Sy195-205-215-225c9 Manual 2014-11-13-389-409

Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator
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
T-101 Terminal 1 Battery relay coil (positive) M-2 D-1
T-102 Terminal 1 Battery relay coil (negative) M-2 D-1
Battery relay contact (out-
T-103 Terminal 1 M-2 D-1
put)
T-104 Terminal 1 Battery relay contact (input) M-2 D-1
T-106 Terminal 1 Starting motor (B terminal) J-6 L-3
.
De al
T-107 Terminal 1 Alternator (B terminal) K-6 L-5
pt
T-108 Terminal 1 Preheating fuse (21#) M-2 G-9
T-109 Terminal 1 Preheating fuse (17#) M-2 G-9
T-110 Terminal
g n1
o
Body grounding M-1 B-1
T-111 Terminal 1 Body grounding K-6
Preheating resistance wire
in ti
T-112 Terminal 1 J-7 H-9

terminal
T-115 Terminal 1 Starting motor grounding J-6 L-3
Body grounding (at the sides
et a
T-119 Terminal 1 M-1 B-9

of battery)
n
T-201 Terminal 1 Body grounding X-6

rk er
T-202 Terminal 1 Body grounding X-6

K5 R 5 Horn relay X-6 H-9
K6 R 5 Lamp relay X-6 I-9
Ma t
K8 R 5 Top lamp relay X-6 J-9

In
K7 R 5 Parking relay X-6 J-8

KB — 5 Battery relay M-2 D-1
K3 R 5 Starting relay X-6 L-4
KH — 5 Preheating relay Y-6 G-9
K10 R 5 Pilot valve relay X-6 K-1
CN-106F A 2 Junction connector W-6 J-2
CN-142M D 12 Intermediate connector W-6 C-9
CN-131M D 12 Intermediate connector R-5 C-9
CN-302F A 3 Intermediate connector R-6 D-9
CN-301M S 6 Intermediate connector R-6 F-9
CN-132F D 12 Intermediate connector R-5 C-5
CN-1-110 D 6 Intermediate connector AB-4 K-5
CN-121F D 12 Intermediate connector W-6 D-8
7-8 Shop Manual - November 2014

SY195/205/215/225C9 Crawler Hydraulic Excavator Troubleshooting
Location
circuit circuit
circuit
CN-241M D 12 Intermediate connector W-6 F-8
CN-1-112 3 3 Intermediate connector W-6 C-9
CN-1-111 D 8 Intermediate connector W-6 C-9
CN-7-705 D 12 Monitor panel P-5 D-9
CN-801F H 6 Intermediate connector J-7 K-8
CN-445M S 6 Intermediate connector I-7 F-3
CN-204F A 2 Intermediate connector X-6 C-8
.
CN-412F A 3 Intermediate connector X-6 C-8
De al
pt
CN-112M A 2 Washing motor K-5 K-4
CN-102M A
g n 2 Platform lamp E-5 K-2
CN-104M A 2 Boom lamp (left) E-7 K-1
o
CN-105M A 2 Boom lamp (right) E-7 K-2
Hydraulic oil temperature
in ti
CN-113M A 2 I-7 F-9
sensor
CN-101M S 1 Fuel level sensor F-6 F-9
CN-152M A 2 Intermediate connector W-6 F-8
et a
CN-613F L 6 Safety relay X-6 K-7

n
CN-661F S 16 Intermediate connector W-6 I-8

rk er
CN-161M S 16 Intermediate connector W-6

CN-115M DF 3 Main pressure sensor (front) I-7 F-4
CN-116M DF 3 Main pressure sensor (rear) I-7 F-4
Ma t
CN-128M DF 3 Arm-in pilot sensor I-6 F-5

In
CN-122M DF 3 Arm out pilot sensor I-6 F-4

CN-126M DF 3 Boom-up pilot sensor I-6 F-5
CN-125M DF 3 Boom-down pilot sensor I-6 F-6
CN-124M DF 3 Bucket-curl pilot sensor I-6 F-6
CN-127M DF 3 Bucket-dump pilot sensor I-6 F-6
CN-123M DF 3 Swing pilot sensor I-6

F-7
CN-120M DF 3 Travel pilot sensor (left) I-6 F-7
CN-121M DF 3 Travel pilot sensor (right) I-6 F-8
CN-448M S 2 Speed sensor I-7 F-9
CN-307M H 8 Top lamp switch R-5 C-3
CN-303M H 8 Work lamp switch R-6 C-2
CN-305M H 8 Washer switch R-6 C-2
Shop Manual - November 2014 7-9

Location
circuit circuit
circuit
CN-304M H 8 Wiper switch R-6 C-1
CN-104M A 2 Horn switch R-6 E-3
CN-306M H 8 Preheating switch R-5 F-1
CN-207F S 12 Air conditioner unit W-6
CN-113F AMP 2 F. pump solenoid valve I-7 F-2
CN-114F AMP 2 R. pump solenoid valve I-7 F-1
Boom priority solenoid valve
CN-135F AMP 2 J-6 F-2
.
2
De al
Bucket Confluence solenoid
CN-134F AMP 2 J-6 F-3
pt
valve
Boom priority solenoid valve
CN-132F AMP 2 J-6 F-3
g n 1
CN-136F AMP 2 Pilot solenoid valve J-6 L-2
o
Hi/Lo speed travel solenoid
CN-131F AMP 2 J-6 F-1
in ti
valve
CN-133F AMP 2 Swing priority solenoid valve J-6 F-4
F-108 W 1 Coolant temperature sensor J-7 F-8
et a
F-104 W 1 Horn (right) I-5 K-2

n
F-103 W 1 Horn (left) I-5 K-2

CN-616F AMP 81 Controller W-6 A-4
rk er
CN-615F AMP 40 Controller W-6 A-9

CN-800M S 2 Alternator terminal L/R K-6
Ma t
CN-7-707 AMP 2 Cigarette lighter P-4

In
CN-150M D 8 Intermediate connector AE-3

CN-107M HL 7 Radio W-6
PF021 - - Fuse box X-4
CN-1-001M A 2 Speaker (left) AE-6
CN-1-002M A 2 Speaker (right) AD-7
CN-1-103M A 2 Front right lamp AB-6
CN-1-004M A 2 Front left lamp AC-5
CN-1-005 H 1 Cab lamp AE-7

Connector code Description

S SWP type, Yazaki
A/AMP AMP, Japan
D DT type, Japan
H Hebi
HL Hulane Connectors
L Ling Xing Electronic Equipment
DF Delphi, U.S.
W AMP, Japan
Terminal Round terminal
.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

7.3.1 Connector location layout
CN-105M CN-104M CN-101M
.
De al
pt
6
g no
in ti
CN-102M
5
et a
n
rk er
4
Ma t
In
ZX215-1005033
A B C D E F

CN-113M CN-448M F-108

CN-113F T-112
CN-801F
CN-114F
T-106
CN-115M
T-115
CN-116M
T-111
CN-445M
CN-800M
T-107
.
De al
CN-112M
pt
g n CN-124M
CN-125M
o
CN-126M
in ti
F-104
F-103
et a
n
CN-128M
rk er
CN-127M
Ma t
CN-123M
CN-122M
In
CN-121M
CN-120M
CN-131F
CN-132F
CN-133F
CN-134F
CN-135F
CN-136F
ZX215-1005034
G H I J K L M

CN-307M CN-306M CN-132F

CN-305M
CN-304M
9 CN-303M
CN-104M
CN-302
CN-131M
8
CN-301M
.
De al
7
pt
g no
6
in ti
et a
5 CN-7-705
n
rk er
4
Ma t
CN-7-707
In
ZX215-1005035
N O P Q R S T

CN-1-111
CN-661F CN-161M CN-152M
CN-1-112
T-201
CN-241M T-202
K5
CN-121F
K6
K10
CN-142M K3
K7
K8
CN-613F
.
De al
CN-615F
pt
g n CN-616F
KH
o
in ti
CN-412F
et a
n
rk er
Ma t
In
CN-204F
PF021
CN-207F
CN-107M
CN-106F
ZX215-1005036
T U V W X Y Z

.
De al
pt
g no
in ti
et a
n
rk er
Ma t
In

CN-1-002M
9
CN-1-005
CN-1-001M
8
CN-1-103M
.
De al
pt
6 g no
in ti
5 CN-1-004M
et a
n
4
rk er
CN-1-110
Ma t
3
In
2
CN-150M
ZX215-1005037
AA AB AC AD AE AF

7.3.2 Electrical element circuit diagram (cab circuit) PF021

CN-1-112
F1
CANH
(D-3)
22 20 A
20
1 1
CANL 120ȍ resistance F3 5A
2 2 23
CN-7-705
CN-616F CANH
3
(D-12)
3
24 F4 15A
Monitor
CANL
Ground 1
29
4 4 4
25 F5 5A
8 8 8
2 CN-1-111 22 21
(D-8) 9 9 9
3 0 10 10 10 F7 10A
1 1 26
24Vpower 4 2 2 12 12 12
CN-131M CN-302F
9
5 3 3 CN-142M F9 5A
50 (D-12) 50
(D-12)
50 (A-3) 50 28
6 1 1 1 1
Fuel ctrl dial

1 1 1
7 5062 506 506 506 5A
2
00
2 2 2 2
00 3 3 00 3
2 29 F10
8 00 3 3 3 3
4 4
9 20 A
5 5 42 F11
10 6 6
11 43 F14 10A
12 CN-412F
AIN16 13 (A-3)
49 F15
15A
14 CAN+ 1 1
B
15 2 2 70 F17 10A
16
CAN- 3 3
GPS CN-121F
17 (D-12)
0
8 18
19
43
1
2
1
2 2
4
2
4
CN-204F
20 (A-2) 5 5
21 9 9
10 10
22
11 11 1 3 4 5 8 9 10 11 12
23 12 12 CN-241M
24 (D-12)
1 3 4 5 8 9 10 11 12
25
26
27
28
29
.
30
31
De al
32
33
Fuel control knob voltage 34
pt
7 35
36
37
38
39
40
g n 41
42
43
44
45
o
46
47
48
6 49
in ti
50
51
52
53
00
s GND 54 28 X-1
00
s GND 55
50
s PWR 56
57 CAN- 70 X-2
58
59 CAN+
et a
60
61
62
CN-132F
63
5
(D-12)
n
64 1
65 2
1
33 X-3
2
66 3 3 24 X-4
67 4 4 25 X-5
68 5
rk er
5
69
37 X-6
70 12 12
71
36 X-7
72
00
s GND 73
s PWR 74
50 35 L X-8
50
s PWR 75
72 X-9
76 CAN+
CAN-
CAN+ 77
35 H X-10
Ma t
4 CAN- 78
79
23 X-11
80
81
X-12
In
CN-615F
82 X-13
83
84
85 X-14
86
87
88
89
90
23 31
3 91
92 Top lamp switch 21
20
93 Horn switch
94 CN-104M
95 70 72
96
97 CN-307M
98
99 TERMINAL
B BRACCR1 R2 C
100 Work lamp switch HEAT
101
OFF Start switch
ON
102 START
2 103
104
24 33 22 13
105 CN-303M
106
107 Washer switch
22 11
108 11
109 Stabilized voltage diode 25 37 13 13
110 9 9
CN-152M CN-153M
111 1 2 1 2 CN-332M
CN-305M
112 S-6
113
0 0 42 0 42 Wiper switch
Ground 114
0
Ground 115
36
116 25
117
35 L 1 2 3 4 5
118
1 2
42
24Vpower supply 119
1 35 H 1 2 3 4 5
42
24Vpower supply 120 KB
121
122
CN-304M Battery relay + - + -
Chassis GND
ZX215-1005038
A B C D E F

★ This circuit diagram has been compiled by extracting the wiper system and each switch control system
from the overall electrical circuit diagram.
Access lamp
28
Horn relay Lamp relay Top lamp relay

9
K5 K6 K8
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
31 0 23 32 33 0 24 34 72 0 70 71 0
8
CN-1-110
(D-6) Wiper
0
1 1
X-1 25
.
2 2
36 3
De al
M
CN-161F 3
X-2 (S-16)
35H 4 4
1 1 7
pt
3 3
4 4
5 5 35 L
6 6 5 5
X-3
X-4
g no
7
8
7
8
X-5
X-6 6
CN-112M
in ti
X-7 (A-2) Washer motor
0
1 1
X-8 2 2 37 M
X-9
X-10
et a
Right top lamp

X-11
1 1
0
5
n
2 2 71
X-12
X-13 Left top lamp

rk er
1 0
1
X-14 2 2 71
CN-150M
(S-8) F-104
R+
1 1
R+
(W-1)
R- R- Horn
2 2 4
Ma t
L+ L+ 1 1
3 3 CN-661F
L- 4 4 L-
(S-12)
0
5 5 0 32 F-103
3 3
71 71
(W-1)
In
6 6 34
4 4
0 7 7 0
1 1
26 8 8 26
F6
21 20 b CN-102M Rotating stage
(A-2) work lamp
F8
0
1 1
0 3
21 38 34 34
2 2
CN-102M Left boom

1 (A-2)
20 b
R+
0
work lamp
L+
2 1 1
3 2 2 34
0
4 CN-102M
20 b
5 Right boom
R- (A-2) work lamp
6 0
L- 1 1
7
CN-107M
2 2 34 2
Radio panel
Right speaker
Compressor clutch
57 1
61 a
0 57 4 Left speaker
60 a
1 2 5
0 6 0 0 Cab lamp
CN-109M 38 7 26
1 1
38 26
8 2 2
CN-207F
Air conditioner panel
CN-442F
(S-12)
CN-7-111
(S-8)
1
60a 60a
4 4 7 7
61a 61a Ex air sensor
8 8 8 8
ZX215-1005039
G H I J K L

7.3.3 Electrical control circuit diagram (engine circuit)

CN-332M
S-6 TERMINAL B BR ACCR1 R2 C
T-102 22 22
CN-616F T-119 T-110 11 11 HEAT
Body ground CN-241F
13 13 OFF
1 0 20
(D-12) 9 9 ON
Grounding 2 1 1 22 11 8 11
START
3 - + - + 2 2 10
8
22 13 16 11
4 42 20 20
F1 20A22
Controller power supply 5 9 9 F2 5A10
21 21
6 11 11
PF021
7
9 8
CN-152M CN-153M
9
10 1 2 1 2
11
12 0 42 0 42
13
14 506
Throttle position feedback 15
16
17
18
19
20 X-1
21 21
22
8 23
24
25
26 X-2
27 10
28
29
30 X-3
21
.
31
32
De al
33
34
35 13 X-4
pt
36
37
7 38
39
40 X-5
41 18
g n
42
43
44
45 22 X-6
46
o
47
48
49
50 12 X-7
6
in ti
51
52
53 00
54 00
55 50 X-8
5Vpower supply 56 0
57
58
59 606 X-9
60
et a
61
62 X-10
63 50
64
n
65
5 66 507 X-11
67
68 X-12
69 MT+
rk er
70
71 X-13
72 00 00
73 50
5Vpower supply74 X-14
50 MT-
5Vpower supply75
76
77 F16 CN-221M
78
Ma t
79 1 1
4 80
81
CN-615F
In
CN-161F
82 27
83 12 12 105
84
85 14 14
Pilot switch
86
87
88
89
90
91
92
3 93
94
95
96
97
98
99
100
101
102
103
104 MT+
Throttle motor output signal+ 105
106
2
107
108
109
110
111
112 MT- 7 7
113
Grounding 114
0
Grounding 115
0 CN-331F
116
117 21
0 105 11 12
118 CN-241F F11 21
24Vpower supply
42 T-102 T-101 T-103 T-104
1 2 3 4 5 Preheat switch 1 2 3 4 5
119 4
24V power supply120 42 1 2
1 2 3 4 5
K3 1
1 2 3 4 5 2 3 4 5
121
1
1 2 3 4 5
122 KB 16 18
Battery relay
Pilot valve relay CN-306M Locking relay
ZX215-1005040
A B C D E F G
★ This circuit diagram has been compiled by extracting the engine preheat system, startup system and
governor system from the overall electrical circuit diagram.
T-112
17
Preheat relay Parking relay
KH
1 2 3 4 5 K7 1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
F13 160A
T-108 T-109
0 18 16 17 0 13 64 63 65 9
7 7 17 Preheater
9 9
14
CN-661M 12 12
(S-16)
10 10
Preheater indicator
15 15
CN-442F
(D-12) 17
1 1
0 2 2
CN-121F
CN-661F
CN-801F
22
64 B
8
(D-12) (H-6) 63 A
65 P2
(S-16)
X-1 21 5 5 606 22 P1
1 1 1 1 E
64
65
2 2 Parking motor
X-2 10 6 6 63 0
12 3 3
0
X-3 7 7 4 4
21 65
63
9 9 6 6
.
X-4 13
De al
64
10 10
18
X-5
7
pt
X-6 22
X-7 12
g n
X-8 0 CN-613F
12 a
1 1
o
X-9 606 14 12a
S
2 2 14
L Safety relay
6
10
10 R
3 3 47
P
X-10
in ti
50 47
4 4 0
0
6 6
X-11 507
X-12 MT-
et a
X-13 00
5
n
X-14 MT+ 10
14 R
21 L
47 B
P
E
rk er
0
Generator
Body ground
4
Ma t
In
CN-112M
1 2
12 a 12
CN-111F
1 1
12
2 2
12 a
21
E
0
Starting motor
3
A3 Body ground
F-310 Charging indicator

10
1 1
14
F-311
2 2
Connector 282080-1 CN-316F
(AMP-2)
1 2
606
1 1
2
2 2
Pilot solenoid valve
M13
(S-6)
50
1 1
507
2 2 1
2 Throttle motor
3
MT-
3 3 5 AC-2000
6
00
MT+
5 5 1
6 6
ZX215-1005041
G H I J K L M

7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit)
CN-101M
509 (S-1)
CN-616F 1 1 Fuel level sensor
CN-448M
1 (S-2)
Grounding 2 108A 1 1
3 108B Engine speed sensor
4 2 2
9 Controller power supply 5

6 CN-113M
(A-2)
7
8 511 1 1
9 42 Hydraulic oil temp. sensor
2 2
10
Oil level sensor 11 CN-152M
12 (A-2)
13 0
14 1 1 240欧
15 511 2 2 w1/4 F-108
16 (W-1)
17 510 Coolant temp. sensor
18
Speed sensor GND 19 508
8 20
21 0
Oil pressure switch
22
CN-121M
23 (DF-3)
24 50 A A
25 0 Right travel pilot
26 B B
27 201 C C
pressure sensor
28 CN-120M
29 50 (DF-3)
.
Coolant temp. sensor 30 A A
Hydraulic oil temp. sensor 31 0 Left travel pilot
De al
B B
32 200 C C
pressure sensor
33 CN-123M
34
pt
(DF-3)
50
7 35
36 0
A A
Swing pilot
B
37 208
B
pressure sensor
Pulse input 38 C C
39 CN-124M
40 (DF-3)
50
g n 41
42
43
44
0
205
A
B
C
A
B
C
Bucket curl pilot
pressure sensor
45 CN-127M
o
(DF-3)
46 50 A
47 0
A
Oil pressure switch 48 B B Bucket dump pilot
6 Travel sensor (left) 49 204 C C

pressure sensor
in ti
Bucket dump sensor 50 CN-125M
Boom lower sensor 51 (DF-3)
Arm out sensor 52 50 A A
Rear pump main pressure sensor 53
0 B B Boom lower pilot
s GND 54 207 C pressure sensor
s GND 55 C
s PWR 56 CN-126M
57 (DF-3)
58
50 A A
59 0 Boom raise pilot

et a
B B
60 206 C C
pressure sensor
61 CN-128M
62 (DF-3)
63 50
5 A A
n
64 0 B B Arm in pilot
65 203 C
pressure sensor
66 C
Travel sensor (right) 67 CN-122M

Swing sensor 68 (DF-3)
50
rk er
Bucket curl sensor 69 A A

Boom raise sensor 70 0 B B
Arm out
Arm in sensor 71 202 C C
pressure sensor
Front pump main pressure sensor 72
CN-115M
5V power supply GND 73 (DF-3)
5Vpower supply GND 74
5Vpower supply GND 75
50 A A
76 0 B B
Front pump
77 501 C C
pressure sensor
4
Ma t
78 CN-116M
79 50 (DF-3)
80 A A
81 0 B B
Rear pump
CN-615F 502 pressure sensor
In
C C
Hi/Lo speed travel
CN-133F
82 608 (AMP-2)
1 Swing priority-A4
83 0
1
proportional
84 2 2
solenoid valve
85
86 CN-134F
87 604 1 1
(AMP-2) Bucket confluent-A5
Front pump solenoid proportional valve 88 0 2 2 proportional
Rear pump solenoid proportional valve 89 solenoid valve
90
3 91 602
CN-132F
(AMP-2)
Boom priority 1-A4
92 1 1
93 0 2 2 proportional
solenoid valve
94 CN-135F
95 (AMP-2)
96 603 1 1 Boom priority 2-A4
Swing priority solenoid valve 98 solenoid valve
Bucket confluent valve 99
Boom priority 1 100
Boom priority 2 101
102
103
104
105
2 106
107
108
109
110 CN-113F
(AMP-2)
111
112 702 1 1 Front pump
Grounding 114 CN-114F
solenoid valve
Grounding 115 (AMP-2)
116 703 1 Rear pump
117 0
1
proportional
118 2 2
solenoid valve
24Vpower supply 119 CN-131F
1 24Vpower supply 120

121 24Vpower supply 607
(AMP-2)
1 1 Hi/Lo speed travel

122 0 2 2 solenoid valve
ZX215-1005042
A B C D E F G

7.3.5 SWP type connector
Male (Plug) Female (Socket)
7222-7414-40 7123-7414-40 (No.of pin: 1)
.
De al
pt
g no
in ti
7222-1424-40 7123-1424-40 (No.of pins: 2)

et a
n
rk er
7222-7464-40 7123-7464-40 (No.of pins: 6)

Ma t
In
7222-7484-40 7123-7484-40 (No.of pins: 8)
7222-7564-40 7123-7564-40 (No.of pins: 16)

7.3.6 A/AMP type connector
Male (Plug) Female (Socket)
282104-1 282080-1 (No.of pin: 2)
.
De al
pt
g no
282105-1 282087-1 (No.of pin: 3)
in ti
et a
n
rk er
174354-2 174352-2 (No.of pin: 2)

Ma t
In
1473252-1 1473255-1 (No.of pin: 40)
1473244-1 1473247-1 (No.of pin: 81)

7.3.7 DT type connector
Shell (Plug) Shell (Socket)
A B B A
DT06-2S DT04-2P
.
A
De al
A B
B
pt
g no
C C
DT06-3S DT04-3P (No.of pin: 3)
in ti
1 6 6 1
et a
2 5 5 2
n
3 4 4 3
rk er

5 8
8 5
Ma t
In
1 4 4 1
12 7 7 12
1 6 6 1
DT06-12S DT04-12P (No.of pin: 12)

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
1 Display User Code in monitor panel
Display Service Code in electrical system after checking According
2
failure history to displayed
Display Failure Code in mechanical system after checking code
3
failure history
Engine-related failure
Engine does not start up easily. (It always takes some
.
4 S-1
De al
time to start up the engine)
pt
5 Engine misfires. E-1 S-2
6 Color of exhaust gas is too dark.(Incomplete combustion) S-3
7
g n
Engine pickup is poor.
o
S-4
8 Engine runs rough or is unstable. E-2 S-5
in ti
9 Engine is short of output, or lacks power H-2 S-6

10 Auto Idle fails. E-4 H-5
Excessive engine oil consumption, or color of exhaust gas
et a
11 S-7
is blue
n
12 Premature engine oil contamination S-8

13 Excessive fuel consumption S-9
rk er
Engine cooling water is mixed with engine oil, spurts out

14 S-10
or decreases
15 Engine oil amount increases. (Water or fuel gets in) S-11
Ma t
16 Abnormal noises are heard S-12

In
17 Excessive vibrations are caused S-13

Failure related to work equipment, swing and travel
18 Power supply of machine cannot be cut off. E-3
19 There are abnormal noises from around hydraulic pump H-4
20 All work equipment, travel and swing do not move H-3
21 Speeds of all work equipment, travel and swing are slow H-1 S-6
When Machine Swings and Travels Simultaneously,
22 H-13
Travel Speed Lowers Largely
Work equipment-related failure
23 All the equipment do not work E-6
24 Cylinder do not work singly H-9
25 Drift of cylinder is too large H-10
26 Work equipment time lag is too big H-11

Troubleshooting
No. Symptom
Code E mode H mode (Engine)
Other work equipment moves, when specific work equip-
27 H-12
ment is relieved
28 Boom-up speed or power is low. E-7 H-6
29 Arm speed or power is low. E-8 H-7
30 Bucket speed or power is low. E-9 H-8
Travel-related failure
31 Travel speed or power is low. E-10 H-15
32 Dual Speed Travel Not Functioning E-13
33 Machine tends to swerve while in travel H-14
.
34 Machine is difficult to steer, or lacks power H-16
De al
pt
35 Travel speed cannot be shifted H-17
36 Track shoe does not move (only on one side)
g n H-18
Swing-related failure
o
37 Machine does not swing H-19
38 Swing acceleration is poor, or swing speed is slow H-20
in ti
Upper structure overruns remarkably when stopping

39 H-21
swinging
et a
40 Large shock is made when stopping swinging H-22

41 Large sound is made when stopping swinging H-23
n
42 Hydraulic drift of swing is large H-24

rk er
Monitor panel-related failure

43 Monitor display is blank. E-11
Ma t
44 Monitor displays nothing. E-12

45 Engine coolant temperature reading is incorrect. E-14
In
46 Fuel level reading is incorrect. E-15

47 Arm-in pilot pressure reading is incorrect. E-17
48 Arm-out pilot pressure reading is incorrect. E-18
49 Boom-up pilot pressure reading is incorrect. E-19
50 Boom-down pilot pressure reading is incorrect. E-20
51 Bucket-close pilot pressure reading is incorrect. E-21
52 Bucket-open pilot pressure reading is incorrect. E-22
53 Swing pilot pressure reading is incorrect. E-23
54 Left travel pilot pressure reading is incorrect. E-24
55 Right travel pilot pressure reading is incorrect. E-25
Other failure
56 Preheating function fails. E-5
57 Wiper does not work. E-16

7.5 Troubleshooting with an Event Code
Information in troubleshooting table .......................................................................................... 7-29

E111 (controller memory failure (FROM)) .................................................................................. 7-30
E212 (throttle motor current & motor connection abnormal) ..................................................... 7-31
E213 (throttle motor operation suspends) ................................................................................ 7-32
E214 (throttle motor working range abnormal) .......................................................................... 7-33
E015 (power supply voltage abnormal) ..................................................................................... 7-34
E116 (controller internal temperature abnormal) ....................................................................... 7-35
E017 (abnormal output of 5v power supply in sensor) .............................................................. 7-36
E118 (abnormal communication between controller and monitor) ............................................ 7-37
E320 (abnormality in front pump output pressure) .................................................................... 7-38
.
E321 (abnormality in rear pump output pressure) ..................................................................... 7-39
De al
E322 (abnormality in arm-in pilot pressure)............................................................................... 7-40
pt
E323 (abnormality in arm-out pilot pressure) ............................................................................ 7-41
E324 (abnormality in boom-raise pilot pressure) ...................................................................... 7-42
g n
E325 (abnormality in boom-lower pilot pressure) ...................................................................... 7-43
o
E326 (abnormality in bucket-curl pilot pressure) ....................................................................... 7-44
E327 (abnormality in bucket-dump pilot pressure) .................................................................... 7-45
in ti
E328 (abnormality in swing pilot pressure ................................................................................. 7-46

E329 (abnormality in left travel pilot pressure) ......................................................................... 7-47
et a
E330 (abnormality in right travel pilot pressure) ........................................................................ 7-48

E231 (abnormality in fuel control dial set voltage) ..................................................................... 7-49
n
E237 (abnormality in hydraulic oil temperature) ........................................................................ 7-50

rk er
E541 (abnormality in engine speed) .......................................................................................... 7-51

E450 (abnormality (a) in front pump proportional solenoid coil current) .................................... 7-52
E450 (abnormality (b) in front pump proportional solenoid coil current) .................................... 7-53
Ma t
E451 (abnormality (a) in rear pump proportional solenoid coil current)..................................... 7-54
E451 (abnormality (B) in rear pump proportional solenoid coil current) .................................... 7-55
In
E452 (abnormality (A) in swing priority proportional solenoid coil current)................................ 7-56
E452 (abnormality (B) in swing priority proportional solenoid coil current)................................ 7-57
E453 (abnormality (A) in bucket confluence proportional solenoid coil current) ....................... 7-58
E453 (abnormality (B) in bucket confluence proportional solenoid coil current) ....................... 7-59
E455 (abnormality (A) in boom priority 2 proportional solenoid coil current) ............................. 7-60
E455 (abnormality (B) in boom priority 2 proportional solenoid coil current) ............................. 7-61
E460 (abnormality in dual speed travel solenoid valve) ............................................................ 7-62

Sy195-205-215-225c9 Manual 2014-11-13-389-409

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

7.3 Connector Location and Electrical Circuit Diagram

T-112 Terminal 1 J-7 H-9

T-119 Terminal 1 M-1 B-9

T-201 Terminal 1 Body grounding X-6

T-202 Terminal 1 Body grounding X-6

K8 R 5 Top lamp relay X-6 J-9

K7 R 5 Parking relay X-6 J-8

7-8 Shop Manual - November 2014

CN-613F L 6 Safety relay X-6 K-7

CN-661F S 16 Intermediate connector W-6 I-8

CN-161M S 16 Intermediate connector W-6

CN-128M DF 3 Arm-in pilot sensor I-6 F-5

CN-122M DF 3 Arm out pilot sensor I-6 F-4

CN-123M DF 3 Swing pilot sensor I-6

Shop Manual - November 2014 7-9

F-104 W 1 Horn (right) I-5 K-2

F-103 W 1 Horn (left) I-5 K-2

CN-615F AMP 40 Controller W-6 A-9

CN-7-707 AMP 2 Cigarette lighter P-4

CN-150M D 8 Intermediate connector AE-3

7-10 Shop Manual - November 2014

Connector code Description

Shop Manual - November 2014 7-11

7.3.1 Connector location layout

CN-105M CN-104M CN-101M

7-12 Shop Manual - November 2014

CN-113M CN-448M F-108

Shop Manual - November 2014 7-13

CN-307M CN-306M CN-132F

7-14 Shop Manual - November 2014

Shop Manual - November 2014 7-15

7-16 Shop Manual - November 2014

Shop Manual - November 2014 7-17

7.3.2 Electrical element circuit diagram (cab circuit) PF021

Fuel ctrl dial

7-18 Shop Manual - November 2014

Horn relay Lamp relay Top lamp relay

Right top lamp

X-13 Left top lamp

CN-102M Left boom

Shop Manual - November 2014 7-19

7.3.3 Electrical control circuit diagram (engine circuit)

F-310 Charging indicator

Shop Manual - November 2014 7-21

9 Controller power supply 5

Oil pressure switch 48 B B Bucket dump pilot

6 Travel sensor (left) 49 204 C C

59 0 Boom raise pilot

Travel sensor (right) 67 CN-122M

Bucket curl sensor 69 A A

1 24Vpower supply 120

1 1 Hi/Lo speed travel

7-22 Shop Manual - November 2014

7.3.5 SWP type connector

Male (Plug) Female (Socket)

7222-7414-40 7123-7414-40 (No.of pin: 1)

7222-1424-40 7123-1424-40 (No.of pins: 2)

7222-7464-40 7123-7464-40 (No.of pins: 6)

7222-7484-40 7123-7484-40 (No.of pins: 8)

7222-7564-40 7123-7564-40 (No.of pins: 16)

Shop Manual - November 2014 7-23

7.3.6 A/AMP type connector