Sany - Troubleshooting

SY195/205/215/225C9 Crawler Hydraulic Excavator Troubleshooting
Troubleshooting
7 Troubleshooting
Shop Manual - June 2013 7-1

Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
7-2 Shop Manual - June 2013

7 TROUBLESHOOTING
7.1 Points to Remember When Troubleshooting


7.2 Troubleshooting Procedures
1. Read related technical manuals in detail.

Have a knowledge of related system,
principle of operation, and structure,
function and technical specification of
parts.
2. Ask operator
3. Check before starting

Item Criterion Remedy

4. Operate machine by yourself (trial run)
5. Perform troubleshooting
6. Find out possible causes
Remark:

7.3 Connector Location and Electrical Circuit Diagram
Location
Connec- No. of Sensor,
Type Name of device Cab Engine
tor No. pin Layout solenoid
circuit circuit
circuit

Location
circuit circuit
circuit

Location
circuit circuit
circuit

Connector code Description

7.3.1 Connector location layout






7.3.2 Electrical element circuit diagram (cab circuit)


7.3.3 Electrical control circuit diagram (engine circuit)


7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit)

7.3.5 SWP type connector

7.3.6 A/AMP type connector

7.3.7 DT type connector

7.4 Failure Symptoms and Troubleshooting Codes
Troubleshooting
No. Symptom
Code E mode H mode (Engine)
Action to be taken concerning Service Code, User Code and Failure Code
Engine-related failure
Failure related to work equipment, swing and travel
Work equipment-related failure

Troubleshooting
No. Symptom
Code E mode H mode (Engine)
Travel-related failure
Swing-related failure
Monitor panel-related failure
Other failure

7.5 Troubleshooting with an Event Code

Information in troubleshooting table
Cause Standard value in normal state and remarks on troubleshooting
Related circuit diagram

E111 (controller memory failure (FROM))
Cause Standard value in normal state/Remarks on troubleshooting

E212 (throttle motor current & motor connection abnormal)

E213 (throttle motor operation suspends)

E214 (throttle motor working range abnormal)

E015 (power supply voltage abnormal)
- + - +

E116 (controller internal temperature abnormal)

E017 (abnormal output of 5v power supply in sensor)

E118 (abnormal communication between controller and monitor)

E320 (abnormality in front pump output pressure)

E321 (abnormality in rear pump output pressure)

E322 (abnormality in arm-in pilot pressure)

E323 (abnormality in arm-out pilot pressure)

E324 (abnormality in boom-raise pilot pressure)

E325 (abnormality in boom-lower pilot pressure)

E326 (abnormality in bucket-curl pilot pressure)

E327 (abnormality in bucket-dump pilot pressure)

E328 (abnormality in swing pilot pressure

E329 (abnormality in left travel pilot pressure)

E330 (abnormality in right travel pilot pressure)

E231 (abnormality in fuel control dial set voltage)

E237 (abnormality in hydraulic oil temperature)

E541 (abnormality in engine speed)

E450 (abnormality (a) in front pump proportional solenoid coil current)

E450 (abnormality (b) in front pump proportional solenoid coil current)

E451 (abnormality (a) in rear pump proportional solenoid coil current)

E451 (abnormality (B) in rear pump proportional solenoid coil current)

E452 (abnormality (A) in swing priority proportional solenoid coil current)

E452 (abnormality (B) in swing priority proportional solenoid coil current)

E453 (abnormality (A) in bucket conﬂuence proportional solenoid coil current)

E453 (abnormality (B) in bucket conﬂuence proportional solenoid coil current)

E455 (abnormality (A) in boom priority 2 proportional solenoid coil current)

E455 (abnormality (B) in boom priority 2 proportional solenoid coil current)

E460 (abnormality in dual speed travel solenoid valve)

7.6 Troubleshooting of Electrical System (E - Mode)

Information in troubleshooting table
Cause Standard value in normal state and remarks on troubleshooting
Related circuit diagram

E-1 Engine does not start


E-2 Engine runs rough or is unstable

E-3 Power supply of machine cannot be cut off


E-4 Auto idle not functioning

E-5 Preheating function fails

E-6 Work equipment does not work

E-7 Boom-raise speed or power is low

E-8 Arm speed or power is low

E-9 Bucket speed or power is low


E-10 Travel speed or power is low

E-11 Blank monitor display

E-12 Monitor displays nothing

E-13 Dual speed travel not functioning

E-14 Incorrect engine coolant reading

E-15 Incorrect fuel level reading

E-16 Wiper does not work

E-17 Incorrect arm-in pilot pressure reading

E-18 Incorrect arm-out pilot pressure reading

E-19 Incorrect boom-raise pilot pressure reading

E-20 Incorrect boom-lower pilot pressure reading

E-21 Incorrect bucket-curl pilot pressure reading

E-22 Incorrect bucket-dump pilot pressure reading

E-23 Incorrect swing pilot pressure reading

E-24 Incorrect left travel pilot pressure reading

E-25 Incorrect right travel pilot pressure reading

7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode)

A Schematic of hydraulic system and mechanical system


Information contained in troubleshooting table

H-1 Work equipment speed slow, or swing and travel speeds slow

H-2 Engine speed drops sharply or engine stalls

H-3 Work equipment, swing, and travel systems do not work

H-4 Abnormal noise in hydraulic pump

H-5 Auto deceleration not functioning

H-6 Boom speed slow

H-7 Arm speed slow

H-8 Bucket speed slow

H-9 Work equipment cylinders no response in separate operation

H-10 Work equipment drifts excessively


H-11 Work equipment moves sluggishly
H-12 Other work equipment moves while single oil circuit is relieved

H-13 Travel speed drops considerably while swinging and travelling

H-14 Machine deviates during travel

H-15 Travel speed is low

H-16 Machine is not steered well or steering power is low

H-17 Travel speed cannot be changed

H-18 Travel system fails (only at one side)

H-19 Swing operation fails


H-20 Swing acceleration poor or swing speed low


H-21 Upper structure overruns remarkably when it stops swinging

H-22 Large shock is produced when upper structure stops swinging
H-23 High noise is produced when upper structure stops swinging

H-24 Swing drift excessive

Sany - Troubleshooting

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SY195/205/215/225C9 Crawler Hydraulic Excavator Troubleshooting

Shop Manual - June 2013 7-1

7-2 Shop Manual - June 2013

7.1 Points to Remember When Troubleshooting

Shop Manual - June 2013 7-3

7-4 Shop Manual - June 2013

7.2 Troubleshooting Procedures

1. Read related technical manuals in detail.

3. Check before starting

Shop Manual - June 2013 7-5

Item Criterion Remedy

7-6 Shop Manual - June 2013

4. Operate machine by yourself (trial run)

6. Find out possible causes

Shop Manual - June 2013 7-7

7.3 Connector Location and Electrical Circuit Diagram

7-8 Shop Manual - June 2013

Shop Manual - June 2013 7-9

7-10 Shop Manual - June 2013

Connector code Description

Shop Manual - June 2013 7-11

7.3.1 Connector location layout

7-12 Shop Manual - June 2013

Shop Manual - June 2013 7-13

7-14 Shop Manual - June 2013

Shop Manual - June 2013 7-15

7-16 Shop Manual - June 2013

Shop Manual - June 2013 7-17

7.3.2 Electrical element circuit diagram (cab circuit)

7-18 Shop Manual - June 2013

Shop Manual - June 2013 7-19

7.3.3 Electrical control circuit diagram (engine circuit)

7-20 Shop Manual - June 2013

Shop Manual - June 2013 7-21

7-22 Shop Manual - June 2013

7.3.5 SWP type connector

Shop Manual - June 2013 7-23

7.3.6 A/AMP type connector

7-24 Shop Manual - June 2013

7.3.7 DT type connector

Shop Manual - June 2013 7-25

7.4 Failure Symptoms and Troubleshooting Codes

Failure related to work equipment, swing and travel

Work equipment-related failure

7-26 Shop Manual - June 2013

Monitor panel-related failure

Shop Manual - June 2013 7-27

7.5 Troubleshooting with an Event Code

7-28 Shop Manual - June 2013

Information in troubleshooting table

Cause Standard value in normal state and remarks on troubleshooting

Related circuit diagram

Shop Manual - June 2013 7-29

E111 (controller memory failure (FROM))

Cause Standard value in normal state/Remarks on troubleshooting

7-30 Shop Manual - June 2013

E212 (throttle motor current & motor connection abnormal)

Cause Standard value in normal state/Remarks on troubleshooting

Shop Manual - June 2013 7-31

E213 (throttle motor operation suspends)

Cause Standard value in normal state/Remarks on troubleshooting

7-32 Shop Manual - June 2013

E214 (throttle motor working range abnormal)

Cause Standard value in normal state/Remarks on troubleshooting