint of the travel motor.

(1): Central swivel joint (port T) - Left travel

motor (port T)

(2): Central swivel joint (port T) - Right travel

motor (port T)
Fig.8-185
(3): Central swivel joint (port B) - Left travel
motor (port PA)

(4): Central swivel joint (port D) - Right travel

motor (port PB)

(5): Central swivel joint (port A) - Left travel

motor (port PB)

(6): Central swivel joint (port C) - Right travel

motor (port PA)

(7): Central swivel joint - Left travel motor (port

P)

(8): Central swivel joint - Right travel motor

(port P)

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2. Disconnect the eight hoses (7) through (13)

between:

(9): Central swivel joint and right travel control

valve

(10): Central swivel joint and right travel con-

trol valve

(11): Central swivel joint and left travel control

valve

(12): Central swivel joint and left travel control

valve

(13): Central swivel joint and oil tank Fig.8-186

3. Remove the fixing bolt (14).

4. Remove the pin (15) and the pin (16).

5. Remove the six mounting bolts (17) from

the transition plate. Remove the swivel joint
assembly (18).

Central swivel joint: 56 kg

Fig.8-187

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8.20.2 Installation

• Installation is performed in the reverse or-

der of removal.

Install the central swivel joint facing the di-

rection indicated in the illustration.
(In the illustration, the machine is seen from
the above.)
• Refilling of oil (hydraulic tank)
Refill through the filler opening the hydraulic
oil to the specified level. Start the engine to
circulate oil in the hydraulic system, and
check the oil level again.
• Purging the air

★ Purge the air from the travel motor. See “Air Fig.8-188
in Each Component - Purge” on page 6-34.

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8.21 Central Swivel Joint AS

8.21.1 Disassembly

1. Remove the fixing bolt (14).

2. Remove the cover (3)、baffle (4)、O-rings

(6)

3. Remove the snap ring (5).

4. Remove the rotor (2) from the housing (1).

5. Remove the rotating seal (7) 、 the wearing

ring (8)、 O-rings (9) and the dust ring (10)
from the housing (2).

★ Be careful not to damage the sliding sur-

face of the seal of the rotor (1).

6. Remove the spacer (8) and the gasket (9)

from the housing (6).

7. Remove the spacer (9) and the gasket (8)

from the housing (2).

8. Remove the plug (11) from the rotor (1).

Fig.8-189

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8.21.2 Assembly

1. Install the dust ring (11) on the rotor (12).

2. Install the O-rings (10) in the housing (9).

3. Fix the rotor (12) on a work bench. Install

the housing (6) on the rotor (12).

4. Use a rubber hammer to tap the housing (6)

in order to match the rotor (12) properly.

5. Install the spacer (8) and gasket (9) in the Fig.8-190

housing (6).

6. Install the gasket (4), O-ring seal (5) and

snap ring (7) on the rotor (12).

7. Install the O-rings (3) and (5), and the plug

(4) on the rotor (12).

8. Install the cover (2) and tighten the bolts

(1).
Fixing bolts: 49 Nm{5 kgm}

8.22 Hydraulic Tank AS

8.22.1 Removal

1. Drain the hydraulic oil into a suitable con-

tainer for storage or disposal.
Hydraulic oil: About 400 L

2. Open the engine hood.

3. Remove the engine hood (1), cover (2) and

control valve cover (3).

4. Remove the cover mounting frame (4).

Fig.8-191

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5. Disconnect the three hoses.

(5): Oil return (solenoid valve)

(6): Oil drain (rear pump)

(7): Oil drain (front pump)

★ Tap the hoses for identification.

★ Use socket nuts to protect the hose con-

nectors and cone seals against damage.

Fig.8-192

6. Remove the six hoses.

(8): Oil return (main valve)

(9): Oil return (main valve)

(10): Oil return (T block)

(11): Oil return (swivel joint)

(12): Oil return (swing motor)

(13): Oil return (main valve)

★ Tag the hoses for identification. Use socket

nuts to protect the hose connectors and cone
seals against damage.

Fig.8-193

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7. Remove tube (14) on bottom of hydraulic

tank and hose (15) connected to oil suction
tube of the main pump.

8. Remove the six mounting bolts (16) on bot-

tom of hydraulic tank and hoist up hydraulic
tank assembly.

Hydraulic tank assembly: 256 kg

Fig.8-194

8.22.2 Installation

● Installation is performed in the reverse order

of removal.

Drain plug (hydraulic tank): 58.8~78.5

Nm {6.0~8.0 kgm}

★ After tightening the hose clamping screw,

check that the screw should be in the range
indicated in the illustration. Fig.8-195

Screw (hose clamp): 8.8 ±0.5 Nm {0.9

±0.05 kgm}

★ Install the hose clamp and tighten the screw

according to the illustration on the right.

Bolt: 245.2~308.9 Nm {25~31.5 kgm}

● Refilling of oil (hydraulic tank)

★ Refill hydraulic oil through the filler opening

to the specified level. Start the engine to circu-
late oil in the hydraulic system, and check the
oil level again.

● Purging of air Fig.8-196

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★ See “Air in Each Component - Purge” on

page 6-34..

8.23 Control Valve AS

8.23.1 Removal

Lower the work equipment to the ground in or-

der to ensure safety. Stop the engine. Power
on the machine and relieve system pressure.
Use the breather valve to release the pres-
sure in the hydraulic tank. Place the hydraulic
lockout control in the LOCK position.

● Tag each line so as to ensure correction

reinstallation.

1. Remove the engine hood (1).

2. Remove the coverplate (2) on the control

valve.

Fig.8-197

3. Remove the engine partition (3).

Fig.8-198

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4. Remove the oil return hose (4) (Hydraulic

hammer).

Fig.8-199

5. Remove all the pilot hoses and tag them

properly.

Fig.8-200

6. Remove the tubes (5) and (6) from the main

valve to boom cylinder. Seal the ports prop-
erly. main valve to boom cylinder. Seal the
ports properly.

Fig.8-201

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7. Disconnect the bucket hoses (7) and (8).

Seal the ports properly.

8. Disconnect the arm hoses (9) and (10).

Seal the ports properly.

Fig.8-202

9. Disconnect the hoses (11), (12), (13) and

(14) between the central swivel joint and the
main valve. Seal the ports properly.

10. Disconnect the swing motor hoses (15)

and (16). Seal the ports properly.

11. Disconnect the hose (17) between control

valve and swing motor port (M).

Fig.8-203

12. Disconnect the hydraulic pump hoses

(18)、 (19) and (20).

Fig.8-204

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13. Remove the valve (21), the harness and

hoses of the solenoid valve and tag them
properly.

Fig.8-205

14. Remove the bolts (22) of the control valve

assembly. Lift the control valve assembly in
order to dissemble it.

Control valve AS: 380 kg

Fig.8-206

8.23.2 Installation

• Installation is performed in the reverse pro-

cedure of removal.
• Refilling the oil (to hydraulic tank)
Refill hydraulic oil through the filler opening
to the specified level. Start the engine to cir-
culate oil in the hydraulic system, and check
the oil level again.
• Purging the air

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8.24 Hydraulic Pump AS

8.24.1 Removal

Lower the work equipment to the ground in or-

der to ensure safety. Stop the engine. Press
the release button of the breather valve to re-
lease remaining pressure in the hydraulic
tank.

Disconnect the cable from the negative (-)

post of the battery before performing the job.

★ Tag each pipeline so as to ensure correc-

tion reinstallation.

1. Remove the oil inlet filter element from the

hydraulic tank and stop oil outflow with an oil
stopper.

★ If no oil stopper is used, remove the drain

plug and drain the oil from the hydraulic tank
and the lines.

Hydraulic oil tank: About 440 L

Fig.8-207

2. Remove the right engine hood、muffle and

holder R.

Fig.8-208

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3. Remove the hydraulic pump cover.

Fig.8-209

4. Remove fuel oil filter and cover with pump.

Fig.8-210

5. Remove all nine hoses connecting with

pump，and seal the port properly.

Fig.8-211

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6. Disconnect the solenoid valve harnesses

Fig.8-212

7. Remove the twelve bolts of the hydraulic .

Lift the hydraulic pump assembly in order to
remove it.

Hydraulic pump assembly: 184 kg

Fig.8-213

8.24.2 Installation

● Installation is performed in the reverse order

of removal.

★ After tightening the hose clamping screw,

check that the screw should be in the range
indicated on the right illustration.

Screw (inlet hose clamp): 8.8±0.5 Nm

{0.9±0.05 kgm}

★ Install the hose clamp and tighten the screw Fig.8-214

according to the illustration on the right.

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Mating surface (hydraulic pump hous-

ing): Gasket sealant: (Loctite 515)

● Refilling the oil (hydraulic tank)

Refill hydraulic oil through the filler opening to

the specified level. Start the engine to circu-
late oil in the hydraulic system, and check the
oil level again.

Hydraulic tank: About 440 L

● Purging the air

Fig.8-215

8.25 Middle Oil Seal (Hydraulic Pump Input Shaft)

8.25.1 Removal

1. Remove the hydraulic pump assembly .

See “Hydraulic Pump AS - Remove and In-
stall” on page “Hydraulic Pump AS” on page
8-110.

2. Remove the screw . Remove the bearing

cover and jump ring.

3. Pry the oil seal out with a screwdriver.

★ Be careful not to damage the shaft while

prying the oil seal.

Fig.8-216

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8.25.2 Installation

● Installation is performed in the reverse order

of removal.

Seal lip: grease (No.1 Calcium base

grease)

Seal circumference: grease (No.1 Cal-

cium base grease)

★ Apply a thin layer of grease to the oil seal

circumference.

Fig.8-217

8.26 Independent Radiator AS

8.26.1

8.26.2 Installation

1. Remove the pipe （1）. （2）， and motor

hose（3）（4）（5）.

★ Be careful not to damage the shaft while

prying the oil seal.

2. Remove shield （6）， fan （7）、 motor

（8）、holder（9）and bolt（10）

★ Pay attention to radiator while removing

bolts.

8.27 Work Equipment Pilot Valve AS

8.27.1 Assembly

★ This section discusses only the precautions when reassembling the work equipment pilot valve
assembly.

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Fig.8-218

● Reassembly of the work equipment pilot ★ Thread adhesive (Tianshan 1277)Apply the
valve assembly thread adhesive (Tianshan 1277) to two points
1. Install the plate (9) in the valve body (8) with on the inner threads, as indicated in the
O-ring seal. Tighten the socketheaded screw illustration on the right. The amount of
(10). application is approximately 0.02 g.
Screw (socket head): 25~33 Nm U-joint (3): 98~133 Nm {10~13.5 kgm}
{2.55~3.36 kgm} ★ Tightening is to be made to the specified
torque.

2. Insert the spring (7) into the spool hole in

the valve body (8). Put the spool (6) in the
spring. Install the plug (5) on the spool. Push
the plug (5) to the spool hole.

3. Install the plate (4) on the plug (5). Tighten

the U-joint (3).

4. Install the plate (2). Align the position of the

plate (2) and tighten the nut (1).

Nut: 98~133 Nm {10~13.5 kgm} Fig.8-219

★ Location of each oil port is stamped on the Contact surface between plug (5) and
bottom of valve body. plate (2):
Plug (5) circumference: Grease 0.3~0.8cc (No.1 Calcium base grease)
Grease (No.1 Calcium base grease) ★ After assembling plate (2), see “Work
U-joint working surface: Equipment and Swing PPC Valves - Adjust” on
Grease (No.1 Calcium base grease) page 6-26.
Threads in valve body:

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8.28 Travel Pilot Valve AS

8.28.1 Assembly

★ This section discusses only the precautions when reassembling the travel pilot valve assembly.

Fig.8-220

● Reassembly of travel pilot valve assembly

1. Install the spring (8) into the spool installation hole in the body assembly (9). Install the spool (7).
Place the cover assembly (6) on the spool and press the cover assembly (6) with a hand.

2. Install the cover (4) after aligning the holes. Tighten the socket-headed bolts (1).
Bolt (socket head): 98~114 Nm {10~11.6 kgm}

3. Install the dust ring (3) on the plug. Install the cover (2) and fix the cover (2) with the camshaft
(5).
Contact surface between the plug and the dust ring (5): Grease (No.1 Calcium base
grease)

8.29 Hydraulic Cylinder AS

8.29.1 Disassembly

Special tools

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Tool Quanti
Sketches Necessity
Description ty

For pulling
out/ pushing ■ 1
in the bushing

For press
fitting the dust ■ 1
ring

For O-ring
seal ■ 1
correction

For inserting
the cylinder ■ 1
head

For inserting
■ 1
the piston

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1. Drain the oil and remove the tubing.

2. Fix the cylinder.

★ Fix the cylinder in a vertical or level manner.

A vertically fixed cylinder can be disas-
sembled and assembled easily.

★ The pin bore in the head end can be used

for fixing of the cylinder. The pin can prevent
the cylinder from turning.

★ Remove the tubing in case of tubing inter-

ference while fixing the cylinder.

Fig.8-221

3. Removal of cylinder head

★ Unscrew the bolts with Allen Wrench.

★ Using an extension rod, as shown in the il-

lustration on the right, will make the work
easy.

Fig.8-222

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4. Pulling out the piston rod

★ Be sure to have removed the tubing cover.

★ Prepare a suitable container to collect oil

coming out of the oil port.

★ After pulling out the piston rod (1) to its limit,

slowly loosen the cylinder head and pull it out.

★ Remove piston rod (1) with cylinder head

(2) and place them on a wooden sleeper.

Fig.8-223

5. Fixing the piston rod

★ Pin bore on the rod end or the flat part of

the ear can be used to fix the piston rod and
prevent it from turning.

Fig.8-224

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6. Remove of piston nut (5)

A. Remove the fixing screw (3) from the piston

nut (5).

★ Around the fixing screw there are two points

that have been punched against loosening.
After removing the riveted part with a hand
drill, loosen and remove the fixing screw (3).

B. Remove the steel ball (4) inside the fixing

screw .

C. Remove the piston nut (5). Fig.8-225

★ The piston nut (5) is very tight. To loosen

the piston nut (5), prepare a hydraulic jack or
a spanner powered by hydraulic cylinder. An
extension rod should be ready when removing
the piston nut (5) manually.

Fig.8-226

7. Removal of piston assembly

Remove in turn the piston (7), buffer sleeve

(6) and cylinder head (2).

Fig.8-227

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8. Removal of the buffer sleeve (8) on the

head end

A. Remove first the piston nut (5).

B. Use a tool like rubber hammer to tap the

piston nut (5) slightly in order to remove it.
The piston rod and the buffer sleeve (8)
should be kept intact. Remove the elastic re-
tainer (9).

C. Slide the buffer sleeve (8) toward the piston

threads in order to remove the two-piece stop-
Fig.8-228
per ring.

D. Remove the buffer sleeve (8).

E. There is an opening in the buffer seal (10).

Take advantage of this opening to remove the
buffer seal (10).

9. Removal of piston seal

A. The slide ring (12) and the guard ring (13)

can be simply removed with hands.

B. The seal (14) can be removed with a ham-

mer and a flat-head screwdriver.

C. Remove the O-ring seal (15) with a pry bar.

★ The removed seals should not be reused.

Fig.8-229

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10. Removal of buffer ring (16)

★ The buffer ring (16) is installed in the inner

groove in the cylinder head. Use a tool with
sharp end to pry it out and remove it with a
scraper.

11. Removal of the U-ring (17) and the dust

ring (18).

A. Remove the U-ring (17) with a tool such as

screwdriver.

B. Press a tool (such as a screwdriver) Fig.8-230

against the dust ring (18) and hammer the
screwdriver to remove the dust ring (18).

★ The removed seals should not be reused.

12. Removal of bushing (19)

A. Remove the elastic ring (20) from the cylin-

der head (2) with a screwdriver.

B. Push the bushing (19) out with the help of

clamps and press.

13. Removal of pin bushing (21)

A. Remove the dust ring (22) on the side of

cylinder barrel and piston rod with a tool such
as screwdriver.

B. Remove the bushing (21) with the help of a Fig.8-231

suitable cushion block.

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8.29.2 Assembly

1. Installation of bushing (21)

A. Use an installation tool to press the bushing

(21) into the bushing (lubricated with hydraulic
oil) on the side of piston rod and cylinder
barrel.

B. Install the dust ring (22) with the help of a

suitable cushion block.

Fig.8-232

2. Assembly of cylinder head (2)

A. Use the press to push in the bushing (19).

★ Apply hydraulic oil to the inside of cylinder

head in advance. Make sure that the bushing
(19) pushed in is free from a raised shoulder.

Fig.8-233

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B. Use the press to push in the dust ring (18).

C. Install the guard ring and the U-ring (17)

sequentially in the U-groove.

★ Install the U-ring (17) in correct direction.

Make sure that the U-ring is intact before
installation.

★ Inverse installation will cause leak of oil.

★ Make sure that the U-ring is free from any

corrugation or permanent deformation after
installation. Fig.8-234

D. Installation of buffer ring (16)

★ Make sure that the seal is installed in cor-

rect direction. Inverse installation can cause
high pressure between the buffer ring (16)
and the U-ring (17), which may lead to defor-
mation or breakage of oil cylinder.

E. Install the elastic ring (20) to prevent the fall

of the bushing (19).

Fig.8-235

3. Assembling the piston assembly

A. Installation of seal (14).

★ Install first the O-ring seal and the one-side

guard ring (13) on the piston. Place the piston
on the press. As shown in the illustration on
the right, the seal (14) is installed with the
tools indicated.

B. Correction of seal (14)

★ Install the seal (14) and the guard ring (13)

on the other side. In order to prevent the ex- Fig.8-236
pansion of the seal (14), a corrector must be
used to correct the seal (14) which has been
stretched during installation. The piston rod
may not be able to go in the cylinder barrel if
the seal (14) is not corrected timely.

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C. Installation of slide ring (12)

★ Slightly open the slide ring (12) and install it

axially. Excessive opening of the slide ring
(12) can fail installation.

4. Assembling the piston rod assembly

A. Fix the piston rod (1).

B. Install the cylinder (2) on the piston rod.

★ Make sure that the dust ring lip or the U-ring

lip is not stopped by the shoulder of any part.
Install the cylinder head and the piston rod
with the tools.

Fig.8-237

C. If the bottom side of cylinder contains a buf-

fer (not for bucket cylinder), install the buffer
bearing and the buffer seal in the following
order.

a. Let the notched side of the buffer seal (10)

face the piston while installing the buffer seal
(10) in the groove.

b. Install the buffer sleeve (8) according to the

indication in the illustration on the right.

c. Install the stopper ring in the groove. Install

the elastic ring after the buffer sleeve (8) is
pushed to the bottom. A rubber hammer
should be used for the tapping job in order to
Fig.8-238
avoid damaging the piston rod and the buffer
bearing.

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D. If the head side of cylinder contains a buf-

fer, install the buffer sleeve (6) and the buffer
seal (23) according to the following order.

a. The piston nut must be installed after instal-

lation of the buffer bearing.

b. The buffer seal (23) must be installed in the

groove, with its notches facing the piston.

c. The buffer sleeve (6) must be installed ac-

cording to the illustration on the right.

Fig.8-239

E. Tighten the piston nut (5).

Piston nut (arm): 9600 Nm {979.6 kgm}

Piston nut (boom and bucket): 6200

Nm {632.6 kgm}

★ Insufficient tightening can cause oil leak-

age, loose nut and thread breakage. In addi-
tion, excessive tightening can cause
expansion of the buffer shaft on the extending
side or deformation of piston on the contact
side.

★ Thoroughly clean and grease (with banana

oil) the threaded portions of the piston, nuts
and piston rod before tightening the nuts.

F. Treatment of the piston against loosening

Fig.8-240

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★ After the piston nut (5) is tightened, put in

the steel ball (4), tighten the setscrew (3) and
punch to rivet the two peripheral points.

Setscrew (3): 66.9 Nm {6.8 kgm}

5. Install the piston into the cylinder barrel.

A. Fix the barrel in a vertical or level manner.

B. Install the piston rod into the cylinder

barrel.

★ If fixed in a vertical manner, the piston rod

falls into the barrel under its gravity.

★ Make sure that the slide ring does not fall

while the piston is inserted into the barrel.

Fig.8-241

6. Tightening of cylinder head

Tighten the bolts following the sequence

shown in the illustration on the right.

Bolt: 267 Nm {27.2 kgm}

7. Install the tubing.

Fig.8-242

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8.30 Work Equipment AS

8.30.1 Removal

Fully extend the arm and the bucket. Lower

the work equipment to the ground. Move the
hydraulic lockout control to the locked
position.

Release remaining pressure in the hydraulic

circuit. See “Remaining Pressure in Hydraulic
Lines - Relieve” on page 6-29.

1. Disconnect the grease hose (1).

2. Lift the boom cylinder assembly (2). Re-

move the lockbolt (3).

3. Remove the plate (4) and then the pin (5).

★ There are shims installed. Count the shims

and check the thickness. Place the shims in a
safe place.
Fig.8-243
4. Start the engine and retract the piston rod.

★ Secure the piston rod with a wire rope in or-

der to prevent the piston from slipping out.
Place the cylinder on a bench or support. The
grease fitting on the bottom side must be re-
moved in the later case.

★ Remove the other boom cylinder in the

same way.

5. Remove the two hoses (6) of bucket cylin-

der and the two hoses (7) of the arm cylinder.

★ Cork the hoses to prevent outflow of oil. Tie

the hoses to the valve side

6. Remove the mid-connector (8) used for

work lamp.

Fig.8-244

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7. Remove the decorative plate (9). Lift the

work equipment and remove the plate (10).
Remove the pin (11) from the bottom.

★ There are shims installed. Count the shims

and mark their locations.

8. Remove the work equipment assembly and

disassemble it.

Work equipment assembly: Fig.8-245

Model Weight
SY500H 3656 kg

8.30.2 Installation

● Installation is performed in the reverse order

of removal.

★ A clearance (a: 0.5 - 1.5 mm) should be left

between the plate and the nut when tightening
the locknut.

Greasing after assembling the pin:

Grease (MoS2 G2-LI)

Never put your finger in the pin bore during

alignment. Fig.8-246

★ Adjust the shim thickness in order to have a

desired clearance (a: 0.5 ＜ a ＜ 1 mm) be-
tween the piston end (12) and the plate (4).

★ Standard shim thickness: 1.0 mm and 2.0

mm.

Greasing after assembling the pin:

Grease (MoS2 G2-LI)

Never put your finger in the pin bore during

alignment. Fig.8-247
● Refilling the hydraulic oil

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Refill hydraulic oil to the specified level. Start

the engine to circulate the oil in the hydraulic
system, and check the oil level again. Add
more hydraulic oil if necessary.

● Purging the air

Purge the air from travel motor. See “Air in

Each Component - Purge” on page 6-34.

8.31 Air Conditioner AS

8.31.1 Removal

Special tools

Part Neces
ID Model Qty
Name sity
Rob
Refrig
inair
erant ● 1
34711-
refiller
S 2K
Refrig Inoue
erant Qing- ● 1
refiller Hua

Disconnect the cable from the negative (-)

post of the battery.

1. Drain the coolant.

Coolant: About 22.5 L

2. Recover refrigerant from the air-condition-

ing system with the tool (S).

Fig.8-248

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 Disassembly and Assembly SY500H Hydraulic Excavator

3. Remove the pad on the bottom cover (1).

Fig.8-249

4. Use the start key to open the left rear cover

of the cab. Remove the external air filter ele-
ment (2).

Fig.8-250

5. Remove the monitor lower covers (3) and

(4).

★ Disconnect the wire (M19) of the cigar light-

er before removing the cover (3).

6. Remove the air duct (5) on the right side.

Fig.8-251

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7. Remove the back cover (6).

Fig.8-252

8. Remove the back air duct (7).

9. Remove the left air duct (8).

10. Remove the baffle (9).

11. Remove the right air duct (10).

Fig.8-253

12. Remove the cover (11).

13. Remove the cab's center connector (12).

14. Remove the radio antenna(13).

Fig.8-254

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15. Remove the air duct (14), connector (15)

and air conditioner wiring connection (16). Re-
move the four mounting bolts and the control-
ler assembly (17). Remove the cover (18).

Fig.8-255

16. Remove the air conditioner water pipes

(19) and (20) as well as the dripping tube (21)
under the bottom cover.

Fig.8-256

17. Remove the air conditioner unit (22).

★★ Also disconnect the two hoses connecting

to the bottom of the air conditioner when re-
moving the air conditioner unit.

Fig.8-257

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8.31.2 Installation

● Installation is performed in the reverse order of removal.

★ Keep the hoses free from contamination by dirt, dust or water while installing the return hose of
the air conditioner.

★ Make sure that the O-ring seal is present in the connection before connecting a hose of the air
conditioner.

★ Make sure that the O-ring seals are free from any damage or deformation.

★ Apply compressor oil (ND8#) to the threads of the parts connected with the refrigerant lines.
Tighten the line connections with a double-end spanner.

Screw (hose clamp): 8.83~14.7 Nm {0.9~1.5 kgm}

Bolt (pressure plate): 13.5±1.2 Nm {1.38±0.12 kgm}

● Refilling refrigerant

Refill refrigerant (HFC-134a) into the air conditioner circuit with the tool (S).

8.32 Counterweight AS
8.32.1 Removal

1. Hook the wire rope to the lifting eyes.

Fig.8-258

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2. Remove the four bolts (2 ).

3. Lift the counterweight levelly with wire rope

or chain hoist.

★ Take care not to damage the engine, radia-

tor or cooler.

Counterweight AS: 8550kg

Fig.8-259

8.32.2 Installation

● Installation is performed in the reverse order

of removal.

Threads (mounting bolt - counter-

weight): Thread adhesive (Tianshan 1277)

Mounting bolt (counterweight):

1,180~1,470 Nm {120~150 kgm}

Fig.8-260
★ Counterweight Installation and adjustment

A. Lift the counterweight with a crane to a suit-

able position over the frame.

B. Push the counterweight and install the

bolts. Adjustment is to be made according to
the following specification.

• Clearance with swivel: 10±5 mm(L)

• Clearance with bodywork door: 10±5 mm(L)
• Step difference from swing frame in left to
right direction b: max. 5 mm
• Step difference from bodywork door in left
to right direction a: 10±4
• Step difference from bodywork top cover in
upper to lower direction c: max. 5 mm

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8.33 Cab AS
8.33.1 Removal

Disconnect first the cable connecting to the

negative (-) post of the battery.

1. Remove the floor mat (1).

Fig.8-261

2. Remove the strorage boxes（2）and back

covers (3)

Fig.8-262

3. Disconnect the left harness (4) and radio

antenna （5）, the monitor harness connec-
tor (6) ， the engine ECU harness connector
(7) .

Fig.8-263

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4. Remove the window washer harness (8)

Fig.8-264

5. Remove the fresh air duct (9)

Fig.8-265

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6. Remove the storage box (10) from the

console.

Fig.8-266

7. Disconnect the electric checking harness

(12) reservoir(11)

Fig.8-267

8. Disconnect the window washer fluid reser-

voir(13).

Fig.8-268

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9. Remove the window washer hose(14).

Fig.8-269

10. Remove the five bolts (16) and the four

nuts (17).

★ Check the length of bolt before removal.

11. Lift the cab assembly (18) in order to re-

move it.

Cab AS: 433 kg

Fig.8-270

8.33.2

● Installation is performed in the reverse order

of removal.

Bolt: 200 Nm {20.4 kgm}

Nut: 210 Nm {21.4 kgm}

Fig.8-271

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8.34 Monitor
8.34.1 Removal

Disconnect first the cable from the negative (-)

post of the battery.

1. Unscrew the three bolts (4). Remove the

mounting plate and the monitor assembly
from the bracket (3).

2. Remove the nut (1) and the gasket (2) to

separate the monitor (5) from the mounting
plate.

Fig.8-272

8.34.2 Installation

● Installation is performed in the reverse order

of removal.

8.35 Controller AS
8.35.1 Removal

Disconnect first the cable from the negative (-)

post of the battery.

1. Remove the back covers (1) and (2).

Fig.8-273

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2. Remove the controller wiring connectors (3)

and (4).

3. Remove the four bolts and the controller as-

sembly (5).

Fig.8-274

8.35.2 Installation

● Installation is performed in the reverse order

of removal.

8.36 Radio
8.36.1 Structure

1. Main structure

Fig.8-275

2. Wiring

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SY500H Hydraulic Excavator Disassembly and Assembly

Fig.8-276

8.36.2 Removal

1. Remove the console cover (1).

● Disconnect the power supply prior to

removal.

Fig.8-277

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2. Remove the radio connector CN-003F (3).

Fig.8-278

3. Remove the four screws (5) and the wash-

ers (6) in order to remove the radio (2) and the
radio mounting brackets (4) from the console
cover (1).

4. Remove the four screws (7) and the wash-

ers (8) in order to remove the radio (2) from
the radio mounting brackets (4).

Fig.8-279

8.36.3 Installation

● Installation is performed in the reverse order

of removal.

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8.36.4 Connector model and wiring

Fig.8-280

8.37 Battery
8.37.1 Structure

Fig.8-281

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(1) Spinning post (7) Active material paste

(2) Charge densimeter (8) Bag-type screen
(3) Heat-sealing cover (9) Polar group
(4) PP housing (10) Liquid-gas separator
(5) Central polar ear (11) Central busbar
(6) Forged grid

8.38 Battery
8.38.1 Installation and Removal

● Turn the start switch to the OFF position before removal.

1) Turnoff the switch (1).

● Open the tools box cover, Turnoff the switch

(1) to the OFF position.

CAUTION
● Battery gas can cause explosion. No
sparks or flames are allowed near the
battery.

2) Remove the bolts of the tools box， take

out the tools box (2).
Fig.8-282

3) Remove the bolts of the tools box base，

take out the base (3).

4) Remove the nuts of the batteries cover，

take out the battery cover (4).

5) Disconnect battery wiring cable and break-

er cable.

6) Remove the nuts of the sheet metal，take

out the sheet metal (5).

7) Take out battery (6). Fig.8-283

8.38.2 Installation

● Installation is performed in the reverse order

of removal.
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 SY500H Hydraulic Excavator Disassembly and Assembly

8.38.3 Replacement

There are two 12V batteries with grounding

negative (-) posts in the machine. If one bat-
tery fails in the 24V system, it must be re-
placed with one of the same type. Batteries of
different types are probably charged at differ-
ent speeds, which may cause one of them to
fail due to overloading.

● During installation, apply vaseline to battery

terminals in order to prevent corrosion.

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8.39 Start Switch

8.39.1 Structure

Fig.8-284

(1) Housing (8) Shield (15) Cover (22) Contact SPR-A

(2) Key (9) Pin (16) Spring (23) Contact B
(3) Ring (10) Spring (17) Ball (24) Terminal
(4) Knob (11) Disc (18) Spring (25) Bolt
(5) Nut (12) Spring (19) Contact SPR-B (26) O-ring seal
(6) Cylinder (13) Plug (20) Contact A (27) Harness AS
(7) Cap (14) Rotor (21) Seat (28) Washer

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8.39.2 Removal

1. Unscrew the setscrew to remove the con-

sole cover.

Fig.8-285

2. Remove both setscrews in order to sepa-

rate the mounting plate and the start switch
from the console cover.

● Unplug the connector of start switch before

removal.

Fig.8-286

3. Remove the nut so as to remove the start

switch from its mounting plate.

Fig.8-287

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8.39.3 Installation

● Installation is performed in the reverse order

of removal.

8.39.4 Working principle and wiring

Working principle

Wiring

Fig.8-288

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8.40 Electrical Power Center

8.40.1 Installation and Removal

1) Open the door of electrical box.

Fig.8-289

2) Take off the connector and terminal.

Fig.8-290

3) Remove the bolts so as to separate the

Electrical Power Center from the electrical
box.

Fig.8-291

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8.40.2 Installation

● Installation is performed in the reverse order

of removal.

8.41 Wiper
8.41.1 Structure

Fig.8-292

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8.41.2 Working principle

Fig.8-293

8.41.3 Removal

1. Remove the decorative button in order to

remove the interior decoration.

Fig.8-294

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2. Remove the moving mechanism and the

motor.

● Unscrew the bolts to remove the wiper mo-

tor and moving mechanism from the cab.

Fig.8-295

3. Remove the arm and the blade.

● Unscrew the nut to remove the wiper arm

and blade from the cab.

Fig.8-296

8.41.4 Installation

● Installation is performed in the reverse order

of removal.

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8.41.5 Wiper arm angle adjustment

• The arm should stops moving when the

blade reaches the stopper.
• If the arm is still working when the blade
reaches the stopper or the arm already
stops working before the blade reaches the
stopper, the moving angle of wiper should
be adjusted to prevent breakdown of the
wiper.
• Adjust the wiper in such a way. Loosen the
locknut; adjust the arm working angle ac-
cording to actual condition. Make sure that
the wiper motor stops working at the mo-
ment that the blade reaches the mechanical
stopper.
Fig.8-297

8.42 Relays
8.42.1 Engine relays

1. Starter relay - check

Check the conduction and action. Replace the

relay in case of any failure.

Fig.8-298

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2. Battery relay-check

Check the conduction and action. Replace the

relay in case of any failure.

Fig.8-299

3. Glow relay-check

Check the conduction and action. Replace the

relay in case of any failure.

4. Safety relay

● Check the resistance between terminal 2

and terminal 3.

Standard Value Approx. 200W

● Check the conduction and action. Replace

the relay in case of any failure.
Fig.8-300

8.42.2 Other load relays

1. Function and locations

Other load relays are mounted in the electrical

cabinet behind the cab.

2. Removal and installation

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Removal

Unplug the relay from its seat.

Installation

● Installation is performed in the reverse order

of removal.

Fig.8-301

3. Relay connector and wiring

Fig.8-302

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 Disassembly and Assembly SY500H Hydraulic Excavator

8.43 Connector Terminals

8.43.1 Insertion

1. Hold tightly a wire terminal at a distance of

about 25 mm from its end.

Fig.8-303

2. Hold the connector. Let the rear seal face

you.

Fig.8-304

3. Align the terminal with a hole on the seal

and push it perpendicularly to the bottom.
Slightly pull back the wire in order to ensure
that the terminal is locked in place.

Fig.8-305

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 SY500H Hydraulic Excavator Disassembly and Assembly

8.43.2 Removal

1. Hold the connector, with its back end facing

you. Select a suitable tool and clip on the
wire.

Fig.8-306

2. Push the tool along the wire into the con-

nector so that the tool can expand the terminal
lock shoulder and reach its flanged part.

Fig.8-307

3. Pull out the tool to remove the wire with

terminal.

Fig.8-308

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8-156 Shop Manual-June 2016

 SY500H Hydraulic Excavator System Schematics

System Schematics

9 System Schematics .......................................................................................................9-1

9.1 Hydraulic Circuit Diagram ....................................................................................................9-3
9.2 Electrical Diagram.................................................................................................................9-4
9.3 Cab harness........................................................................................................................ 9-16
9.4 Control Switch Harness..................................................................................................... 9-17
9.5 Tool box Harness................................................................................................................ 9-18
9.6 Pump room Harness.......................................................................................................... 9-19
9.7 Vehicle Body Harness ....................................................................................................... 9-20
9.8 Boom Harness.................................................................................................................... 9-21

Shop Manual-June 2016 9-1

System Schematics SY500H Hydraulic Excavator

WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.

9-2 Shop Manual-June 2016

 SY500H Hydraulic Excavator System Schematics

9.System Schematics
9.1 Hydraulic Circuit Diagram

Fig.9-1

Shop Manual-June 2016 9-3

 System Schematics SY500H Hydraulic Excavator

9.2 Electrical Diagram

Fig.9-2

9-4 Shop Manual-June 2016

 SY500H Hydraulic Excavator System Schematics

Fig.9-3

Shop Manual-June 2016 9-5

 System Schematics SY500H Hydraulic Excavator

Fig.9-4

9-6 Shop Manual-June 2016

 SY500H Hydraulic Excavator System Schematics

Fig.9-5

Shop Manual-June 2016 9-7

 System Schematics SY500H Hydraulic Excavator

Fig.9-6

9-8 Shop Manual-June 2016

 SY500H Hydraulic Excavator System Schematics

Fig.9-7

Shop Manual-June 2016 9-9

 System Schematics SY500H Hydraulic Excavator

Fig.9-8

9-10 Shop Manual-June 2016

 SY500H Hydraulic Excavator System Schematics

Fig.9-9

Shop Manual-June 2016 9-11

System Schematics SY500H Hydraulic Excavator

Fig.9-10

9-12 Shop Manual-June 2016

 SY500H Hydraulic Excavator System Schematics

Fig.9-11

Shop Manual-June 2016 9-13

System Schematics SY500H Hydraulic Excavator

Fig.9-12

9-14 Shop Manual-June 2016

SY500H Hydraulic Excavator System Schematics

Fig.9-13

Shop Manual-June 2016 9-15

System Schematics SY500H Hydraulic Excavator

9.3 Cab harness

Fig.9-14

9-16 Shop Manual-June 2016

SY500H Hydraulic Excavator System Schematics

9.4 Control Switch Harness

Fig.9-15

Shop Manual-June 2016 9-17

System Schematics SY500H Hydraulic Excavator

9.5 Tool box Harness

Fig.9-16

9-18 Shop Manual-June 2016

SY500H Hydraulic Excavator System Schematics

9.6 Pump room Harness

Fig.9-17

Shop Manual-June 2016 9-19

System Schematics SY500H Hydraulic Excavator

9.7 Vehicle Body Harness

Fig.9-18

9-20 Shop Manual-June 2016

SY500H Hydraulic Excavator System Schematics

9.8 Boom Harness

Fig.9-19

Shop Manual-June 2016 9-21

System Schematics SY500H Hydraulic Excavator

9-22 Shop Manual-June 2016

www.sanygroup.com

Sany Heavy Machinery Co., Ltd.

Sany Heavy Machinery Industrial Park, Dongcheng avenue, Kunshan Economic
Development Zone, Jiangsu, China

P.C.: 215300
E-mail: crd@sany.com.cn
Service hotline: 4008 28 2318 Tel: 4008 87 9318