LATEST SY195-205-215C9-shop MANUAL-20130104

www.sanygroup.
com Quailty Changes the World
Crawler Hydraulic
Excavator
SY195C-9
SY205C-9
SY215C-9
SANY HEAVY MACHINERY LIMITED

318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District,
Shanghai, P.R. of China 201413
Tel: (86) 21 5700 8518

Service hotline:(86) 4006 098 318
E-mail: crd@sany.com.cn
Documentation No.: B06T03ENAM1-SY195/205/215C9
Shop Manual
SY195/205/215C9
Crawler Hydraulic Excavator
Shop Manual
● Compiled for experienced technicians, this shop manual aims to provide technical information
required for maintenance and repair of the machine.
● Work equipment or optional components not available locally may be included in this shop
manual. Consult authorized Sany dealers for information on these parts and components.
Material or technical specification is subject to change without prior notice.
● SY195C9, SY205C9 and SY215C9 excavators employ MITSUBISHI 6D34TL-20 engine.
Information on the engine is in Chapter 9.
WARNING
Read and follow the safety precautions and
instructions in this manual and on the ma-
chine decals. Failure to do so may cause
serious injury, death or property damage.
SY195-205-215C9 Crawler Hydraulic Excavator Table of Contents
Table of Contents
1 Introduction
1.1 How to Read the Shop Manual ................................................................................ 1-3
1.2 Terms for Maintenance Standard............................................................................. 1-6
1.3 Handling Electrical and Hydraulic Components....................................................... 1-9
1.3.1 Points to remember when handling electric components .............................. 1-9
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18
1.4 Hose Connector ..................................................................................................... 1-20
1.4.1 Type of hose connector................................................................................ 1-21
1.4.2 Hose connector tightening torque table ....................................................... 1-21
1.4.3 Connection of O-rings .................................................................................. 1-22
1.5 Table of Standard Tightening Torques .................................................................. 1-23
PD
1.6 Type of Bolts .......................................................................................................... 1-24
1.7 Tightening Sequence ............................................................................................. 1-24
1.8 Maintenance of Half Flanges ................................................................................. 1-25
1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25
1.9 Conversion Table ................................................................................................... 1-26
2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3
IO
2.2 General Shop Safety ............................................................................................... 2-6
2.2.1 Rules and shop behavior ............................................................................... 2-7
2.2.2 Housekeeping ................................................................................................ 2-7
2.2.3 Shop Liquids Storage..................................................................................... 2-8
2.2.4 Cleaning Parts ............................................................................................... 2-8
2.2.5 Jacking Up the Machine................................................................................. 2-9
2.2.6 Electrical Dangers .......................................................................................... 2-9
2.2.7 Removing Attachments ................................................................................ 2-10
2.2.8 Cleaning the Machine .................................................................................. 2-10
2.2.9 Using the Correct Tools................................................................................ 2-10
2.2.10 Hoisting a Load ...........................................................................................2-11
2.2.11 Appropriate Working Apparel ..................................................................... 2-12
2.2.12 Safety Partners .......................................................................................... 2-12
2.2.13 Two people when engine running .............................................................. 2-13
2.2.14 Driving Pins ................................................................................................ 2-13
2.2.15 Aligning Parts or Components ................................................................... 2-14
Shop Manual - December 2012 I

Table of Contents SY195-205-215C9 Crawler Hydraulic Excavator
2.2.16 Fire Extinguisher and Emergency Exits ..................................................... 2-14

2.2.17 Personal Protective Equipment.................................................................. 2-14
2.2.18 Running the Machine ................................................................................. 2-15
2.2.19 Accumulator ............................................................................................... 2-16
2.2.20 Adding Fluids to a System ......................................................................... 2-16
2.2.21 Track Recoil Springs .................................................................................. 2-17
2.2.22 High-Pressure Fluid Lines.......................................................................... 2-17
2.2.23 Safe Work Preparations ............................................................................. 2-18
2.2.24 Mounting and Dismounting ........................................................................ 2-19
2.2.25 Battery Hazards ......................................................................................... 2-20
2.2.26 Jump-Start Safety ...................................................................................... 2-21
2.2.27 Disconnecting the System Power .............................................................. 2-21
2.2.28 Lockout/tagout ........................................................................................... 2-22
2.2.29 Sequence of Procedures ........................................................................... 2-22
PD
2.2.30 Chemical hazard ........................................................................................ 2-24
2.2.31 Material Safety Data Sheets (MSDS) ........................................................ 2-24
2.3 Precautions for sling work and giving signals ........................................................ 2-25
3 Specifications
3.1 Dimensions .............................................................................................................. 3-3
3.2 Working Ranges ...................................................................................................... 3-4
3.3 Technical Specifications........................................................................................... 3-5
IO
3.3.1 Engine ............................................................................................................ 3-5
3.3.2 Swing motor ................................................................................................... 3-5
3.3.3 Control valve .................................................................................................. 3-5
3.3.4 Travel motor ................................................................................................... 3-6
3.4 Weight Table ............................................................................................................ 3-7
3.5 Recommended Oil, Fuel and Coolant...................................................................... 3-8
3.6 Capacity Table ......................................................................................................... 3-9
3.7 Engine Performance Curve ................................................................................... 3-10
4 Structure and Function

4.1 Engine and Cooling System .................................................................................... 4-3
4.1.1 Engine-related parts....................................................................................... 4-3
4.1.2 Radiator and intercooler................................................................................. 4-4
4.2 Power Train.............................................................................................................. 4-5
4.2.1 Power transmission system .......................................................................... 4-5
4.2.2 Final drive assembly ...................................................................................... 4-6
II Shop Manual - December 2012

4.2.3 Swing machinery.......................................................................................... 4-10

4.2.4 Swing bearing .............................................................................................. 4-12
4.3 Undercarriage and Frame...................................................................................... 4-13
4.3.1 Track frame and recoil spring....................................................................... 4-13
4.3.2 Idler .............................................................................................................. 4-15
4.3.3 Carrier roller ................................................................................................. 4-17
4.3.4 Track roller ................................................................................................... 4-18
4.3.5 Track shoe ................................................................................................... 4-19
4.3.6 Triple grouser shoe ...................................................................................... 4-23
4.4 Hydraulic System, Part 1 ....................................................................................... 4-24
4.4.1 Hydraulic equipment layout.......................................................................... 4-24
4.4.2 Hydraulic tank and filter ............................................................................... 4-26
4.4.3 Hydraulic pump ................................................................................................... 4-27
4.4.4 Pilot pump .................................................................................................... 4-34
4.5
PD
4.4.5 Regulator .................................................................................................... 4-35
4.4.5.1 Control mechanism makeup ............................................................... 4-37
4.4.5.2 Adjustment of the regulator ................................................................. 4-38
4.4.5.3 Operation ............................................................................................ 4-40
Hydraulic System, Part 2 ....................................................................................... 4-43
4.5.1 Control valve ................................................................................................ 4-43
4.5.2 Operating principle ....................................................................................... 4-46
4.5.2.1 When spool is in neutral position ........................................................ 4-46
IO
4.5.2.2 Travel .................................................................................................. 4-48
4.5.2.3 Arm...................................................................................................... 4-49
4.5.2.4 Boom................................................................................................... 4-54
4.5.2.5 Bucket ................................................................................................. 4-57
4.5.2.6 Swing .................................................................................................. 4-59
4.5.2.7 Option ................................................................................................. 4-61
4.5.2.8 Travel straight ..................................................................................... 4-62
4.5.2.9 Lock valve function ............................................................................. 4-63
4.5.2.10 Main relief valve function .................................................................. 4-65
4.5.2.11 Port relief valve function .................................................................... 4-66
4.5.3 Section view ................................................................................................. 4-70
4.6.1 Swing motor ................................................................................................. 4-81
4.6.2 Swing holding brake..................................................................................... 4-83
4.6.3 Relief valve portion ...................................................................................... 4-84
4.6.4 Reverse prevention valve ............................................................................ 4-86
Shop Manual - December 2012 III

4.6.4.1 Operation drawing............................................................................... 4-86

4.6.4.2 Explanatory drawing of effects ............................................................ 4-87
4.6.5 Center swivel joint ........................................................................................ 4-89
4.6.6 Travel motor ................................................................................................. 4-91
4.6.6.1 Operation of components.................................................................... 4-93
4.6.7 Valve control system .................................................................................. 4-105
4.6.8 Pilot valve.................................................................................................. 4-107
4.6.8.1 Work equipment and swing pilot valve.............................................. 4-107
4.6.8.2 Travel PPC valve ...............................................................................4-111
4.6.9 Solenoid valve.............................................................................................4-115
4.6.10 Accumulator ..............................................................................................4-116
4.6.11 Pilot oil filter ...............................................................................................4-117
4.6.12 Pump oil pressure sensor .........................................................................4-118
4.6.13 Hydraulic cylinder......................................................................................4-119
PD
4.6.14 Work equipment ....................................................................................... 4-121
4.7 Air Conditioning System....................................................................................... 4-127
4.7.1 A/C components layout drawing ................................................................ 4-128
4.7.2 Control panel.............................................................................................. 4-129
4.7.3 Circuit diagram ........................................................................................... 4-130
4.7.4 Refrigeration principle ................................................................................ 4-132
4.7.4.1 Refrigeration cycle diagram .............................................................. 4-132
4.7.4.2 Heating cycle diagram ...................................................................... 4-132
IO
4.7.5 Compressor ............................................................................................... 4-133
4.7.6 Clutch ......................................................................................................... 4-135
4.7.8 Condenser ................................................................................................. 4-136
4.7.7 Expansion valve ......................................................................................... 4-136
4.7.9 Evaporator ................................................................................................. 4-137
4.7.10 Receiver tank ........................................................................................... 4-137
4.7.11 Pressure switch ........................................................................................ 4-138
4.7.12 Fresh air sensor ....................................................................................... 4-139
4.7.13 Refrigerant ............................................................................................... 4-139
4.7.14 Compressor oil ......................................................................................... 4-158
4.8 Engine Control ..................................................................................................... 4-159
4.8.1 System operation ...................................................................................... 4-160
4.8.2 Components............................................................................................... 4-161
4.8.2.1 Fuel control dial................................................................................. 4-161
4.8.2.2 Controller .......................................................................................... 4-163
4.9 Electrical Control System..................................................................................... 4-165
IV Shop Manual - December 2012

4.9.1 Control function .......................................................................................... 4-165

4.9.2 Machine control system diagram ............................................................... 4-166
4.9.3 Engine and pump composite control function ............................................ 4-168
4.9.4 Pump control function ................................................................................ 4-172
4.9.4.1 Electrical positive flow control ........................................................... 4-173
4.9.4.2 Constant power control ..................................................................... 4-176
4.9.5 Valve control function ................................................................................. 4-178
4.9.5.1 Bucket flow control ............................................................................ 4-179
4.9.5.2 Swing priority control......................................................................... 4-180
4.9.6 Duo travel speed control ............................................................................ 4-181
4.9.7 Engine preheating/overheating alarm ....................................................... 4-183
4.9.7.1 Engine preheating ............................................................................. 4-184
4.9.7.2 Engine overheating alarm ................................................................. 4-185
4.9.8 Engine oil under–pressure alarm ............................................................... 4-185
PD
4.9.9 Auto deceleration/acceleration control ....................................................... 4-186
4.9.10 Engine speed calibration function ............................................................ 4-188
4.9.11 Electrical Components ............................................................................. 4-190
4.9.11.1 Pump pressure sensor .................................................................... 4-190
4.9.11.2 Pilot pressure sensor ...................................................................... 4-191
4.9.11.3 Engine speed sensor ...................................................................... 4-192
4.9.11.4 Coolant temperature sensor............................................................ 4-193
4.9.11.5 Fuel level sensor ............................................................................. 4-194
IO
4.9.11.6 Oil pressure switch .......................................................................... 4-195
4.10 Monitoring System ............................................................................................. 4-196
4.10.1 Machine monitor ...................................................................................... 4-197
4.10.2 Monitor functions...................................................................................... 4-198
4.10.3 Monitor operation ..................................................................................... 4-201
5 Standard Values
5.1 Standard Values of Engine - related Parts............................................................... 5-3
5.2 Standard Values of Chassis-related Parts ............................................................... 5-4
6 Testing and Adjusting

6.1 Engine Speed - Test and Calibrate .......................................................................... 6-3
6.1.1 Testing ........................................................................................................... 6-3
6.1.2 Adjusting ........................................................................................................ 6-3
6.2 Exhaust Gas Color - Test ......................................................................................... 6-5
6.3 Valve Clearance - Adjust.......................................................................................... 6-7
Shop Manual - December 2012 V

6.3.1 Testing............................................................................................................ 6-7

6.3.2 Adjusting ........................................................................................................ 6-9
6.4 Compression Pressure - Measure ......................................................................... 6-10
6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-12
6.5.1 Testing.......................................................................................................... 6-12
6.5.2 Adjusting ...................................................................................................... 6-14
6.6 Engine Oil Pressure - Measure.............................................................................. 6-16
6.7 Engine Speed Sensor - Adjust ............................................................................... 6-18
6.8 A/C Compressor Belt Tension - Test and Adjust ................................................... 6-19
6.8.1 Testing ......................................................................................................... 6-19
6.8.2 Adjusting ...................................................................................................... 6-19
6.9 Swing Bearing Clearance - Measure ..................................................................... 6-21
6.10 Track Tension - Test and Adjust ........................................................................... 6-23
6.10.1 Testing........................................................................................................ 6-23
PD
6.10.2 Adjusting .................................................................................................... 6-24
6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust .................................. 6-25
6.11.1 Measuring .................................................................................................. 6-25
6.11.2 Adjusting..................................................................................................... 6-27
6.12 Control Circuit Oil Pressure - Test and Adjust...................................................... 6-29
6.12.1 Testing........................................................................................................ 6-29
6.12.2 Adjusting .................................................................................................... 6-30
6.13 Solenoid Valve Output Pressure - Measure......................................................... 6-31
IO
6.14 Pilot Valve Output Pressure - Measure................................................................ 6-33
6.15 Pilot Valves (Work Equipment and Swing) - Adjust ............................................. 6-35
6.16 Work Equipment Hydraulic Drift - Test ................................................................. 6-36
6.17 Residual Pressure in Hydraulic Circuit - Release ................................................ 6-39
6.18 Oil Leakage - Measure ........................................................................................ 6-40
6.19 Air in Each Component - Bleed............................................................................ 6-45
7 Troubleshooting
7.1 Points to Remember When Troubleshooting ........................................................... 7-3
7.2 Troubleshooting Procedures .................................................................................... 7-5
7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-8
7.3.1 Connector location layout ............................................................................ 7-12
7.3.2 Electrical element circuit diagram (cab circuit)............................................. 7-18
7.3.3 Electrical control circuit diagram (engine circuit).......................................... 7-20
7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit) ........... 7-22
7.3.5 SWP type connector .................................................................................... 7-23
VI Shop Manual - December 2012

7.3.6 A/AMP type connector ................................................................................. 7-24

7.3.7 DT type connector ....................................................................................... 7-25
7.4 Failure Symptoms and Troubleshooting Codes ..................................................... 7-26
7.5 Troubleshooting with an Event Code ..................................................................... 7-28
7.6 Troubleshooting of Electrical System (E - Mode)................................................... 7-63
7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode) ...................... 7-93
8 Disassembly and Assembly

8.1 How to Read This Manual ....................................................................................... 8-3
8.1.1 Removing and Installing an Assembly ........................................................... 8-3
8.1.2 Disassembling and assembling an assembly ................................................ 8-3
8.1.3 Special tools................................................................................................... 8-3
8.2.1 The symbols used in this section .................................................................. 8-4
8.2 Operating Precautions ............................................................................................. 8-4
PD
8.3 Start Motor AS - Remove and Install ....................................................................... 8-8
8.3.1 Removal ......................................................................................................... 8-8
8.3.2 Installation ...................................................................................................... 8-8
8.4 Injection Pump AS - Remove and Install ................................................................. 8-9
8.4.1 Removal ......................................................................................................... 8-9
8.4.2 Installation .....................................................................................................8-11
8.5 Engine Front Seal - Remove and Install ................................................................ 8-13
8.5.1 Removal ....................................................................................................... 8-13
IO
8.5.2 Installation .................................................................................................... 8-13
8.6 Engine Rear Seal - Remove and Install................................................................. 8-14
8.6.1 Removal ....................................................................................................... 8-14
8.6.2 Installation .................................................................................................... 8-15
8.7 Cylinder Head AS - Remove and Install ................................................................ 8-16
8.7.1 Removal ....................................................................................................... 8-16
8.7.2 Installation .................................................................................................... 8-20
8.8 Radiator AS - Remove and Install.......................................................................... 8-22
8.8.1 Removal ....................................................................................................... 8-22
8.8.2 Installation .................................................................................................... 8-25
8.9 Engine and Hydraulic Pump AS - Remove and Install .......................................... 8-26
8.9.1 Removal ....................................................................................................... 8-26
8.9.2 Installation .................................................................................................... 8-32
8.10 Final Drive AS - Remove and Install .................................................................... 8-33
8.10.1 Removal ..................................................................................................... 8-33
8.10.2 Installation .................................................................................................. 8-34
Shop Manual - December 2012 VII

8.11 Final Drive AS - Disassemble and Assemble ....................................................... 8-35

8.11.1 Disassembly ............................................................................................... 8-35
8.11.2 Assembly .................................................................................................... 8-39
8.12 Swing Motor and Swing Drive AS - Remove and Install ...................................... 8-44
8.12.1 Removal ..................................................................................................... 8-44
8.12.2 Installation .................................................................................................. 8-45
8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble......................... 8-46
8.13.1 Disassembly............................................................................................... 8-46
8.13.2 Assembly.................................................................................................... 8-51
8.14 Idler AS - Disassemble and Assemble ................................................................. 8-56
8.14.1 Disassembly............................................................................................... 8-56
8.14.2 Assembly.................................................................................................... 8-57
8.15 Sprocket - Remove and Install............................................................................. 8-60
8.15.1 Removal ..................................................................................................... 8-60
PD
8.15.2 Installation .................................................................................................. 8-60
8.16 Track AS - Remove and Install ............................................................................ 8-61
8.16.1 Removal ..................................................................................................... 8-61
8.16.2 Installation .................................................................................................. 8-63
8.17 Swing Bearing AS - Remove and Install .............................................................. 8-64
8.17.1 Removal ..................................................................................................... 8-64
8.17.2 Installation .................................................................................................. 8-65
8.18 Swing Platform AS - Remove and Install ............................................................. 8-66
IO
8.18.1 Removal ..................................................................................................... 8-66
8.18.2 Installation .................................................................................................. 8-69
8.19 Swivel Joint AS - Remove and Install .................................................................. 8-70
8.19.1 Removal ..................................................................................................... 8-70
8.19.2 Installation .................................................................................................. 8-72
8.20 Swivel Joint AS - Disassemble and Assemble ..................................................... 8-73
8.20.1 Disassembly............................................................................................... 8-73
8.20.2 Assembly.................................................................................................... 8-74
8.21 Hydraulic Tank AS - Remove and Install.............................................................. 8-75
8.21.1 Removal ..................................................................................................... 8-75
8.21.2 Installation .................................................................................................. 8-77
8.22 Control Valve AS - Remove and Install ................................................................ 8-78
8.22.1 Removal ..................................................................................................... 8-78
8.22.2 Installation .................................................................................................. 8-82
8.23 Hydraulic Pump AS - Remove and Install ............................................................ 8-83
8.23.1 Removal ..................................................................................................... 8-83
VIII Shop Manual - December 2012

8.23.2 Installation .................................................................................................. 8-87

8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install .................... 8-88
8.24.1 Removal ..................................................................................................... 8-88
8.24.2 Installation .................................................................................................. 8-88
8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......................... 8-89
8.25.1 Assembly.................................................................................................... 8-89
8.26 Pilot Valve AS (Travel) - Disassemble and Assemble .......................................... 8-91
8.26.1 Assembly.................................................................................................... 8-91
8.27 Hydraulic Cylinder AS - Disassemble and Assemble........................................... 8-92
8.27.1 Disassembly............................................................................................... 8-93
8.27.2 Assembly.................................................................................................... 8-98
8.28 Work Equipment AS - Remove and Install......................................................... 8-103
8.28.1 Removal ................................................................................................... 8-103
8.28.2 Installation ................................................................................................ 8-105
PD
8.29 Air Conditioner AS - Remove and Install............................................................ 8-106
8.29.1 Removal ................................................................................................... 8-106
8.29.2 Installation .................................................................................................8-110
8.30 Counterweight AS - Remove and Install .............................................................8-111
8.30.1 Removal ....................................................................................................8-111
8.30.2 Installation .................................................................................................8-112
8.31 Cab AS - Remove and Install..............................................................................8-113
8.31.1 Removal ....................................................................................................8-113
IO
8.31.2 Installation .................................................................................................8-117
8.32 Cab Window Glass – Disassemble and Assemble .............................................8-118
8.32.1 Removal ....................................................................................................8-119
8.32.2 Installation ................................................................................................ 8-123
8.33 Front Window AS - Disassemble and Assemble................................................ 8-136
8.33.1 Disassemble ............................................................................................ 8-136
8.33.2 Assemble ................................................................................................. 8-139
8.34 Monitor - Remove and Install ............................................................................. 8-144
8.34.1 Removal ................................................................................................... 8-144
8.34.2 Installation ................................................................................................ 8-144
8.35 Controller AS - Remove and Install.................................................................... 8-145
8.35.1 Removal ................................................................................................... 8-145
8.35.2 Installation ................................................................................................ 8-145
8.36 Radio ................................................................................................................. 8-146
8.36.1 Structure .................................................................................................. 8-146
8.36.2 Removal ................................................................................................... 8-147
Shop Manual - December 2012 IX

8.36.3 Installation ................................................................................................ 8-148

8.36.4 Connector model and wiring .................................................................... 8-148
8.37 Battery ............................................................................................................... 8-149
8.37.1 Structure .................................................................................................. 8-149
8.37.2 Removal ................................................................................................... 8-150
8.37.3 Installation ................................................................................................ 8-151
8.37.4 Replacement ............................................................................................ 8-151
8.38 Start Switch........................................................................................................ 8-152
8.38.1 Structure ................................................................................................. 8-152
8.38.2 Removal ................................................................................................... 8-153
8.39 Fuse Box............................................................................................................ 8-155
8.39.1 Removal ................................................................................................... 8-155
8.40 Wiper ................................................................................................................. 8-156
8.40.1 Structure .................................................................................................. 8-156
PD
8.40.2 Working principle ..................................................................................... 8-156
8.40.3 Removal ................................................................................................... 8-157
8.40.5 Installation ................................................................................................ 8-158
8.40.4 Angle adjustment of wiper arm................................................................. 8-158
8.41 Relay.................................................................................................................. 8-159
8.41.1 Engine relays ........................................................................................... 8-159
8.41.2 Other relays ............................................................................................. 8-160
8.42 Sensor ............................................................................................................... 8-163
IO
8.43 Connector Terminals - Insert and Remove ........................................................ 8-165
8.43.1 Insertion ................................................................................................... 8-165
8.43.2 Removal ................................................................................................... 8-166
9 Engine
9.1 General .................................................................................................................... 9-3
9.1.1 Terms and standard ....................................................................................... 9-3
9.1.2 Engine serial No. and name plate .................................................................. 9-5
9.2 Engine Assembly ..................................................................................................... 9-6
9.2.1 Specifications ................................................................................................. 9-6
9.2.2 Structure and operating principle ................................................................... 9-7
9.2.2.1 Structure layout ..................................................................................... 9-7
9.2.2.2 Valve mechanism .................................................................................. 9-8
9.2.2.3 Cylinder head gasket ............................................................................ 9-9
9.2.2.4 Water director........................................................................................ 9-9
9.2.2.5 Connecting rod.................................................................................... 9-10
X Shop Manual - December 2012

9.2.2.6 Piston .................................................................................................. 9-10

9.2.2.7 Timing gear ..........................................................................................9-11
9.2.3 Troubleshooting ........................................................................................... 9-12
9.2.4 General inspection and adjustment ............................................................. 9-13
9.2.4.1 Compression pressure – measure ...................................................... 9-13
9.2.4.2 Valve clearance – inspect and adjust.................................................. 9-16
9.2.5 Cylinder head & valve mechanism............................................................... 9-18
9.2.5.1 Pre-disassembling work ...................................................................... 9-21
9.2.5.2 Disassembling method........................................................................ 9-21
9.2.5.3 Inspecting method............................................................................... 9-22
9.2.5.4 Assembling method............................................................................. 9-22
9.2.6 Rocker arm and bracket............................................................................... 9-25
9.2.6.2 Installation procedure.......................................................................... 9-27
PD
9.2.7 Cylinder head ............................................................................................... 9-28
9.2.8 Piston, connecting rod and cylinder bushing ............................................... 9-39
9.2.8.1 Pre-disassembling work ...................................................................... 9-41
9.2.8.3 Assembling Method............................................................................. 9-46
IO
9.2.9 Piston and connecting rod ........................................................................... 9-49
9.2.10 Flywheel ..................................................................................................... 9-55
9.2.10.1 Pre-disassembling inspection .......................................................... 9-57
9.2.10.2 Disassembling method...................................................................... 9-57
9.2.10.3 Assembling method........................................................................... 9-57
9.2.11 Timing gear ................................................................................................ 9-59
9.2.11.1 Disassembling procedure.................................................................. 9-61
9.2.11.2 Inspecting method ............................................................................. 9-62
9.2.11.3 Assembling method ........................................................................... 9-63
9.2.12 Camshaft.................................................................................................... 9-64
9.2.12.2 Pre-disassembling work .................................................................... 9-66
9.2.12.3 Inspecting method............................................................................. 9-67
Shop Manual - December 2012 XI


9.2.13 Crankshaft and crankcase ......................................................................... 9-69
9.2.14 Camshaft bushing ...................................................................................... 9-81
9.2.14.2 Inspecting procedure ........................................................................ 9-83
9.2.14.1 Camshaft bushing – replace ............................................................. 9-83
9.3 Lubricating System ................................................................................................ 9-88
9.3.1 Specifications ............................................................................................... 9-88
9.3.2 Structure and operating principle ................................................................. 9-89
9.3.2.1 Lubricating system layout ................................................................... 9-89
PD
9.3.2.2 Engine oil pump .................................................................................. 9-90
9.3.2.3 Oil cooler and oil filter ......................................................................... 9-91
9.3.2.4 Lubrication of parts ............................................................................. 9-94
9.3.3 Troubleshooting ........................................................................................... 9-99
9.3.4 General inspection and adjustment ........................................................... 9-100
9.3.4.1 Oil filter element – replace ................................................................ 9-100
9.3.4.2 Engine oil – replace .......................................................................... 9-102
9.3.4.3 Oil pressure – measure..................................................................... 9-103
IO
9.3.5 Oil pan, primary oil filter and injection pipe ................................................ 9-105
9.3.6 Oil pump..................................................................................................... 9-107
9.3.7 Engine oil filter ............................................................................................9-110
9.3.8 Engine oil cooler .........................................................................................9-112
9.3.8.1 Inspecting method..............................................................................9-114
9.3.9 Engine oil cooler, oil filter ............................................................................9-115
9.3.9.1 Disassembling method.......................................................................9-117
9.3.9.2 Inspecting method..............................................................................9-117
9.3.9.3 Assembling method............................................................................9-118
9.4 Fuel Supply and Engine Control ...........................................................................9-119
9.4.1 Specifications ..............................................................................................9-119
9.4.2 Structure and operating principle ............................................................... 9-120
9.4.2.1 Fuel system (fuel flow diagram) ........................................................ 9-120
XII Shop Manual - December 2012

9.4.2.2 Fuel tank ........................................................................................... 9-121

9.4.2.3 Fuel tank attachment circuit .............................................................. 9-123
9.4.2.4 Fuel filter ........................................................................................... 9-125
9.4.2.5 Injection pump................................................................................... 9-126
9.4.2.6 Governor ........................................................................................... 9-129
9.4.2.7 Fuel feed pump ................................................................................. 9-130
9.4.2.8 Automatic advance unit ..................................................................... 9-132
9.4.2.9 Fuel injector ...................................................................................... 9-133
9.4.3 Troubleshooting ......................................................................................... 9-134
9.4.4.1 Injection timing – inspect and adjust ................................................. 9-136
9.4.4.2 Air in fuel system – release ............................................................... 9-140
9.4.4.3 Fuel filter – replace ........................................................................... 9-141
9.4.5 Fuel filter .................................................................................................... 9-142
PD
9.4.6 Primary fuel filter (revolving type) .............................................................. 9-145
9.4.7 Secondary fuel filter (revolving type).......................................................... 9-147
9.4.8 Injection pump............................................................................................ 9-149
9.4.9 Fuel injector ............................................................................................... 9-154
IO
9.4.9.3 Cleaning method ............................................................................... 9-158
9.5 Cooling System.................................................................................................... 9-161
9.5.1 Specifications ............................................................................................. 9-161
9.5.2.1 Cooling system (coolant flow diagram) ............................................. 9-161
9.5.2.2 Thermostat ........................................................................................ 9-162
9.5.2.3 Water pump....................................................................................... 9-163
9.5.4.1 Belt tension – inspect and adjust ...................................................... 9-165
9.5.4.2 Inspect: Belt crack and damage........................................................ 9-167
9.5.4.3 Replace coolant and clean cooling system ....................................... 9-169
Shop Manual - December 2012 XIII

9.5.4.4 Release air in the cooling system ..................................................... 9-172

9.5.4.5 Leak inspection ................................................................................. 9-172
9.5.5 Radiator, engine oil cooler and intercooler ................................................ 9-173
9.5.6 Fan and belt ............................................................................................... 9-176
9.5.7 Water pump ............................................................................................... 9-177
9.5.7.4 Post-installation inspection ............................................................... 9-181
9.5.8 Thermostat ................................................................................................. 9-182
9.6 Air Intake and Exhaust System ............................................................................ 9-185
9.6.1 Specifications ............................................................................................. 9-185
PD
9.6.2.1 Air filter .............................................................................................. 9-185
9.6.2.2 Turbocharger..................................................................................... 9-186
9.6.4 Air filter ....................................................................................................... 9-188
9.6.4.1 Cleaning procedure........................................................................... 9-189
9.6.5 Turbocharger.............................................................................................. 9-191
IO
9.6.5.4 Post-disassembling work .................................................................. 9-195
9.6.5.7 Post-assembling work ....................................................................... 9-197
9.6.6 Intake manifold........................................................................................... 9-198
9.6.7 Exhaust manifold ....................................................................................... 9-199
9.6.8 Exhaust pipe and muffler ........................................................................... 9-200
9.7 Electrical System ................................................................................................. 9-201
9.7.1 Specifications ............................................................................................. 9-201
9.7.2.1 Start motor ........................................................................................ 9-202
9.7.2.2 Alternator........................................................................................... 9-203
9.7.3 Circuit diagram ........................................................................................... 9-204
XIV Shop Manual - December 2012

9.7.3.1 Alternator with a neutral diode .......................................................... 9-204

9.7.4.1 Power source and charging .............................................................. 9-208
9.7.4.2 Engine startup, preheating and shutdown ........................................ 9-209
9.7.5 Switches..................................................................................................... 9-210
9.7.5.1 Thermostat switch ............................................................................. 9-210
9.7.5.2 Inspection of engine oil pressure switch ........................................... 9-210
9.7.6 Dust indicator and heating plug ..................................................................9-211
9.7.6.1 Inspection of dust indicator ................................................................9-211
9.7.6.2 Inspection of heating plug ..................................................................9-211
9.7.7 Start motor ................................................................................................. 9-212
PD
9.7.7.5 Post-assembling inspection .............................................................. 9-227
9.7.8 Alternator.................................................................................................... 9-230
9.7.10 Pre-heating system .................................................................................. 9-241
IO
9.7.9 Safety relay ................................................................................................ 9-241
10 System Schematics
10.1 Hydraulic System Diagram .................................................................................. 10-3
10.2 Air-Conditioning Electrical Circuit Diagram .......................................................... 10-4
10.3 Fuse Box Relay ................................................................................................... 10-5
10.4 Control Switches and Monitor Electrical Diagram ............................................... 10-6
10.5 Operator Cab Electrical Circuit Diagram.............................................................. 10-7
10.6 Chassis Electrical Circuit Diagram....................................................................... 10-8
Shop Manual - December 2012 XV

PD
IO
XVI Shop Manual - December 2012

SY195-205-215C9 Crawler Hydraulic Excavator Introduction
Introduction
1 Introduction
1.1 How to Read the Shop Manual ................................................................................ 1-3
1.2 Terms for Maintenance Standard............................................................................. 1-6
PD
1.3 Handling Electrical and Hydraulic Components....................................................... 1-9
1.4 Hose Connector ..................................................................................................... 1-20
1.5 Table of Standard Tightening Torques .................................................................. 1-23
1.6 Type of Bolts .......................................................................................................... 1-24
1.7 Tightening Sequence ............................................................................................. 1-24
1.8 Maintenance of Half Flanges ................................................................................. 1-25
1.9 Conversion Table ................................................................................................... 1-26
IO
Shop Manual - December 2012 1-1

Introduction SY195-205-215C9 Crawler Hydraulic Excavator
PD
IO
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.
1-2 Shop Manual - December 2012

1 INTRODUCTION
1.1 How to Read the Shop Manual
1. Composition of shop manual
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
PD
use this manual,.
Shop Safety
This section covers basic shop safety infor-

mation relating to this equipment. It also de-
scribes what the hazard alerts mean that are
used throughout the manual.
IO
Specifications
Technical specification of work equipment and

optional parts are given in this section.
Structure and function
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
This section explains the standard values for

a new machine and judgement criteria for test-
ing, adjusting, and troubleshooting. This stan-
dard 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 dur-
ing inspection and repair work. Troubleshoot-
ing table that involves “Fault”and “Cause”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
PD
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.
Engine
IO
This section explains the disassembling and
assembling of engine components. Detailed
information on the cooling system, lubricating
system, electrical system and the alternator is
also provided in this section.
System Schematics
This section provides hydraulic circuit dia-

grams and electrical circuit diagrams.
2. Revision and distribution
Any additions, revisions, or other change of

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

3. 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 { }.
PD
IO

1.2 Terms for Maintenance Standard
The maintenance standard values necessary

for judgment of products and parts are de-
scribed by the following terms.
1. 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 allow-
able difference from that size is indicated.
● The above size set temporarily is called
"tolerance".
PD
the "standard size" and the range of differ-
ence from the standard size is called the
● The tolerance with the symbols of + or – is

indicated on the right side of the standard
size.
Example
IO
Standard size Tolerance
–0.022
120 Std.size F 60
–0.126
Tolerance of hole
NOTE: The tolerance may be indicated in (upper):+0.046
Std.clearance (max.):0.122
the text and a table as [standard size (upper
limit of tolerance/lower limit of tolerance)]. Std.clearance (min.):0.030
Example) 120 (–0.022/–0.126) Tolerance of shaft

(lower):-0.076
Tolerance of shaft
(upper):-0.030
● Usually, the size of a hole and the size
of the shaft to be fitted to that hole are
indicated by the same standard size
and different tolerances of the hole and
shaft. The tightness of fit is decided by
the tolerance.
ZX215-1000003
● Indication of size of rotating shaft and

hole and relationship drawing of them.

Example
Tolerance
Standard size
Shaft Hole
-0.030 +0.046
φ60
-0.076 0
2. Standard clearance and standard 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
PD
clearance.
● A value of performance and function of

new products or equivalent is called the
"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 stan-
IO
dard value.
3. 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
standard range.

4. 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
permissible value is estimated from vari-
PD
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
5. 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
IO
used is called the "clearance limit".
● If the clearance between the parts exceeds

the clearance limit, they must be replaced
or repaired.
6. Interference limit
● The allowable maximum interference be-

tween the hole of a part and the shaft of
another 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
To maintain the performance of the machine

over a long period, and to prevent failures or
other troubles before they occur, correct "oper-
ation", "maintenance and inspection", "trouble-
shooting", and "repairs" must be carried out.
This section deals particularly with correct re-
pair 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 equip-
ment" (particularly gear oil and hydraulic oil).
1.3.1 Points to remember when handling electric components
tors
PD
1. Handling wiring harnesses and connec-
Wiring harnesses consist of wiring con-

necting one component to another compo-
nent, connectors used for connecting and
disconnecting one wire from another wire,
and protectors or tubes used for protecting
the wiring.
IO
Compared with other electrical compo-
nents 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 ZX215-1000004
and repair operations, they are frequently

removed and installed again, so they are
likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.

2. Main failures occurring in wiring har-

ness
1) Defective contact of connectors (defective

contact between male and female)
Improper insertion
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 deformed or the position is not correctly
aligned, or because there is corrosion or
oxidation of the contact surfaces. ZX215-1000005
2) Defective crimping or soldering of connec-

tors PD Crimped portion
The pins of the male and female connec-

tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
ZX215-1000006
IO
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 solder-
ing may be damaged, or the wiring may be
broken.
ZX215-1000007

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, depending on the
direction of the water jet. Accordingly, take
care not splash water over the connector.
The connector is designed to prevent
ZX215-1000008
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 by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing
PD
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 between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
IO
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
ZX215-1000009
restorer.
NOTE:
● When wiping the mating portion of the

connector, be careful not to use exces-
sive force or deform the pins.
● If there is oil or water in the com-

pressed air, the contacts will become
even dirtier, so remove the oil and wa-
ter from the compressed air completely
before cleaning with compressed air.

3. Removing, installing, and drying con-

nectors and wiring harnesses
1) Disconnecting connectors
a. Hold the connectors when disconnect-

ing. Press lightly
when removing
Lock stopper
When disconnecting the connectors,
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 stop- ZX215-1000010
per, press down the stopper with your

thumb and pull the connectors apart.
NOTE: Never pull with one hand.
b. When removing from clips

PD
● Both of the connector and clip have
Both stoppers
stoppers, which are engaged with each

other when the connector is installed.
IO
ZX215-1000011
● When removing a connector from a clip,

pull the connector in a parallel direction
to the clip for removing stoppers.
ZX215-1000012

c. Action to take after removing connec-

tors
After removing any connector, cover

it with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
NOTE: If the machine is left disas-

sembled for a long time, it is particularly
easy for improper contact to occur, so ZX215-1000013
always cover the connector.
2) Connecting connectors
a. Check the connector visually

PD
Check that there is no oil, dirt, or water
stuck to the connector pins (mating
portion).
Clicks into position
Check that there is no deformation,

defective contact, corrosion, or damage
ZX215-1000021
to the connector pins.
Check that there is no damage or

IO
breakage to the outside of the connec-
tor.
NOTE: 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 not to
make it too hot as this will cause short
circuits.

NOTE: If there is any damage or break-

age, 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.
ZX215-1000014
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
PD
clamp is out of position, adjust it to its
correct position.
NOTE: If the connector cannot be

corrected easily, remove the clamp and
ZX215-1000015
adjust the position.
● If the connector clamp has been re-

moved, be sure to return it to its origi-
nal position. Check also that there are
IO
no loose clamps.
3) Connecting DT connectors
2 a 1 c
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
● Male connector: 1
● Female connector: 2
d
b
● Normal locking state (Horizontal): a, b, ZX215-1000016
d
● Incomplete locking state (Diagonal): c

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.
ZX215-1000009
a. Disconnect the connector and wipe off
the water with a dry cloth.
NOTE: If the connector is blown dry

with compressed air, there is the risk
that oil in the air may cause defective
contact, so remove all oil and water
PD
from the compressed air before blowing
with air.
b. Dry the connector with a dryer.
If water gets inside the connector, use

ZX215-1000017
a dryer to dry the connector.
NOTE: Hot air from the dryer can be

used, but regulate the time that the
IO
hot air is used in order not to make the
connector or related parts too hot, as
this will cause deformation or damage
to the connector.
c. Carry out a continuity test on the con- T adapter

nector.
After drying, leave the wiring harness

ZX215-1000018
disconnected and carry out a continuity
test to check for any short circuits
between pins caused by water.
NOTE: After completely drying the con-

nector, blow it with contact restorer and
reassemble.

4. Handling the integrated control monitor
1) The controller contains a microcomputer

and an electronic control circuits. 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 controller. ZX215-1000019
3) Cover the control connectors with tape or a

vinyl bag. Never touch the connector con-
tacts with your hand. PD Tool
Box
4) Do not leave it where it may be exposed to
rain.
5) Do not place the controller on oil, water, or

soil, or in any hot place, even for a short
time.
ZX215-1000020
6) Precautions for arc welding
IO
When welding on the controller, disconnect
all wiring harness connectors connected
to the controller. Fit an arc welding ground
close to the welding point.
ZX215-1000021

5. Points to remember when troubleshoot-

ing electric circuits
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.
NOTE: Disconnect and connect the related

connectors several times to check.
3) Always connect any disconnected connec-

tors before going on to the next step.
NOTE: If the power is turned ON with the

PD
connectors still disconnected, unnecessary
abnormality displays will be generated.
4) When carrying out troubleshooting of cir-

cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
IO
NOTE: If there is any change, there is
probably defective contact in that circuit.

1.3.2 Points to remember when handling hydraulic equipment
With the increase in pressure and precision

of hydraulic equipment, the most common
cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil, or
when disassembling or assembling hydraulic
equipment, it is necessary to be particularly
careful.
1. 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.
2. Disassembly and maintenance work in

the field
If disassembly or maintenance work is

PD ZX215-1000023
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 desir-
able to use unit exchange. Disassembly
IO
and maintenance of hydraulic equipment
should be carried out in a specially pre-
pared dust-proof workshop, and the perfor-
mance should be checked with special test
equipment.
3. 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 entering or of the surround-
ing area being made dirty by leaking oil so
never do this. Do not simply drain oil out
onto the ground, but collect it and ask the ZX215-1000024
customer to dispose of it, or take it back
with you for disposal.

4. 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 filter out the dirt that
has collected during storage, so this is an
even more effective method.
5. Change hydraulic oil when the tempera- ZX215-1000025
ture is high
When hydraulic oil or other oil is warm, it

flows easily. In addition, the sludge can
PD
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 hydraulic 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
IO
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the

equipment, or changing the oil, use flush- Flushing oil
ing 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 hydraulic oil. ZX215-1000026

7. Cleaning operations
After repairing the hydraulic equipment

(pump, control valve, etc.) or when run-
ning 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 cannot remove, so ZX215-1000027
it is an extremely effective device.
1.4 Hose Connector

PD
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.
1 4 3 5 2
NOTICE
Connector
● Do not over-tighten the nut (3). Exces-
ZX215-1000028
sive force applied on the metal sealing
IO
surface (4) and (5) may cause the joint
(1) to break. Be sure to tighten nut (3)
according to technical specifications.
● Scratches or other damages on seal-

ing surface (4) and (5) may cause leaks
at the joint. Be extremely careful not
to damage the sealing surfaces during
connecting and disconnecting work.

1.4.1 Type of hose connector
24°
24°
Male Female
ZX215-1000029
1.4.2 Hose connector tightening torque table
Wrench size mm Wrench size mm Tightening torque

Type
Connecting nut Hose joint N·m(kgf·m,Ibf·ft)
24° Male
PD19
22
27
36
41
19
22
27
36
41
59(6,44)
98(10,72)
118(12,87)
235(24,173)
295(30,218)
50 50 490(50,361)
60 60 670(68,494)
70 70 980(100,723)
IO
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)
NOTICE
● 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 special purpose.

1.4.3 Connection of O-rings
Place O-ring (6) in contact with the contact

surface of the joint (7) to seal the pressurized
7 6 9
oil.
NOTICE
● Replace o-rings (6) with new ones
when re-connecting hoses. Hose connector
8 10
● Before tightening nut (9), make sure the ZX215-1000030

o-ring (6) has been placed into the o-
ring seat (8).Displacement 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).
PD
Damaged o-ring (6) may cause oil leak-
age.
● If oil leakage due to loosened nut (9) is

detected, do not try to stop the leakage
by tightening nut (9). Instead, replace
o-ring (6) with a new one and make
sure it is well positioned, and tighten
IO
nut (9).
Wrench size mm Wrench size mm Tightening torque

Connecting nut Hose joint N·m (kgf·m,Ibf·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
torque wrench)
Bolt Bolt Wrench Hex wrench Hexagonal bolt Hexagonal socket head bolt
diameter grade size 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
M20
M27
M10
10.9
10.9
10.9
12.9
27
30
41
17
PD
14
17
19
6
382
549
1320
78
38.98
56.02
134.7
7.96
281.9
405.16
974.16
57.76
382
549
1320
78
38.98
56.02
134.7
7.96
281.9
405.16
974.16
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
IO
NOTICE
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 insufficient fastening.
● The torque values listed in the table are intended for general application. If different
torque values 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. Hex bolt Socket head hex bolt
Use correct bolts and tighten them properly 8.8 10.9 12.9
when assembling machines or components.
ZX215-1000031
1.7 Tightening Sequence
When two or more bolts are being tightened,

Cross tightening Diagonal tightening
follow the tightening sequence shown on the
PD
right to ensure even tightening. 1 1
6 3
3 4
4 5
2 2
Central and diagonal tightening
12 9 4 1 6 7 14
IO
13 8 5 2 3 10 11
ZX215-1000032
CAUTION
● Always use suitable tools for specific
work. Use of improper tools and meth-
ods may cause a hazardous situation.
● Use tools of correct sizes when loosen-

ing or tightening the nuts or bolts. Oth-
erwise, the tools may slide and cause
personal injury.
ZX215-1000033

1.8 Maintenance of Half Flanges
1. Clean the sealing surface of the flange and

check it carefully. Scratches and coarse-
ness cause leaks or abrasion of seals.
Uneven surface 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

ZX215-1000034
the O-rings are not damaged. Do not file
the surface of the O-ring. Apply grease
onto the O-ring to locate it.
3. Tighten the half flanges carefully. Locate

the opening at the center so that it is per-
PD
pendicular to the oil opening. Tighten the Improper
bolt manually to maintain the location of
the components.
ZX215-1000035
IO
1.8.1 Table of tightening torques for half flange bolts
● Unless specified otherwise, tighten the half flange bolts to the torques below.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
10 14 59~74 6.0~7.5
12 17 98~123 10.0~12.5
16 22 235~285 23.5~29.5

1.9 Conversion Table

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
1. Convert 55 mm into inches
1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw
a horizontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular
line down from (B).
PD
3) Take the point where the two lines cross as (C). This point (C) gives the value when con-
verting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches
1) 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.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.

IO
3) 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.

Length
Millimeters to Inches
(B) 1mm=0.03937in
0 1 2 3 4 5 6 7 8 9
0 0.000 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
(C)
(A) 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 PD 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
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
IO
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

Inches to Millimeters
in. mm in. mm
1/64 0.3969 33/64 13.0969
1/32 0.7938 17/32 13.4938
3/64 1.1906 35/64 13.8906
1/16 1.5875 9/16 14.2875
5/64 1.9844 37/64 14.6844
3/32 2.3813 19/32 15.0813
7/64 2.7781 39/64 15.4781
1/8 3.1750 5/8 15.8750
9/64 3.5719 41/64 16.2719
5/32 3.9688 21/32 16.6688
11/64 4.3656 43/64 17.0656
3/16
7/32
13/64
15/64
PD4.7625
5.1594
5.5563
5.9531
11/16
23/32
45/64
47/64
17.4625
17.8594
18.2563
18.6531
1/4 6.3500 3/4 19.0500
17/64 6.7469 49/64 19.4469
9/32 7.1438 25/32 19.8438
19/64 7.5406 51/64 20.2406
IO
5/16 7.9375 13/16 20.6375
21/64 8.3344 53/64 21.0344
11/32 8.7313 27/32 21.4313
23/64 9.1281 55/64 21.8281
3/8 9.5250 7/8 22.2250
25/64 9.9219 57/64 22.6219
13/32 10.3188 29/32 23.0188
27/64 10.7156 59/64 23.4156
7/16 11.1125 15/16 23.8125
29/64 11.5094 61/64 24.2094
15/32 11.9063 31/32 24.6063
31/64 12.3031 63/64 25.0031
1/2 12.7000 1 25.4000

Feet to Meters
ft. 0 1 2 3 4 5 6 7 8 9 ft.
m m m m m m m m m m
- - 0.305 0.610 0.914 1.219 1.524 1.829 2.134 2.438 2.743 -
10 3.048 3.353 3.658 3.962 4.267 4.572 4.877 5.182 5.486 5.791 10
20 6.096 6.401 6.706 7.010 7.315 7.620 7.925 8.230 8.534 8.839 20
30 9.144 9.449 9.754 10.058 10.363 10.668 10.973 11.278 11.582 11.887 30
40 12.192 12.497 12.802 13.106 13.411 13.716 14.021 14.326 14.630 14.935 40
50 15.240 15.545 15.850 16.154 16.459 16.764 17.069 17.374 17.678 17.983 50
60 18.288 18.593 18.898 19.202 19.507 19.812 20.117 20.422 20.726 21.031 60
70 21.336 21.641 21.946 22.250 22.555 22.860 23.165 23.470 23.774 24.079 70
80 24.384 24.689 24.994 25.298 25.603 25.908 26.213 26.518 26.822 27.127 80
90 27.432 27.737 28.042 28.346 28.651 28.956 29.261 29.566 29.870 30.175 90
100
Meters to Feet
PD
30.480 30.785 31.090 31.394 31.699 32.004 32.309 32.614 32.918 33.223 100
m 0 1 2 3 4 5 6 7 8 9 m
ft. ft. ft. ft. ft. ft. ft. ft. ft. ft.
- - 3.2808 6.5617 9.8425 13.1234 16.4042 19.6850 22.9659 26.2467 29.5276 -
IO
10 32.8084 36.0892 39.3701 42.6509 45.9318 49.2126 52.4934 55.7743 59.0551 62.3360 10
20 65.6168 68.8976 72.1785 75.4593 78.7402 82.0210 85.3018 88.5827 91.8635 95.1444 20
30 98.4252 101.7060 104.9869 108.2677 111.5486 114.8294 118.1102 121.3911 124.6719 127.9528 30
40 131.2336 134.5144 137.7953 141.0761 144.3570 147.6378 150.9186 154.1995 157.4803 160.7612 40
50 164.0420 167.3228 170.6037 173.8845 177.1654 180.4462 183.7270 187.0079 190.2887 193.5696 50
60 196.8504 200.1312 203.4121 206.6929 209.9738 213.2546 216.5354 219.8163 223.0971 226.3780 60
70 229.6588 232.9396 236.2205 239.5013 242.7822 246.0630 249.3438 252.6247 255.9055 259.1864 70
80 262.4672 265.7480 269.0289 272.3097 275.5906 278.8714 282.1522 285.4331 288.7139 291.9948 80
90 295.2756 298.5564 301.8373 305.1181 308.3990 311.6798 314.9606 318.2415 321.5223 324.8032 90
100 328.0840 331.3648 334.6457 337.9265 341.2074 344.4882 347.7690 351.0499 354.3307 357.6116 100

Miles to Kilometers
miles 0 1 2 3 4 5 6 7 8 9 miles
km km km km km km km km km km
- - 1.609 3.219 4.828 6.437 8.047 9.656 11.265 12.875 14.484 -
10 16.093 17.703 19.312 20.921 22.531 24.140 25.749 27.359 28.968 30.577 10
20 32.187 33.796 35.405 37.015 38.624 40.234 41.843 43.452 45.062 46.671 20
30 48.280 49.890 51.499 53.108 54.718 56.327 57.936 59.546 61.155 62.764 30
40 64.374 65.983 67.592 69.202 70.811 72.420 74.030 75.639 77.248 78.858 40
50 80.467 82.077 83.686 85.295 86.904 88.514 90.123 91.732 93.342 94.951 50
60 96.561 98.170 99.779 101.388 102.998 104.607 106.216 107.826 109.435 111.044 60
70 112.654 114.263 115.872 117.482 119.091 120.701 122.310 123.919 125.529 127.138 70
80 128.748 130.357 131.966 133.575 135.185 136.794 138.403 140.013 141.622 143.231 80
90 144.841 146.450 148.059 149.669 151.278 152.887 154.497 156.106 157.715 159.325 90
PD
100 160.934 162.543 164.153 165.762 167.371 168.981 170.590 172.199 173.809 175.418 100
Kilometers to Miles
km 0 1 2 3 4 5 6 7 8 9 km
miles miles miles miles miles miles miles miles miles miles
- - 0.621 1.243 1.864 2.485 3.107 3.728 4.350 4.971 5.592 -
10 6.214 6.835 7.456 8.078 8.699 9.321 9.942 10.563 11.185 11.806 10
IO
20 12.427 13.049 13.670 14.292 14.913 15.534 16.156 16.777 17.398 18.020 20
30 18.641 19.262 19.884 20.505 21.127 21.748 22.369 22.991 23.612 24.233 30
40 24.855 25.476 26.098 26.719 27.340 27.962 28.583 29.204 29.826 30.447 40
50 31.069 31.690 32.311 32.933 33.554 34.175 34.797 35.418 36.039 36.661 50
60 37.282 37.904 38.525 39.146 39.768 40.389 41.010 41.632 42.253 42.875 60
70 43.496 44.117 44.739 45.360 45.981 46.603 47.224 47.845 48.467 49.088 70
80 49.710 50.331 50.952 51.574 52.195 52.816 53.438 54.059 54.681 55.302 80
90 55.923 56.545 57.166 57.787 58.409 59.030 59.652 60.273 60.894 61.516 90
100 62.137 62.758 63.380 64.001 64.622 65.244 65.865 66.487 67.108 67.729 100

Area
Square inches to square centimeters
in2 0 1 2 3 4 5 6 7 8 9 in2
cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2
- - 6.452 12.903 19.355 25.806 32.258 38.710 45.161 51.613 58.064 -
10 64.516 70.968 77.419 83.871 90.322 96.774 103.226 109.677 116.129 122.580 10
20 129.032 135.484 141.935 148.387 154.838 161.290 167.742 174.193 180.645 187.096 20
30 193.548 200.000 206.451 212.903 219.354 225.806 232.258 238.709 245.161 251.612 30
40 258.064 264.516 270.967 277.419 283.870 290.322 296.774 303.225 309.677 316.128 40
50 322.580 329.032 335.483 341.935 348.386 354.838 361.290 367.741 374.193 380.644 50
60 387.096 393.548 399.999 406.451 412.902 419.354 425.806 432.257 438.709 445.160 60
70 451.612 458.064 464.515 470.967 477.418 483.870 490.322 496.773 503.225 509.676 70
80 516.128 522.580 529.031 535.483 541.934 548.386 554.838 561.289 567.741 574.192
PD 80
90 580.644 587.096 593.547 599.999 606.450 612.902 619.354 625.805 632.257 638.708 90
100 645.160 651.612 658.063 664.515 670.966 677.418 683.870 690.321 696.773 703.224 100
Square centimeters to square inches
cm2 0 1 2 3 4 5 6 7 8 9 cm2
in2 in2 in2 in2 in2 in2 in2 in2 in2 in2
- - 0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395 -
IO
10 1.550 1.705 1.860 2.015 2.170 2.325 2.480 2.635 2.790 2.945 10
20 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340 4.495 20
30 4.650 4.805 4.960 5.115 5.270 5.425 5.580 5.735 5.890 6.045 30
40 6.200 6.355 6.510 6.665 6.820 6.975 7.130 7.285 7.440 7.595 40
50 7.750 7.905 8.060 8.215 8.370 8.525 8.680 8.835 8.990 9.145 50
60 9.300 9.455 9.610 9.765 9.920 10.075 10.230 10.385 10.540 10.695 60
70 10.850 11.005 11.160 11.315 11.470 11.625 11.780 11.935 12.090 12.245 70
80 12.400 12.555 12.710 12.865 13.020 13.175 13.330 13.485 13.640 13.795 80
90 13.950 14.105 14.260 14.415 14.570 14.725 14.880 15.035 15.190 15.345 90
100 15.500 15.655 15.810 15.965 16.120 16.275 16.430 16.585 16.740 16.895 100

Volume
Cubic inches to cubic centimeters
in3 0 1 2 3 4 5 6 7 8 9 in3
cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc)
- - 16.387 32.774 49.161 65.548 81.935 98.322 114.709 131.096 147.484 -
10 163.871 180.258 196.645 213.032 229.419 245.806 262.193 278.580 294.967 311.354 10
20 327.741 344.128 360.515 376.902 393.289 409.677 426.064 442.451 458.838 475.225 20
30 491.612 507.999 524.386 540.773 557.160 573.547 589.934 606.321 622.708 639.095 30
40 655.482 671.869 688.257 704.644 721.031 737.418 753.805 770.192 786.579 802.966 40
50 819.353 835.740 852.127 868.514 884.901 901.288 917.675 934.062 950.449 966.837 50
60 983.224 999.611 1015.998 1032.385 1048.772 1065.159 1081.546 1097.933 1114.320 1130.707 60
70 1147.094 1163.481 1179.868 1196.255 1212.642 1229.030 1245.417 1261.804 1278.191 1294.578 70
80 1310.965 1327.352 1343.739 1360.126 1376.513 1392.900 1409.287 1425.674 1442.061 1458.448 80
PD
90 1474.835 1491.222 1507.610 1523.997 1540.384 1556.771 1573.158 1589.545 1605.932 1622.319 90
100 1638.706 1655.093 1671.480 1687.867 1704.254 1720.641 1737.028 1753.415 1769.802 1786.190 100
Cubic centimeters to cubic inches
cm3 cm3
0 1 2 3 4 5 6 7 8 9
(cc) (cc)
3 3 3 3 3 3 3 3 3 3
in in in in in in in in in in
- - 0.0610 0.1220 0.1831 0.2441 0.3051 0.3661 0.4272 0.4882 0.5492 -
IO
10 0.6102 0.6713 0.7323 0.7933 0.8543 0.9153 0.9764 1.0374 1.0984 1.1594 10
20 1.2205 1.2815 1.3425 1.4035 1.4646 1.5256 1.5866 1.6476 1.7086 1.7697 20
30 1.8307 1.8917 1.9527 2.0138 2.0748 2.1358 2.1968 2.2579 2.3189 2.3799 30
40 2.4409 2.5019 2.5630 2.6240 2.6850 2.7460 2.8071 2.8681 2.9291 2.9901 40
50 3.0512 3.1122 3.1732 3.2342 3.2952 3.3563 3.4173 3.4783 3.5393 3.6004 50
60 3.6614 3.7224 3.7834 3.8444 3.9055 3.9665 4.0275 4.0885 4.1496 4.2106 60
70 4.2716 4.3326 4.3937 4.4547 4.5157 4.5767 4.6377 4.6988 4.7598 4.8208 70
80 4.8818 4.9429 5.0039 5.0649 5.1259 5.1870 5.2480 5.3090 5.3700 5.4310 80
90 5.4921 5.5531 5.6141 5.6751 5.7362 5.7972 5.8582 5.9192 5.9803 6.0413 90
100 6.1023 6.1633 6.2243 6.2854 6.3464 6.4074 6.4684 6.5295 6.5905 6.6515 100

U.S. Gallons to liters
U.S. U.S.
0 1 2 3 4 5 6 7 8 9
gal gal
liters liters liters liters liters liters liters liters liters liters
- - 3.7854 7.5709 11.3563 15.1417 18.9271 22.7126 26.4980 30.2834 34.0688 -
10 37.8543 41.6397 45.4251 49.2106 52.9960 56.7814 60.5668 64.3523 68.1377 71.9231 10
20 75.7085 79.4940 83.2794 87.0648 90.8502 94.6357 98.4211 102.2065 105.9920 109.7774 20
30 113.5628 117.3482 121.1337 124.9191 128.7045 132.4899 136.2754 140.0608 143.8462 147.6317 30
40 151.4171 155.2025 158.9879 162.7734 166.5588 170.3442 174.1296 177.9151 181.7005 185.4859 40
50 189.2714 193.0568 196.8422 200.6276 204.4131 208.1985 211.9839 215.7693 219.5548 223.3402 50
60 227.1256 230.9110 234.6965 238.4819 242.2673 246.0528 249.8382 253.6236 257.4090 261.1945 60
70 264.9799 268.7653 272.5507 276.3362 280.1216 283.9070 287.6925 291.4779 295.2633 299.0487 70
80 302.8342 306.6196 310.4050 314.1904 317.9759 321.7613 325.5467 329.3321 333.1176 336.9030 80
90 340.6884 344.4739 348.2593 352.0447 355.8301 359.6156 363.4010 367.1864 370.9718 374.7573 90
PD
100 378.5427 382.3281 386.1136 389.8990 393.6844 397.4698 401.2553 405.0407 408.8261 412.6115 100
Liters to U.S. Gallons
liters 0 1 2 3 4 5 6 7 8 9 liters
gal gal gal gal gal gal gal gal gal gal
- - 0.2642 0.5283 0.7925 1.0567 1.3209 1.5850 1.8492 2.1134 2.3775 -
IO
10 2.6417 2.9059 3.1701 3.4342 3.6984 3.9626 4.2268 4.4909 4.7551 5.0193 10
20 5.2834 5.5476 5.8118 6.0760 6.3401 6.6043 6.8685 7.1326 7.3968 7.6610 20
30 7.9252 8.1893 8.4535 8.7177 8.9818 9.2460 9.5102 9.7744 10.0385 10.3027 30
40 10.5669 10.8311 11.0952 11.3594 11.6236 11.8877 12.1519 12.4161 12.6803 12.9444 40
50 13.2086 13.4728 13.7369 14.0011 14.2653 14.5295 14.7936 15.0578 15.3220 15.5861 50
60 15.8503 16.1145 16.3787 16.6428 16.9070 17.1712 17.4354 17.6995 17.9637 18.2279 60
70 18.4920 18.7562 19.0204 19.2846 19.5487 19.8129 20.0771 20.3412 20.6054 20.8696 70
80 21.1338 21.3979 21.6621 21.9263 22.1904 22.4546 22.7188 22.9830 23.2471 23.5113 80
90 23.7755 24.0397 24.3038 24.5680 24.8322 25.0963 25.3605 25.6247 25.8889 26.1530 90
100 26.4172 26.6814 26.9455 27.2097 27.4739 27.7381 28.0022 28.2664 28.5306 28.7947 100

U.K. Gallons to Liters
lmp lmp
0 1 2 3 4 5 6 7 8 9
gal gal
liters liters liters liters liters liters liters liters liters liters
- - 4.5459 9.0918 13.6377 18.1836 22.7295 27.2754 31.8213 36.3672 40.9131 -
10 45.4590 50.0049 54.5508 59.0967 63.6426 68.1885 72.7344 77.2803 81.8262 86.3721 10
20 90.9180 95.4639 100.0098 104.5557 109.1016 113.6475 118.1934 122.7393 127.2852 131.8311 20
30 136.3770 140.9229 145.4688 150.0147 154.5606 159.1065 163.6524 168.1983 172.7442 177.2901 30
40 181.8360 186.3819 190.9278 195.4737 200.0196 204.5655 209.1114 213.6573 218.2032 222.7491 40
50 227.2950 231.8409 236.3868 240.9327 245.4786 250.0245 254.5704 259.1163 263.6622 268.2081 50
60 272.7540 277.2999 281.8458 286.3917 290.9376 295.4835 300.0294 304.5753 309.1212 313.6671 60
70 318.2130 322.7589 327.3048 331.8507 336.3966 340.9425 345.4884 350.0343 354.5802 359.1261 70
80 363.6720 368.2179 372.7638 377.3097 381.8556 386.4015 390.9474 395.4933 400.0392 404.5851 80
90 409.1310 413.6769 418.2228 422.7687 427.3146 431.8605 436.4064 440.9523 445.4982 450.0441 90
PD
100 454.5900 459.1359 463.6818 468.2277 472.7736 477.3195 481.8654 486.4113 490.9572 495.5031 100
Liters to U.K. Gallons
liters 0 1 2 3 4 5 6 7 8 9 liters
gal gal gal gal gal gal gal gal gal gal
- - 0.2200 0.4400 0.6599 0.8799 1.0999 1.3199 1.5399 1.7598 1.9798 -
10 2.1998 2.4198 2.6398 2.8597 3.0797 3.2997 3.5197 3.7397 3.9596 4.1796 10
IO
20 4.3996 4.6196 4.8396 5.0595 5.2795 5.4995 5.7195 5.9395 6.1594 6.3794 20
30 6.5994 6.8194 7.0394 7.2593 7.4793 7.6993 7.9193 8.1393 8.3592 8.5792 30
40 8.7992 9.0192 9.2392 9.4591 9.6791 9.8991 10.1191 10.3391 10.5590 10.7790 40
50 10.9990 11.2190 11.4390 11.6589 11.8789 12.0989 12.3189 12.5389 12.7588 12.9788 50
60 13.1988 13.4188 13.6388 13.8587 14.0787 14.2987 14.5187 14.7387 14.9586 15.1786 60
70 15.3986 15.6186 15.8386 16.0585 16.2785 16.4985 16.7185 16.9385 17.1584 17.3784 70
80 17.5984 17.8184 18.0384 18.2583 18.4783 18.6983 18.9183 19.1383 19.3582 19.5782 80
90 19.7982 20.0182 20.2382 20.4581 20.6781 20.8981 21.1181 21.3381 21.5580 21.7780 90
100 21.9980 22.2180 22.4380 22.6579 22.8779 23.0979 23.3179 23.5379 23.7578 23.9778 100

Weight
Pound to Kilogram
lbs. 0 1 2 3 4 5 6 7 8 9 lbs.
kg kg kg kg kg kg kg kg kg kg
- - 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 -
10 4.536 4.989 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618 10
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154 20
30 13.608 14.061 14.515 14.968 15.422 15.876 16.329 16.783 17.236 17.690 30
40 18.144 18.597 19.051 19.504 19.958 20.412 20.865 21.319 21.772 22.226 40
50 22.680 23.133 23.587 24.040 24.494 24.947 25.401 25.855 26.308 26.762 50
60 27.215 27.669 28.123 28.576 29.030 29.483 29.937 30.391 30.844 31.298 60
70 31.751 32.205 32.658 33.112 33.566 34.019 34.473 34.926 35.380 35.834 70
80 36.287 36.741 37.194 37.648 38.102 38.555 39.009 39.462 39.916 40.370 80
90 40.823
100 45.359
41.277
45.813
41.730
46.266
PD
42.184
46.720
42.637
47.173
43.091
47.627
43.545
48.081
43.998
48.534
44.452
48.988
44.905
49.441 100
90
Kilogram to Pound
kg 0 1 2 3 4 5 6 7 8 9 kg
lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs.
IO
- - 2.205 4.409 6.614 8.818 11.023 13.228 15.432 17.637 19.842 -
10 22.046 24.251 26.455 28.660 30.865 33.069 35.274 37.479 39.683 41.888 10
20 44.092 46.297 48.502 50.706 52.911 55.116 57.320 59.525 61.729 63.934 20
30 66.139 68.343 70.548 72.752 74.957 77.162 79.366 81.571 83.776 85.980 30
40 88.185 90.389 92.594 94.799 97.003 99.208 101.413 103.617 105.822 108.026 40
50 110.231 112.436 114.640 116.845 119.049 121.254 123.459 125.663 127.868 130.073 50
60 132.277 134.482 136.686 138.891 141.096 143.300 145.505 147.710 149.914 152.119 60
70 154.323 156.528 158.733 160.937 163.142 165.347 167.551 169.756 171.960 174.165 70
80 176.370 178.574 180.779 182.983 185.188 187.393 189.597 191.802 194.007 196.211 80
90 198.416 200.620 202.825 205.030 207.234 209.439 211.644 213.848 216.053 218.257 90
100 220.462 222.667 224.871 227.076 229.280 231.485 233.690 235.894 238.099 240.304 100

Newton to Kilogram
N 0 10 20 30 40 50 60 70 80 90 N
kg kg kg kg kg kg kg kg kg kg
- - 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 -
100 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 100
200 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 200
300 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 300
400 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 400
500 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 500
600 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 600
700 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 700
800 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 800
900 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 900
PD
1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 1000
Kilogram to Newton
kg 0 1 2 3 4 5 6 7 8 9 kg
N N N N N N N N N N
- - 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 -
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
IO
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.34 500.14 509.95 519.76 529.56 539.37 549.18 558.98 568.79 578.60 50
60 588.40 598.21 608.02 617.82 627.63 637.44 647.24 657.05 666.86 676.66 60
70 686.47 696.28 706.08 715.89 725.70 735.50 745.31 755.12 764.92 774.73 70
80 784.54 794.34 804.15 813.96 823.76 833.57 843.38 853.18 862.99 872.80 80
90 882.60 892.41 902.22 912.02 921.83 931.64 941.44 951.25 961.06 970.86 90
100 980.67 990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100

Pressure
Lb/in² to Kg/cm²
lb/
0 1 2 3 4 5 6 7 8 9 lb/in2
in2
(psi) kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 (psi)
- - 0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5625 0.6328 -
10 0.7031 0.7734 0.8437 0.9140 0.9843 1.0546 1.1249 1.1952 1.2655 1.3358 10
20 1.4061 1.4764 1.5468 1.6171 1.6874 1.7577 1.8280 1.8983 1.9686 2.0389 20
30 2.1092 2.1795 2.2498 2.3201 2.3904 2.4607 2.5311 2.6014 2.6717 2.7420 30
40 2.8123 2.8826 2.9529 3.0232 3.0935 3.1638 3.2341 3.3044 3.3747 3.4450 40
50 3.5154 3.5857 3.6560 3.7263 3.7966 3.8669 3.9372 4.0075 4.0778 4.1481 50
60 4.2184 4.2887 4.3590 4.4293 4.4996 4.5700 4.6403 4.7106 4.7809 4.8512 60
70 4.9215 4.9918 5.0621 5.1324 5.2027 5.2730 5.3433 5.4136 5.4839 5.5543 70
80 5.6246 5.6949 5.7652 5.8355
PD 5.9058 5.9761 6.0464 6.1167 6.1870 6.2573 80
90 6.3276 6.3979 6.4682 6.5386 6.6089 6.6792 6.7495 6.8198 6.8901 6.9604 90
100 7.0307 7.1010 7.1713 7.2416 7.3119 7.3822 7.4525 7.5228 7.5932 7.6635 100
Kg/cm² to Lb/in²
kg/
0 1 2 3 4 5 6 7 8 9 kg/cm2
cm2
lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2
(psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi)
IO
- - 14.22 28.45 42.67 56.89 71.12 85.34 99.56 113.78 128.01 -
10 142.23 156.45 170.68 184.90 199.12 213.35 227.57 241.79 256.01 270.24 10
20 284.46 298.68 312.91 327.13 341.35 355.58 369.80 384.02 398.24 412.47 20
30 426.69 440.91 455.14 469.36 483.58 497.81 512.03 526.25 540.47 554.70 30
40 568.92 583.14 597.37 611.59 625.81 640.04 654.26 668.48 682.70 696.93 40
50 711.15 725.37 739.60 753.82 768.04 782.27 796.49 810.71 824.93 839.16 50
60 853.38 867.60 881.83 896.05 910.27 924.50 938.72 952.94 967.16 981.39 60
70 995.61 1009.83 1024.06 1038.28 1052.50 1066.73 1080.95 1095.17 1109.39 1123.62 70
80 1137.84 1152.06 1166.29 1180.51 1194.73 1208.96 1223.18 1237.40 1251.62 1265.85 80
90 1280.07 1294.29 1308.52 1322.74 1336.96 1351.19 1365.41 1379.63 1393.85 1408.08 90
100 1422.30 1436.52 1450.75 1464.97 1479.19 1493.42 1507.64 1521.86 1536.08 1550.31 100

Kg/cm² to Kpa
kg/ kg/
0 1 2 3 4 5 6 7 8 9
cm2 cm2
Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa
- - 98.1 196.1 294.2 392.3 490.3 588.4 686.5 784.5 882.6 -
10 980.7 1078.7 1176.8 1274.9 1372.9 1471.0 1569.1 1667.1 1765.2 1863.3 10
20 1961.3 2059.4 2157.5 2255.5 2353.6 2451.7 2549.7 2647.8 2745.9 2843.9 20
30 2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6 30
40 3922.7 4020.7 4118.8 4216.9 4314.9 4413.0 4511.1 4609.1 4707.2 4805.3 40
50 4903.4 5001.4 5099.5 5197.6 5295.6 5393.7 5491.8 5589.8 5687.9 5786.0 50
60 5884.0 5982.1 6080.2 6178.2 6276.3 6374.4 6472.4 6570.5 6668.6 6766.6 60
70 6864.7 6962.8 7060.8 7158.9 7257.0 7355.0 7453.1 7551.2 7649.2 7747.3 70
80 7845.4 7943.4 8041.5 8139.6 8237.6 8335.7 8433.8 8531.8 8629.9 8728.0 80
90 8826.0 8924.1 9022.2 9120.2 9218.3 9316.4 9414.4 9512.5 9610.6 9708.6
PD 90
100 9806.7 9904.8 10002.8 10100.9 10199.0 10297.0 10395.1 10493.2 10591.2 10689.3 100
Kpa to Kg/cm²
Kpa 0 100 200 300 400 500 600 700 800 900 Kpa
2 2 2 2 2 2 2 2 2 2
kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm
- - 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 -
1000 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 1000
IO
2000 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 2000
3000 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 3000
4000 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 4000
5000 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 5000
6000 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 6000
7000 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 7000
8000 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 8000
9000 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 9000
10000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 10000

Torque
Ft·lbs to Kg·m
ft·lbs 0 1 2 3 4 5 6 7 8 9 ft·lbs
kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m
- - 0.138 0.277 0.415 0.553 0.691 0.830 0.968 1.106 1.244 -
10 1.383 1.521 1.659 1.797 1.936 2.074 2.212 2.350 2.489 2.627 10
20 2.765 2.903 3.042 3.180 3.318 3.457 3.595 3.733 3.871 4.010 20
30 4.148 4.286 4.424 4.563 4.701 4.839 4.977 5.116 5.254 5.392 30
40 5.530 5.669 5.807 5.945 6.083 6.222 6.360 6.498 6.636 6.775 40
50 6.913 7.051 7.190 7.328 7.466 7.604 7.743 7.881 8.019 8.157 50
60 8.296 8.434 8.572 8.710 8.849 8.987 9.125 9.263 9.402 9.540 60
70 9.678 9.816 9.955 10.093 10.231 10.370 10.508 10.646 10.784 10.923 70
80 11.061 11.199 11.337 11.476
PD 11.614 11.752 11.890 12.029 12.167 12.305 80
90 12.443 12.582 12.720 12.858 12.996 13.135 13.273 13.411 13.549 13.688 90
100 13.826 13.964 14.103 14.241 14.379 14.517 14.656 14.794 14.932 15.070 100
Kg·m to Ft·lbs
kg·m 0 1 2 3 4 5 6 7 8 9 kg·m
ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs
- - 7.23 14.47 21.70 28.93 36.17 43.40 50.63 57.86 65.10 -
IO
10 72.33 79.56 86.80 94.03 101.26 108.50 115.73 122.96 130.19 137.43 10
20 144.66 151.89 159.13 166.36 173.59 180.83 188.06 195.29 202.52 209.76 20
30 216.99 224.22 231.46 238.69 245.92 253.16 260.39 267.62 274.85 282.09 30
40 289.32 296.55 303.79 311.02 318.25 325.49 332.72 339.95 347.18 354.42 40
50 361.65 368.88 376.12 383.35 390.58 397.82 405.05 412.28 419.51 426.75 50
60 433.98 441.21 448.45 455.68 462.91 470.15 477.38 484.61 491.84 499.08 60
70 506.31 513.54 520.78 528.01 535.24 542.48 549.71 556.94 564.17 571.41 70
80 578.64 585.87 593.11 600.34 607.57 614.81 622.04 629.27 636.50 643.74 80
90 650.97 658.20 665.44 672.67 679.90 687.14 694.37 701.60 708.83 716.07 90
100 723.30 730.53 737.77 745.00 752.23 759.47 766.70 773.93 781.16 788.40 100

Kg·m to N·m
kg·m 0 1 2 3 4 5 6 7 8 9 kg·m
N·m N·m N·m N·m N·m N·m N·m N·m N·m N·m
- - 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 -
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.34 500.14 509.95 519.76 529.56 539.37 549.18 558.98 568.79 578.60 50
60 588.40 598.21 608.02 617.82 627.63 637.44 647.24 657.05 666.86 676.66 60
70 686.47 696.28 706.08 715.89 725.70 735.50 745.31 755.12 764.92 774.73 70
80 784.54 794.34 804.15 813.96 823.76 833.57 843.38 853.18 862.99 872.80 80
90 882.60 892.41 902.22 912.02 921.83 931.64 941.44 951.25 961.06 970.86 90
100 980.67
N·m to Kg·m
PD
990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100
N·m 0 10 20 30 40 50 60 70 80 90 N·m
kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m
- - 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 -
100 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 10
IO
200 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 20
300 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 30
400 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 40
500 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 50
600 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 60
700 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 70
800 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 80
900 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 90
1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 100

Temperature
A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading
(or vice versa) is to enter the following table in the center (boldface column) of figures. These fig-
ures refer to the temperature in either Fahrenheit or Centigrade degrees.
To convert from Fahrenheit to Centigrade degrees, consider the center column as Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
To convert from Centigrade to Fahrenheit degrees, consider the center column as Centigrade val-
ues, and read the corresponding Fahrenheit temperature on the right.
PD
IO

1°C = 33.8°F
°C °F °C °F °C °F °C °F
-40.0 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -2
-20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6
PD 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
IO
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0.0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.8 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

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SY195-205-215C9 Crawler Hydraulic Excavator Shop Safety
Shop Safety
2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3
2.2 General Shop Safety ............................................................................................... 2-6
PD
2.3 Precautions for sling work and giving signals ........................................................ 2-25
IO

Shop Safety SY195-205-215C9 Crawler Hydraulic Excavator
PD
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WARNING
jury or death.

2 SHOP SAFETY
2.1 Hazard Alert Information

Most accidents are usually caused by the fail-
ure 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 ma-
chine 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,
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on the machine, part or component decals and
different signal words are used to express the
potential level of a hazard.
DANGER
Indicates an imminent hazard which WILL
result in serious injury or death if message
is ignored.
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WARNING
Indicates a potentially hazardous situation
which COULD result in serious injury or
death if message is ignored.
CAUTION
Indicates a potentially hazardous situation
which COULD RESULT IN MINOR OR MA-
JOR INJURY if message is ignored.
NOTICE
Indicates THE MACHINE MAY BE DAM-
AGED if improperly operated or main-
tained.

This is to alert the user of a hazard. It is

usually used in a graphic.
This symbol is used in a graphic to alert

the user to not do something.
SANY cannot predict every circumstance that

might involve a potential hazard in a repair of
the machine. Therefore the safety message in
this manual and on the machine may not in-
clude all possible safety precautions.
If any procedures or actions not specified, rec-

ommended or allowed in this manual are used,
you must be sure that you and others can
perform such procedures and actions safely
and without damaging the machine. If you are
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unsure about the safety of some procedures,
contact your SANY representative.
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WARNING
● Improper repair procedures on this ma-
chine can be hazardous and could re-
sult in serious injury or even death.
● All personnel involved with the repair

of this machine must read this manual
thoroughly before performing any pro-
cedures on this equipment.
● Some actions involved in the operation

or repair of this machine could cause
a serious accident if they are not per-
formed in the manner described in this
manual.
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● All precautions outlined in this manual
apply only to intended repair proce-
dures of the machine or system. If you
perform any repairs not specifically pro-
hibited, 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 described in this manual.
● SANY delivers machines that comply

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with all applicable regulations and
standards of the country 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 appli-
cable standards and regulations of your
country, contact your SANY representa-
tive before performing repairs on this
machine.

2.2 General Shop Safety
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
learning. 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 disreguarding safety rules. Remember
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this, if you are DILIGENT and follow instruc-
tions outlined in this shop manual with care,
repair operations can be safe and enjoyable.
Safe work practices, should become a force of
habit.
WARNING
Mistakes in operation are extremely haz-
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ardous. Read the Safety, Operation &
Maintenance Manual that came with the
machine carefully before operating the
machine. Failure to follow this alert could
result in serious injury or death.

2.2.1 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 di-

sastrous, to make repairs to a machine
without first receiving proper instructions.
Always use the shop manual when per-
forming 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
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repair shop is a “walking hazard” to every-
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.
2.2.2 Housekeeping
● Oils, grease, fuel, antifreeze or any fluid

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spills should be mopped up immediately.
These items pose a serious slip hazard.
Regardless of who was responsible for the
spill, it is your job as a shop employee to
secure and clean up the spill area.
● Keep the shop clean. Scrap or old parts

should be disposed of properly. Never al-
low 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 become cluttered and disorganized in
order to prevent accidents.
● Always keep in mind, proper house clean-

ing is vital for a safe and pleasant work en-
vironment.

2.2.3 Shop Liquids Storage
● Liquids, cleaning solvents or machine flu-

ids 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 confined shop area. Follow all OSHA
regulations regarding fluid storage.
● Never leave open containers of liquids sit-

ting around. These could spill or catch fire.
Always read the container label for infor-
mation on storage and handling of the liq-
uids.
● Never store liquids in containers that are

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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.
● Never handle liquids without using person-

al protective equipment. Treat all liquids
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with caution.
2.2.4 Cleaning 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 explosion or
fire.

2.2.5 Jacking Up the Machine
● If you will be working under the machine

always use approved jack stands that will
support the weight of the machine you are
working on.
● Never rely on the hydraulics of the ma-

chine 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.
2.2.6 Electrical Dangers

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● 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

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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.

2.2.7 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

removed, store it where it cannot fall or
move. Always be sure what you are stor-
ing is sitting stable on a stable surface and
clear of all walkways or fire exits.
2.2.8 Cleaning the Machine
● Always use high-pressure hot water and

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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 sys-
tem.
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● Never pressure-wash or flood the inside of
an operator cab. This will damage sensi-
tive electrical components.
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
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 Hoisting a Load

PD
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
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handle a loads if possible.
● Be sure the lifting equipment is in good

condition 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

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.

2.2.11 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.
2.2.12 Safety Partners

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No one should be allowed to perform work
operations in any shop alone. It should be a
general 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
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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

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

2.2.13 Two people when engine run-

ning
In order to prevent injury, do not perform the

service while the engine is running. If the ser-
vice must be performed while the engine is
running, operate only when two people are on
the spot and follow the regulations below:
● Always have one operator sit on the op-

eration 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.
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● Do not touch any control lever. If some
control lever must be operated, send signal
to other people and warn them to transfer
to safe place quickly.
● Do not drop or insert the tools and other

objects into the fan or fan belt, or the parts
will be broken or thrown out.
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2.2.14 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 ham-
mer.
● Before performing any of these proce-

dures, 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-
age to the component may result. Always
use a soft or non-ferrous hammer to drive
a component or a pin.

2.2.15 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.
2.2.16 Fire Extinguisher and Emer-

gency Exits
● It is important to know where all emergen-

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cy 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.
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● 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.
2.2.17 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 re-
quired.

2.2.18 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 safe-
ty rules.
● Always be aware of rotating components.
● During repair operations while the engine

is running, one worker must remain in the
operator seat of the machine with clear
contact between the person performing the
repairs on the machine at all times.
● If equipped, all lock levers must be in the

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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 op-
erated, always maintain a clear view to the
person doing the repair and signal them
when you are about to move the control le-
ver.
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● Be aware of hot surfaces. During running
operations, most surfaces will be hot, and
some surfaces will be extremely hot. If
necessary, use personnel protective equip-
ment when working around high tempera-
ture 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.

2.2.19 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.
cumulator. Unapproved gases could be

explosive.
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● Use only nitrogen gas to charge the ac-
2.2.20 Adding Fluids to a System
If it should be necessary to add fluids to a

system during running operations, always be
aware that these systems may be hot and un-
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der 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.

2.2.21 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 or death.
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.
Always stand clear of the track travel path

when separating the master link section of the
track. PD
2.2.22 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
relieved before proceeding. Working on a sys-
tem still under pressure could lead to serious
injury, always do as follows:
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● If you will be removing a line or component
with fluid in the system, always cap and
seal the opening to avoid leakage or sys-
tem 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 card-
board when checking for leaks from small
holes.
● If high pressure fluids should penetrate

your skin or get into your eyes, seek medi-
cal attention immediately.

2.2.23 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 system
pressure.
Block the tracks (if equipped) or wheels (if

equipped) with chocks to prevent the machine
from moving.
PD
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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2.2.24 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.

These actions may lead to serious injury.
PD
Always bring the equipment to a full stop
and turn the engine OFF.
● When getting on or off the equipment,

always face the equipment and maintain
a three-point contact (both feet and one
hand or one foot and both hands) with the
handrails, steps and platforms to ensure
that you support yourself correctly.
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● 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-spec-

ified points on the equipment to get on or
off the machine.
● Use all hand-holds when on the machine.

2.2.25 Battery Hazards
Working around batteries always poses a haz-

ard, especially if the battery has been in ser-
vice 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 equip-

ment when working around batteries.
● Battery gasses are extremely explosive.

When opening a battery compartment, al-
ways allow ample time for the gasses to
escape before servicing the battery.PD
● When working with batteries, always work
in a wellventilated area.
● If the battery is corroded, flush the area

with a baking soda and warm water mix.
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● If battery acid should get on your skin or in

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

2.2.26 Jump-Start Safety
When using jumper cables to start the ma-

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

Power
PD
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 electri-

cal disconnect switch, refer to the machines
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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.
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.

2.2.28 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
disabled, 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.
2.2.29 Sequence of Procedures

PD
Only authorized employees performing repairs
on the machine shall perform Lockout/Tagout DA
in accordance with this procedure listed below. NG
ER
DO
If the employee performing repairs to the ma-
OP NO
chine is issued ER T
AT
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E
a lock and key, the employee shall not share
the lock or key with other employees until all
repair procedures are complete and the ma-
chine 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.

Locking out of service
1. Notify all employees who may be poten-

tially affected by the repair process on the
machine.
2. Secure the machine in a safe position. If

DANGER
equipped, set the parking brake or hydrau-
lic lock lever in the PARK or LOCKED posi- DO NOT OPERATE
tion. When this is not being used,
keep it in the storage compartment.
3. Identify, remove or disconnect all power
or energy sources and be sure to install a
Lockout/Tagout device on them. If the ma-
chine is equipped with a Maintenance Alert
Tag, attach this tag to the machine con-
trols. PD
4. Be sure all employees involved in the re-
pairs have installed there lock on the pow-
er source before performing any repairs.
Once an employee has completed there
repair procedure, they must remove there
lock and not access the machine in any
manor.
Returning to service
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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 start-
up.
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
personnel are aware of the time the ma-
chine will be back in service.

4. Remove the Lockout/Tagout equipment

and any additional alert equipment and re-
energize the machine for return to service.
2.2.30 Chemical hazard
Exposure to hazardous chemicals pose a

serious danger if released or mishandled.
Handling 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 materi-
als should use approved personal protective
equipment and follow all environmental safety
regulations.
2.2.31 Material Safety Data Sheets

(MSDS)
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Material Safety Data Sheet (MSDS) informa-
tion relating to the materials the workers could
be exposed to.
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● 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, re-
activity, storage, disposal and protective
equipment required.
● Be sure all personnel involved are familiar

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 with-

out the proper MSDS information. Always
verify the data on the MSDS sheet before
handling any hazardous materials.

2.3 Precautions for sling work

and giving signals
1. Only one appointed worker is allowed to
give signals and co-workers must commu-
nicate with each other frequently. The ap-
pointed 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.
● Do not step on the load.

PD
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
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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 60°, as a rule.

Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
Load capacity kN(kg)

kN
When hoisting a load with 2 or more ropes, 19.6
(kg)
(2000) 18.6
the force subjected to each rope will in- (1900)
16.7
13.7
19.6 (1700)
crease with the hanging angle. The table (2000)
(1400)
9.8
below shows the variation of allowable (1000)
4.9
9.8
load in kN {kg} when hoisting is made with (1000)
(500)
2 ropes, each of which is allowed to sling

up to 9.8 kN {1,000 kg} vertically, at various 30 60 90 120 150
hanging angles. When the 2 ropes sling a Hanging angle (Deg.) ZX215-1000001
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 sub-
kg}.
PD
jected to a force as large as 39.2 kN {4,000
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 slip-
ping.
9. Use the specified eyebolts and fix wire

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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 dur-
ing hoisting. The hook has the maxi-
mum strength at the middle portion.
100% 88% 79% 71% 41%
11. Do not use twisted or kinked wire ropes.
ZX215-1000002
12. When lifting up a load, observe the follow-

ing.
● 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 soft-
ener.
● If the load is unstable or the wire rope

or chains are twisted, lower the load
and lift it up again. PD
● Do not lift up the load slantingly.
13. When lowering a load, observe the follow-

ing.
● When lowering a load, stop it temporar-

ily at 30 cm above the floor, and then
lower it slowly.
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● Check that the load is stable, and then
remove the sling.
● Remove kinks and dirt from the wire

ropes and chains used for the sling
work, and put them in the specified
place.

Selecting wire ropes
Select adequate ropes as per the weight of parts to be hoisted, referring to the table below.
Wire ropes
(Standard “Z” twist ropes without galvanizing)
Nominal Diameter of Rope Allowable Load
mm kN Ton
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
22.4
30
40
PD 43.1
54.9
98.1
176.5
4.4
5.6
10.0
18.0
50 274.6 28.0
60 392.2 40.0
CAUTION
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The allowable load is one-sixth of the
breaking strength of the rope used (Safety
coefficient: 6).

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SY195-205-215C9 Crawler Hydraulic Excavator Specifications
Specifications
3 Specifications
3.1 Dimensions .............................................................................................................. 3-3
3.2 Working Ranges ...................................................................................................... 3-4
PD
3.3 Technical Specifications........................................................................................... 3-5
3.4 Weight Table ............................................................................................................ 3-7
3.5 Recommended Oil, Fuel and Coolant...................................................................... 3-8
3.6 Capacity Table ......................................................................................................... 3-9
3.7 Engine Performance Curve ................................................................................... 3-10
IO

Specifications SY195-205-215C9 Crawler Hydraulic Excavator
PD
IO
WARNING
jury or death.

3 SPECIFICATIONS
3.1 Dimensions
A
D
I
E C
H
F J
G
B PD K
ZX215-1001001
Item Unit SY195C-9 SY205C-9 SY215C-9

A Overall length (shipping) mm 9560 {31'4''} 9680 {31'9''} 9680 {31'9''}
B Overall width mm 2800 {9'2''} 2800 {9'2''} 2980 {9'9''}
C Overall height (Shipping) mm 3250 {10'8''} 3440 {11'3''} 3440 {11'3''}
IO
D Width (top) mm 2710 {8'11''} 2710 {8'11''} 2710 {8'11''}
E Overall height (to cab roof) mm 2990 {9'10''} 2990 {9'10''} 2990 {9'10''}
F Std. track shoe width mm 600 {1'12''} 600 {1'12''} 600 {1'12''}
G Track gauge mm 2200 {7'3''} 2200 {7'3''} 2380 {7'10''}
H Min. ground clearance mm 440 {1'5''} 440 {1'5''} 440 {1'5''}
I Tail swing radius mm 2750 {9'0''} 2750 {9'0''} 2750 {9'0''}
J Length of track on ground mm 3260 {10'8''} 3355 {11'0''} 3445 {11'4''}
K Track length mm 4060 {13'4''} 4160 {13'8''} 4250 {13'11''}

3.2 Working Ranges
g
b
PD
e
c
d
IO
ZX215-1001002
Item Unit SY195C-9 SY205C-9 SY215C-9

a Max. cutting height mm 9410 {30'10''} 9570 {31'5''} 9570 {31'5''}
b Max. dumping height mm 6490 {21'4''} 6700 {21'12''} 6700 {21'12''}
c Max. digging depth mm 6410 {21'0''} 6600 {21'8''} 6600 {21'8''}
d Max. vertical digging depth mm 5790 {18'12''} 5800 {19'0''} 5800 {19'0''}
e Max. digging reach mm 9740 {31'11''} 9950 {32'8''} 9950 {32'8''}
f Min. swing radius mm 3755 {12'4''} 3595 {12'12''} 3595 {12'12''}
g Max. height at min. swing radius mm 7700 {25'3''} 7665 {25'2''} 7665 {25'2''}

3.3 Technical Specifications
3.3.1 Engine
Item Specification
Engine model 6D34TLE2A

Type In-line 6-cylinder; water-cooled, 4-cycle diesel engine
Combustion chamber type Direct injection
Valve mechanism OHV
Max. output power kW{PS}/rpm 114{155}/2050
Max. torque N·m{kgf·m}/rpm 590{60}/1400
Bore×Stroke mm φ104×115
Total displacement cm³{L} 5860{5.860}
Compression ratio
3.3.2 Swing motor

PD 18.2
Producer KAWASAKI
Model M5×180CHB-12A-51A/260
angle type, piston type
Type
(swing brake controller)
IO
Theoretical displacement cm³/rev 129.2
Safety valve set pressure MPa {Kg/cm³} 25.5 {260}
Rated engine speed rpm 2050
Brake release pressure MPa {Kg/cm³} 3.4 {34}
3.3.3 Control valve
Item Specification
Model KMX15RB
Standard flow rate (equivalent to one pump) 300 L/min
When main relief valve is normal 34.3 MPa
Maximum pressure
When main relief valve is boosting 37.3 MPa
Maximum pressure When port relief valve is normal 39.2 MPa
Working oil temperature -20~90°C
Drained oil maximum pressure 0.3 MPa

3.3.4 Travel motor
Maker KYB
Model MAG-170VP-3400E
Variable displacement piston type
Type
(w/ brake valve and parking brake)
Weight kg 275
Equivalent displacement cm³/rev qxi
Large displacement q1 cm³/rev 130.4
Motor displacement q
Small displacement q2 cm³/rev 74.9
Speed reduction rate i 60
2-speed switching Lo-Hi Mpa > 6.86
Pilot pressure Hi-Lo Mpa > 1.96
Braking torque N·m 398
Operating displacement PD L/min 228
Operating pressure Mpa 33.34
Peak pressure Mpa within 44.1
Acting times (above 34.3Mpa and below 44.1Mpa) times < 1,200,000
Large flow rpm 1679
Motor shaft
Small flow rpm 2861
Swing speed
Large flow rpm 28
Reducer
Small flow rpm 47.7
Output torque KN·m within 37
IO
Normal PS
Input power
Maximum PS within 210 (within 30 consecutive sec.)
Normal Mpa within 0.2
Drain pressure
Momentary maximum Mpa within 0.5 (below 0.3 MHz)

3.4 Weight Table

Unit: kg
Machine Model SY195C-9 SY205C-9 SY215C-9
Engine 520 520 520
Radiator assembly 80 80 80
Hydraulic tank assembly (w/o hydraulic oil) 148 148 148
Fuel tank assembly (w/o fuel) 126 126 126
Revolving frame 1770 1770 1770
Operator cab 360 360 360
Operator seat & control console 75 75 75
Counterweight 3900 3900 3900
Hydraulic pump 120 120 120
Control valve 185 185 185
Swing reducer assembly
Final drive assembly
Center swivel joint
Track frame
PD 200
300×2
56
2280
200
300×2
56
2432
200
300×2
56
2746
Swing bearing 286 286 286
Idler 116×2 116×2 116×2
Tensioning device 135×2 135×2 135×2
Carrier roller 25.5×4 25.5×4 25.5×4
IO
Track roller 40×14 40×14 40×16
Boom assembly 1568 1568 1590

Arm assembly 706 709 709
Bucket assembly 769 769 781
Boom cylinder assembly 206×2 206×2 206×2
Arm cylinder assembly 262 262 262
Bucket cylinder assembly 188 188 188
Linkage 68 68 68
Rocker 22×2 22×2 22×2

3.5 Recommended Oil, Fuel and Coolant
Ambient temperature
Fluid
Reservoir -22 -4 14 32 50 68 86 104 122°F
type
-30 -20 -10 0 10 20 30 40 50°C
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
Swing machinery
case Engine oil PD
Idler
SAE 30
Track roller
Carrier roller
SAE 10W
SAE 10W-30
SAE 15W-40
IO
Hydraulic system
L-HV32 Low-temp, wear-resistant
hydraulic oil
Hydraulic
oil L-HM46 Wear-resistant hydraulic oil
L-HM68 Wear-resistant hydra. oil
ASTM D 975 No.2
Diesel
Fuel tank GB252 Super-20 Diesel fuel
fuel
GB252 Super-35 Diesel fuel
Grease fitting Grease NLGI No.2
Cooling system Coolant Add anti-freeze

● Machine oil above API CF-4 (no lower than APC CD) is recommended.
● Gear oil GL-5 is recommended.
● Obtain genuine oil from Sany Heavy Machine or its authorized dealers.
3.6 Capacity Table

Unit: L {US Gal}
Swing mecha- Final drive Hydraulic
Engine oil pan Cooling system Fuel tank
nism casing casing system
22 {5.81} 4.0 {1.06} 5.5 {1.45} 239 {63.14} 22.5 {5.94} 340 {89.82}
PD
IO

3.7 Engine Performance Curve

Testing condition:
1) Temperature: 298K, one standard atmospheric pressure. 2) No fan.
N·m
Torque
600
Torque
500
400
300
kW
120
100
PD Power output
Power output
80
IO
60
40
g/kw·h
Fuel consumption
20 240
Fuel consumption
230
220
210
1000 1200 1400 1600 1800 2000
Engine speed min -1

ZX215-1001003

E
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BL

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PPDAG
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SY195-205-215C9 Crawler Hydraulic Excavator Structure and Function
Structure and Function

4 Structure and Function
4.1 Engine and Cooling System .................................................................................... 4-3
4.2 Power Train.............................................................................................................. 4-5
PD
4.3 Undercarriage and Frame...................................................................................... 4-13
4.7 Air Conditioning System....................................................................................... 4-127
4.8 Engine Control ..................................................................................................... 4-159
4.9 Electrical Control System..................................................................................... 4-165
4.10 Monitoring System ............................................................................................. 4-196
IO

Structure and Function SY195-205-215C9 Crawler Hydraulic Excavator
PD
IO
WARNING
jury or death.

4 STRUCTURE AND FUNCTION
4.1 Engine and Cooling System
4.1.1 Engine-related parts
PD
IO
1 2 3 4 5 6 7
ZX215-1002001
1) Fan Specification
2) Front engine mount
3) Fuel filter Oil capacity: 22 L
4) Start motor
5) Rubber damper assembly
6) Rear engine mount
7) Muffler

4.1.2 Radiator and intercooler
1 2 3 4 5 6
PD 7
9
IO
10
ZX215-1002002
1) Reserve tank Specifications

2) Radiator assembly
3) Radiator inlet hose Radiator assembly: ME444275
4) Radiator outlet hose Aluminum pipe, belt-type radiator

5) Inlet air pipe Inter-cooling, oil radiation/water radiation se-
6) Outlet air pipe ries connection type.
7) Intercooler Reservoir capacity: 8.9 L
8) Guard net
9) Guard
10) Radiator cap

4.2 Power Train
4.2.1 Power transmission system
3 2 1
4 5
PD 6 7 8 9
10
IO
ZX215-1002003
1) Swing motor 6) Accumulator

2) Swing reducer 7) Control valve
3) Swing bearing 8) Final drive AS
4) Idler 9) Hydraulic pump
5) Center swivel joint 10) Engine

4.2.2 Final drive assembly
Final drive AS (KYB)
1 2 3 19 4 17
73±3.6 N·m
205±10 N·m
5
59±4.9 N·m
20
7
PD 18
8
IO
157±8 N·m
12
11 16 10 9
ZX215-1002004
13
14
15
ZX215-1002005

1) Cylinder GP 9) No. 2 sun gear (No. of teeth: 19)

2) Shaft 10) No. 2 planetary gear (No. of teeth: 36)
3) Gear hub (No. of teeth: 85) 11) Seal ring
4) No. 2 planetary carrier 12) Travel motor
5) No. 1 planetary carrier 13) Fill port
6) No. 1 planetary gear (No. of teeth: 36) 14) Level port
7) No. 1 sun gear (No. of teeth: 12) 15) Drain port
8) End cover
Specifications
Reduction ratio:
( (12+85) /12) × ( (19+85) /19) ) -1= 43.246
No.
16
Check item
PD
Backlash between No. 2 sun gear
and No.2 planetary gear
Backlash between No. 1 planetary
Standard clearance
0.13 – 0.47
Criteria
Clearance limit
1.00
Remedy
Replace
17 0.17 – 0.57 1.10

gear and gear hub
18 0.14 – 0.46 1.00
Replace
IO
19 0.16 – 0.56 1.10
gear and gear hub
20 0.38 – 0.66 1.00
carrier and No. 2 sun gear

Final drive AS (Nabtesco)
2 3 4 5 6
102 ±16 Nm
98 ±20 Nm
7
PD 8
10
IO
98 ±20 Nm
12 ±2.5 Nm
12 709 ±108 Nm
11
ZX215-1002006
14 13
IN
OIL LEVEL
DRAIN
15 ZX225-1102047

1) Plunger GP 9) Shaft coupling

2) Crankshaft 10) Retainer
3) Gear hub 11) Motor output shaft
4) Roller bearing 12) Travel motor
5) RV drive gear A 13) Fill port
6) RV drive gear B 14) Level port
7) No. 1 planetary gear (42) 15) Drain port
8) No. 1 sun gear (18)
Specifications
Reduction ratio: 60
PD
IO

4.2.3 Swing machinery
20
19
8
21
7
22
59~74 Nm
PD 10
6
23
5 24
11
4
12
25
26
13
IO
3
27
1 14
15
16
17
18
28
ZX215-1002007

1) Plug 11) No. 2 planetary gear GP

2) Oil seal 12) No. 2 planetary gear (No. of teeth:17)
3) Self-aligning bearing 13) Spring pin
4) Ring gear (No. of teeth:52) 14) Swing reducer screw plug
5) No. 2 planetary carrier 15) Grease fitting
6) No. 1 planetary carrier 16) Self-aligning bearing
7) No. 2 sun gear (No. of teeth: 16) 17) Bearing sealing
8) No. 1 sun gear (No. of teeth:14) 18) Swing pinion
9) Swing motor 19) Dipstick
10) No. 1 planetary gear (No. of teeth:18) 20) Oil filling pipe
Specifications
Reduction ratio:
(14+25) /14× (16+25) /14= 20.04 PD Criteria

Unit: mm
No. Check item Remedy

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

4.2.4 Swing bearing
A
A
1
PD 2
3
IO
549±50 Nm
549±50 Nm
A-A
ZX215-1002008
1) Swing bearing inner race (Teeth: 91) Specifications

2) Ball
3) Swing bearing outer race Reduction ratio: 91/13= 7
Amount of filled grease: 13±1 Kg
a. Inner race soft zone S position
b. Outer race soft zone S position Unit: mm
Check item Criteria Remedy
Axial clearance of bearing Standard clearance Clearance limit

Replace
(when mounted on chassis) 0.5~1.6 3.2

4.3 Undercarriage and Frame
4.3.1 Track frame and recoil spring
1 2 3 4
8
PD 7 6 5
10
11
IO
X
ZX215-1002009
1) Idler ● Dimension and number of track rollers may

2) Track frame vary depending on the machine model, but
the basic structure is the same.
3) Carrier roller
4) Sprocket
Model Q'ty (One side)
5) Track roller
6) Track shoe SY195C9 7
7) Center guard SY205C9 7
8) Front guard SY215C9 8

Standard track shoe
Model
SY195C9M SY205C9M SY215C9M
Item
Shoe width(mm) 600 600 600
Link pitch(mm) 190 190 190
Q'ty (One side) 45 46 47
Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit
Vertical width of
9 Track frame 107 — — Build-up
idler guide
Idler support 105 — — welding or
Horizontal width Track frame
PD 250 — — replace
10
of idler guide Idler support 248 — —
Standard size Repair limit
Free length
Installation Installation Free Installation
x Outside
11 Recoil spring length load length load Replace
diameter
157.9 kN
572 x 235 466 545 133.9 kN
{16112 kg}
IO

4.3.2 Idler
4
3
7
8
157~255 Nm 9
1 2
PD
IO
ZX215-1002010

Unit: mm
Outside diameter of protru- Standard size Repair limit

1
sion 560 —
2 Outside diameter of tread 520 508 Build-up
3 Thickness of tread 30 24 welding or
4 Difference of tread 20 26 replace
5 Total width 164 —
6 Width of tread 39.5 —
Standard Tolerance Standard Clearance
Clearance between shaft size Shaft Hole clearance limit
7
and bushing – 0.250 +0.164
65 0.049 – 0.199 —
– 0.350 – 0.074
Standard Tolerance Standard inter- Interfer-
8
Interference between idler
and bushing
Clearance between bush-

size
72
PD Shaft
+0.108
+0.008
Standard clearance
Hole
-0.032
-0.062
ference
0.040 – 0.170
Clearance limit
ence limit
—
Replace
bushing
9 ing and support (Sum of

0.5~1.0 —
clearance at both sides)
IO

4.3.3 Carrier roller
5 3
PD 6 7
2 1
ZX215-1002011
Unit: mm
IO
1 Outside diameter of flange
169 —
2 Outside diameter of tread 144 130
3 Width of tread 43 —
4 Thickness of tread 34 27
5 Width of flange 17 —
Clearance between shaft size Shaft Hole clearance limit Replace
6
and bushing – 0.05 +0.10
40 0.05 – 0.20 —
– 0.10 0
Standard Tolerance Standard Interfer-
Interference between roller size Shaft Hole interference ence limit
7
and bushing +0.16 -0.040
47 0.12 – 0.24 —
+0.12 -0.08
Standard clearance Clearance limit
8 Axial clearance of roller
0.44 – 0.76 —

4.3.4 Track roller
10
8 9 2 1
549±59 Nm
PD 7
4
5 6
ZX215-1002012
Unit: mm

Standard clearance Repair limit
1 Outside diameter of flange
IO
193 —
2 Outside diameter of tread 160 148
Build-up weld-
3 Thickness of tread 46.5 40.5
ing or replace
4 Total width 237 —
5 Width of tread 46.5 —
6 Width of flange 32 —
7 Inside width 80
Tolerance Standard Clearance
Standard size
Clearance between shaft Shaft Hole clearance limit
8
and bushing – 0.15 0
60 0.07 – 0.17 —
– 0.17 -0.08 Replace
Tolerance Standard Interfer- bushing
Standard size
Interference between roller Shaft Hole interference ence limit
9
and bushing +0.16 0
67 0.12 – 0.24 —
+0.12 -0.08
Clearance between bushing Standard clearance Clearance limit
10 Replace
and collar 0.5 – 1.0 —

4.3.5 Track shoe
8
PD
20
22 24
16 12
13
5
11 21
IO
23 25
7 6 15 2 9 3 14
10
18 17 19
ZX215-1002013

Unit: mm

1 Link pitch
190 193
Reverse or replace
2 Outside diameter of bushing
58.7 53.7
3 Thickness of bushing metal 10.75 5.75
4 Link height
106 98 Repair or replace
Thickness of link metal (bushing press-
5 30.65 22.5
fitting portion)
6 155.57
7 Shoe bolt pitch 119.57
8 62
9
10
11
12
Link
Protrusion of pin
PD
Inside width
Overall width
Tread width
Regular
82.69
2.65
40
38
Master 2.65 Adjust or replace

Regular 3.7
13 Protrusion of bushing
Master 0.0
Regular 207
IO
14 Overall length of pin
Master 209
Regular 136.1
15 Overall length of bushing
Master 128.7
16 Thickness of spacer —
17 Bushing 88.2 – 245 kN {9 – 25 ton}
18 Press-fitting force Regular pin 127.4 – 274.4 kN {13 – 28 ton} —
19 Master pin 78.4 – 147 kN {8 – 15 ton}

Unit: mm
Tightening torque (Nm {kgm}) Retightening angle (°)

a. Regular link Triple grouser 750±22.5
120±10
Shoe bolt shoe {62.5±2.3} Retighten
20 Tightening torque Retightening angle Lower limit torque
b. Master link (Nm {kgm}) (°) (Nm {kgm})
— — —
No. of shoes (each side) SY195C9: 45 SY205C9: 46 SY215C9: 47 —
Tolerance Standard interfer-
Standard size
Interference between Shaft Hole ence
21
bushing and link 0 -0.25
58.7 0.20 – 0.32
-0.05 -0.32
Interference between regu- 0 –0.23
22 PD 36.7 0.19 – 0.29
lar pin and link -0.04 –0.29
Tolerance Standard clear-
Standard size
Clearance between regular Shaft Hole ance
23
pin and bushing 0 0.8 Adjust or
36.7 0.50 – 0.84
-0.04 0.5 replace
Tolerance Standard interfer-
Standard size
Interference between mas- Shaft Hole ence
24
ter pin and link -0.08 -0.23
36.7 0.12 – 0.21
-0.11 -0.29
IO
Tolerance Standard clear-
Standard size
Clearance between master Shaft Hole ance
25
pin and bushing -0.5 1
36.7 1 – 1.7
-0.7 0.5

PD
IO

4.3.6 Triple grouser shoe
5 6 7
1
8
2
3 4
No. Check item

PD Standard size
Criteria
Repair limit
ZX215-1002014
Unit: mm
Remedy
1 Height
26 16
2 Thickness 10
3 29.5
Length of base
IO
4 22 Build-up welding
5 20.5 or replace
6 Length at tip 17
7 18
8 Thickness
36 26

4.4 Hydraulic System, Part 1
4.4.1 Hydraulic equipment layout
1) Bucket cylinder
2) Arm cylinder
2
3) Boom cylinder
4) Hydraulic tank
5) Hydraulic oil filter
6) Control valve
7) Hydraulic pump
8) Radiator
9) Accumulator
10) Left travel motor
11) Right travel motor
12) Swing motor
13) Lockout lever
14) Left pilot valve
PD
15) Center swivel joint
16) Right pilot valve 1
17) Travel pilot valve

18) Solenoid valve assembly
IO
18A. Pilot lockout solenoid valve
18B. Boom priority solenoid valve
18C. Bucket confluence solenoid valve
18D. Swing priority solenoid valve
18E. Hi/Lo travel speed solenoid valve
ZX215-1002015

3 4 5 6 7 8
PD
IO
A
10
11
A
12
18A
13 18B
14 18C
18D
15 18E
16 18F
17
18
ZX225-1102001

4.4.2 Hydraulic tank and filter
2
1
3 PD 4 5 6
A
A
IO
7
A-A
ZX215-1002017
1) Hydraulic tank Specifications

2) Level gauge Tank capacity: 239 L
3) Oil filler cap Available capacity: 172 L
4) Return oil filter element
5) Bypass valve Breather valve
6) Breather valve Filter fineness: 10μm

7) Oil-suction filter element Ambient temperature: -30~100°C
Set pressure:
Air inlet side: 0.004MPa (at 1Lmin)
Air outlet side: 0.017MPa (at 1L/min)

4.4.3 Hydraulic pump
Type: K3V112DTP1N9R a1 PH1 PH2 a2

{36N·m} {36N·m}
a5
A1 {16N·m}
A2
a4
{36N·m}
PD
Clockwise
B3
DR1{170N·m}
B1 DR2{170N·m}
a3
5 Psv2 {36N·m}
4
IO
A3
DR3{170N·m} DR4{170N·m}
3 2 1
ZX215-1002018

Outline
● This pump consists of 2 variable capacity swash plate plunger pumps, 2 regulators, and 1 pi-
lot gear pump.
NOTE: For the location of the hydraulic pump on the machine, see “Hydraulic equipment layout”
on page 4-24.
a1: F. pump main pressure detection port 1) Front pump

a2: R. pump main pressure detection port 2) Rear pump
a3: F. pump regulator pressure detection port 3) Pilot gear pump
a4: Adjustor control pressure detection port 4) Front pump regulator
a5: Pilot gear pump output pressure detection port 5) Rear pump regulator
PH1: F. pump pressure sensor assembly port
PH2: R. pump pressure sensor assembly port
A1: F. pump delivery port PD
A2: R. pump delivery port
A3: Pilot gear pump delivery port
Psv1: F. pump regulator control port
Psv2: R. pump regulator control port
Dr1: F. pump drain plug
Dr2: R. pump drain plug
Dr3: Air bleeder
Dr4: Drain plug
IO
B1: Pump suction port
B3: Pilot gear pump oil suction port

2 3 13 6 7 14 8 9 16 10
15
1
12
1)
4
Front shaft
5
PD 9) End cover
11
ZX215-1002019
2) Min. delivery adjusting screw 10) Rear shaft

3) Front casing 11) Rear casing
4) Swash plate 12) Gear pump
5) Slipper 13) Piston
IO
6) Plunger 14) Max. delivery adjusting screw
7) Cylinder block 15) Gear shaft
8) Valve plate 16) Driving pin

B 6 13 7 8
18
18 4 5
A 17 PD ZX215-1002020
Function
● The torque of the engine is transmitted

to the pump shaft (1), and drives cylinder
block (7) to rotate. At the same time, nine
plungers (6) slide along the thrust plate (8).
IO
Plunger (6) moves back and forth inside
cylinder block (7) and pressurized oil is
sucked and discharged alternatively.
● It is possible to change the discharge

amount by changing the swash plate an-
gle.

Structure
● Cylinder block (7) is supported to shaft (1)

by spline (17).
● Shaft (1) is supported by front and rear

bearings (18).
● Tip of plunger (6) is shaped as a concave

ball and slipper (5) is caulked to it to form
one unit.
● Plunger (6) and slipper (5) constitute the

spherical bearing.
● Swash plate (4) has flat surface (A), and

slipper (5) is always pressed against this
PD
surface while sliding in a circular move-
ment.
● Swash plate (4) conducts high pressure oil

to cylinder surface (B), and forms a static
pressure bearing when it slides.
● Plunger (6) carries out relative movement

in the axial direction inside each cylinder
chamber of cylinder block (7).
IO
● Cylinder block (7) seals the pressurized oil
to thrust plate (8) and carries out relative
rotation.
● This surface is designed so that the oil

pressure balance is maintained at a suit-
able level.
● The oil inside the respective cylinder cham-

bers of cylinder block (7) is sucked in and
discharged through thrust plate (8).

Operation of pump
● Cylinder block (7) rotates together with 1 4 5 7

A
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)
a
between central line (X) of swash plate (4)
X
and the axial direction of cylinder block (7)
changes. B ZX215-1002021
● (a) is named the swash plate angle.

4 5 6
● With central line (X) of swash plate (4) at A F
a swash plate angle (a) in relation to the

axial direction of cylinder block (7), flat sur-
(5).
PD
face (A) acts as a cam in relation to slipper
● In this way, plunger (6) slides on the in-

side of cylinder block (7), so a difference
a
X
7
E
ZX215-1002022
between volumes (E) and (F) is created
inside cylinder block (7).
● A single plunger sucks and discharges the

oil by the amount (F) – (E).
IO
● As cylinder block (7) rotates and the vol-
ume of chamber (E) becomes smaller, the
pressurized oil is discharged.
● On the other hand, the volume of chamber

(F) grows larger and, in this process, the
oil is sucked.
F
● 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 cylin-
der block (7)becomes 0.
● Suction and discharging of pressurized E

oil is not carried out in this state. Namely 4 7 ZX215-1002023
pumping action is not performed. (In real-
ity, however, the swash plate angle is not
set to 0)

Control of delivery
● If swash plate angle (a) becomes larger, 13 16 F

the difference between volumes (E) and
(F) becomes larger and pump delivery (Q)
increases.
● Piston (13) is used for changing swash

plate angle (a).
● Piston (13) carries out linear alternating a

motion under the control of the adjustor.
● This linear motion is transmitted to swash

4 E
plate (4) via drive pin (16). The sliding of ZX215-1002024
the swash plate changes the swash plate
angle and changes the discharge amount
PD
of the main pump.
IO

4.4.4 Pilot pump
NOTE: For the location of the pilot pump on the machine, see “Hydraulic equipment layout” on
page 4-24.
435 433 710 700 354 351
434
310
355
732
311
312
PD
309 307 308 434 850 466 725 435 361 353
ZX215-1002025
307: Valve stem 361: Body

308: Valve base 433: Screw
IO
309: Retainer 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 actuates the main pump and

the drive shaft of the pilot pump through
the transmission case, and drives the pilot
pump through gear engagement.

SKY5P 079
- 17 - S
496 418
(KR3G-0E11-AV)
4.4.5 Regulator
PSV B
KDRDE5C-1
624 627 646 897 415
A
325
408 a
496
924
801 601
755 402 614
466
543
656
407 643 755
A
IO 733 756
631 708 545
724
731 887 611
651 652 733 541
SY195-205-215C9 Crawler Hydraulic Excavator
A-A
(KDRDE5K) PSV
Shop Manual - December 2012

Tightening torque
Name plate and s/n
Tightening torque
the hydraulic pump, see “Hydraulic equipment layout” on page 4-24.
Part No. Thread size

a N•m Type
402, 407
M6 12
PD
408
415 M8 29 s/n
G-OE11-V
418 M5 6.9
466 G1/4 16
496 NPTF1/16 8.8
614 G1/4 36 Direction B
801 M10 29
Hydraulic schematic diagram
ZX225-1102002
NOTE: Both the front pump and the rear pump are equipped with a regulator. For the location of
4-35
Category Part No. Part name Q’ty Remark

C 924 Hexagon socket head locating screw 1
/ 897 Pin 1
/ 887 Pin 1
D 801 Hexagon nut 1 JIS B 1181 N-M10
D 756 O-ring 2
D 755 O-ring 2
D 733 O-ring 2
D 731 O-ring 1
D 724 O-ring 5
D 708 O-ring 1
/ 656 Cover plate 1
/ 652 Spool valve 1
/ 651 Sleeve PD 1
/ 646 Guide spring 1
/ 643 Pilot plunger 1
/ 631 Pf pilot sleeve 1
/ 627 Adjusting roller 1
/ 624 Spring seat 1
/ 614 Plug 1
/ 611 Feedback lever 1
/ 601 Casing 1
IO
/ 545 Ball 2
/ 543 Stopper 2
/ 541 Valve seat 2
C 496 Embedded plug 9
C 466 VIP plug 1
D 418 Hex socket head bolt 2 JIS B 1176 M5-12
/ 325 Valve body 1
B 079 Sol proportional reducing valve 1
B — Regulator assembly 1

Function PSV
● The regulator controls the pump discharge

amount according to the command signal
pressure, keeping the driving power of the
a
pump lower than the engine output.
1
● Pumps 1 and 2 are both equipped with a
regulator. Key components of the regulator
include a solenoid proportional pressure
reducing valve (1), a positive flow regulator 2
(2), a servo reversing valve (3) and a servo
piston (4). The regulator opens and shuts
the oil circuit of the servo piston (3) and
3
changes the tilting angle of the hydraulic 4
tank according to various command signal ZX225-1102003
pressure so as to control the pump dis-
charge amount. PD
4.4.5.1 Control mechanism makeup
Current control
● The inclination (output delivery amount)

of the pump can be controlled freely by
IO
changing of the command current I flow-
ing into the solenoid proportional pressure
reducing valve. This regulator applies posi-
tive flow control (positive control), through
which output delivery amount Q changes
according to the increase of command cur-
rent. Necessary current for corresponding
operation can be input through this control
mechanism. The pump only delivers nec-
essary oil amount and wastes no useless
power.

4.4.5.2 Adjustment of the regulator
806 532 548 531 808 954
953
531: Inclination pin

532: Servo piston
PD SKY5P
- 17 - S
ZX215-1002028
PSV
548: Feedback pin
KDRDE5C-1
806: Retaining nut

808: Retaining nut 924
IO
953: Adjusting screw
954: Adjusting screw
● It is possible to adjust the maximum and

minimum flow by the adjusting screws (953, ZX225-1102004
954) in the pump block side. Flow control

features can be adjusted with the hexagon
socket head locating screw (924) on the
regulator.

Maximum flow adjustment (pump block

side)
● Loosen the hexagon nut (808), and tighten

(or loosen) hexagon socket head locating
screw (954). No control features except the
Output flow Q
maximum flow changes.
Command current I
ZX215-1002033
PD
Minimum flow adjustment (pump block
side)
● Loosen the hexagon nut (806), and tighten

(or loosen) the hexagon socket head locat-
ing screw (953). Though this action is the
Output flow Q
same as the adjustment of maximum flow

and all the other control features do not
IO
change, power required under maximum
output pressure (overflow) is likely to in-
crease if over-tightened. Be careful in this
case.
Command current I
ZX215-1002034

Flow control feature adjustment
● After hexagon nut (810) is loosened, tight-

en (or loosen) the hexagon socket head lo-
cating screw (924) to carry out adjustment.
Output flow Q
When the hexagon socket head locating
screw (924) is being tightened, the control
diagram (as shown) will move to the right.
Command current I
ZX215-1002037
4.4.5.3 Operation
PD
Flow control
Output flow Q
● The output flow of the pump can be con-

trolled by the command current I, as
shown.
IO
Command current I
ZX215-1002030

Action of increasing flow rate
● When command current I increases, the

079
solenoid proportional pressure reducing
valve secondary pressure P2 will increase, 651 652
627 646
and the spool valve (652) will move the 643
801
right with the help of the guide piston (643). P1
924
When a relative balance between the right- 611
ward hydraulic force and the spring force 808 A 532

806
of guide spring (646) is achieved, spool 954 953
valve (652) stops moving.
P1
● As spool valve (652) moves to the right,

because port cl and tank port are intercon- Tilt angle large
ZX225-1102005
nected, pressure of the large diameter
portion of the servo piston is released and
servo piston (532) moves to the left via the
PD
output pressure P1 in the shall diameter PSV
portion. The inclination becomes larger.
● Since feedback lever (611) is integrated

with the servo piston and valve sleeve a
(651), if servo piston (632) moves to the
left, feedback lever swings with point A as
the pivot. In this way, valve sleeve moves
to the right.
IO
● Through this movement, the opening por-
tion between the spool and the valve block
is closed slowly. The servo piston stops
moving when the opening portion is com-
pletely closed. ZX225-1102006

Action of reducing flow rate
● When command current I decreases, the 079
solenoid proportional pressure reducing 651 652

valve secondary pressure P2 will decrease, 627 646
643
and guide piston (643) will move to the left. P1
801
924
However, as spool valve (652) moves, out-
611
put pressure P1 is introduced into the large 532
808 A
diameter chamber of the servo piston via 954
806
953
the port cl. On the other hand, output pres-
sure P1 is introduced into the small diam- P1
eter chamber of the servo piston and servo
piston moves to the right via are difference. Tilt angle small
The inclination becomes smaller. ZX225-1102007
● As servo piston (532) moves to the right,

the feedback lever swings with point A as PSV
PD
the pivot and the valve sleeve moves to the
left. 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
a
completely closed.
IO
ZX225-1102008
Adjustment value of the regulator
Type of regulator KR3G-0E11-AV

-1
Rotating speed (min ) 2050
Adjusting screw (954) screw-in (rotation) +1/4
Adjustment of max. flow
Flow rate change (L/min) -5.9
Adjusting screw (953) screw-in (rotation) +1/4
Adjustment of min. flow
Flow rate change (L/min) +4.7

4.5.1 Control valve

NOTE: For the location of the control valve on the machine, see “Hydraulic equipment layout” on
page 4-24.
(XAo) XBp2 XAa1
BaR XAa2
BoR
BkR
Psp
BbR
XAb1
Dr2
XBtr
XBtL
XAs
PD
Dr6
XBtr
Dr3
(PTa)
PnA2
Dr7
Pns
Bs Btr As Atr
IO
Pz AtL PX PG
PbL
TRAVEL STRAIGHT
Py MR TRAVEL RIGHT
XAtr
TRAVEL LEFT SWING
XAtL BtL Dr1 XBs
XBb1
BOOM1
Bb(Rod) SWING PRIORITY BOOM2
XAb2
AbR
BUCKET OPTION
XAk PCk AkR (XBo)

(Bo)
ARM2 ARM1
XBa2 XBk AoR Dr3 XBa1

(BYPASS CUT 1)
Bk(Rod) DR3 PCV1

(XBp1)
AaR
R2 Ba(Head)
PaL
Aa(Rod) Ak(Head) Ab(Head) (Ao)
P2 P1
R1
R1
ZX225-1102009

XAtr : R. travel (reverse) pilot port XBp2: Bypass cut spool pilot port (P2 side)
XBtr : R. travel (forward) pilot port XAb2: Boom confluence (UP) pilot pressure
(XAo): (Option pilot port) Psp: Swing priority pilot port
(XBo): (Option pilot port) R1: Return port
XAk: Bucket (DIG) pilot port R2: Oil feed port
XBk: Bucket (DUMP) pilot port Atr: R. travel motor port (reverse)
XAb1: Boom 1 (UP) pilot port Btr: R. travel motor port (forward)
XBb1: Boom 2 (DOWN) pilot port (Ao): Option
XAa2: Arm 2 (OUT) pilot port (Bo): Option
XBa2: Arm 2 (IN) pilot port Ak: Bucket cylinder head end port (DIG)
XAtL: L. travel (reverse) pilot port Bk: Bucket cylinder rod end port (DUMP)
XBtL: L. travel (forward) pilot port Ab: Boom cylinder head end port (UP)
XAs: Swing (left) pilot port Bb: Boom cylinder rod end port (DOWN)
XBs: Swing (right) pilot port AtL: L. travel motor port (reverse)
XAa1: Arm 1 (OUT) pilot port
XBa:
Dr1:
Px:
Py:
Arm 1 (IN) pilot port
Drain port
Work equipment signal port
Travel signal port
PD BtL:
As:
Bs:
Aa:
Ba:
L. travel motor port (forward)
Swing motor port (left swing)
Swing motor port (right swing)
Arm cylinder rod end port (OUT)
Arm cylinder head end port (IN)
Pz: Main relief valve boosting pressure P1: Pump port (P1 side)
PG: Pilot pressure resource port P2: Pump port (P2 side)
Pns: Swing logic control valve pilot port MR: Main relief valve
IO
PCK: Bucket (DIG) stroke limit pilot port AR: Arm regeneration check valve
PnA2: Arm 2 logic control valve pilot port AbR: Port relief valve
Dr2: Drain port BbR: Port relief valve
Dr3: Drain port AkR: Port relief valve
Dr6: Drain port BkR: Port relief valve
Dr7: Drain port AoR: Port relief valve
Pal: Lock valve pilot port (arm rod end) BoR: Port relief valve
PbL: Lock valve pilot port (boom head end) AaR: Port relief valve
(XBp1):Bypass cut spool pilot port (P1 side) BaR: Port relief valve
NOTE: For more technical information about the control valve, see “Control valve” on page 3-5.

Hydraulic circuit diagram (with bucket confluence function)
P2 (P3) R1 (P0) P1 PG
d1 d2 d3
Φ0.7 Φ0.7 Φ0.7
MR
CMR2
CMR1
Pz
TRAVEL R XBtr
(PTa) TRAVEL
XAtr STRAIGHT
Px
Atr CPG
Btr
CP1
Dr2
Dr6 LCs Py
XBs
SWING 4-Φ2.1 XBtl TRAVEL L
XAs XAtl
As Btl
Bs Atl
Pns C2
Dr1
SWING
PRIORITY Psp LCb
XBb1
BOOM2XAb2
PD
CCb
BbR
HVb
AbR
XAb1
Bb
(ROD)
Ab
(HEAD)
PbL
BOOM1
LCk
LCo
PCk
(XBo)
XBk
OPTION (XAo)
BUCKET
XAk
AoR
(Ao) BkR (ROD)
(Bo) Bk
IO
Ak
AkR (HEAD)
BoR
AR
PnA2
Dr3 Dr7
LCa LCAT2
2-Φ1.0 LCAP2
2-Φ2.0
XAa1 XBa2
ARM2
ARM1 XBa1 XAa2
(HEAD)
AaR
Ba
BaR
Aa
CCo
(ROD)
HVa
CCk PaL
BYPASS (XBp1)
CUT R2
XBp2
(P5)
ZX225-1102010

4.5.2 Operating principle
4.5.2.1 When spool is in neutral position
[Main circuit]
● When all the spools are in neutral position, ● Working oil supplied from the hydraulic
working oil supplied from the hydraulic pump (Rear) flows in through pump port P2
pump (Front) flows in through pump port and is introduced into the main passage
P1 and is introduced into the main pas- (3). It passes the neutral bypass (2) (neutral
sage (1). It passes the neutral bypass (2) M-shaped spool mechanism) of the spools
(neutral M-shaped spool mechanism) of of R travel (301), swing (305), boom con-
the spools of straight travel (308), L. travel fluence (boom 2: 307), option (309), arm 1
(301), boom 1 (303), bucket (304) and arm (302), and flows back into the working oil
2 (306), and flows back into the working oil tank via return port (R1).
tank via return port (R1).
PD
IO

(1)
(2)
(PTa)
XAtL XBtL
XBb1 XAbL
XAk PCk
X8k
XBa2 XAa2
PD CCo CCk
P2 (P3) R1
(3)
(2)
XBtr XAtr
XAs XBs
Psp XAb2
IO
(XAo) (XBo)
XAa1 XBa1
XBp2 (XBp1)
ZX225-1102011

4.5.2.2 Travel
[Pilot circuit] ● Likewise, when pressure at port XBtr for

the right travel spool (301) rises, neutral
● When the left or right travel spool is bypass (2) at arm 1 side is closed, and
switched, the side bypass circuit is closed working oil supplied from the hydraulic
and pressure at port Py (travel signal port) pump (rear) is introduced into the right
rises. travel motor via port Btr.
[Main circuit] ● On the other hand, return oil from the left
and right travel motor passes the left (right)
● When pressure at pilot port XBtL for left travel spool via port Atl (Atr), and returns to
travel spool (301) rises, neutral bypass (2) working oil tank via return port (R1).
at boom 1 side is closed, and working oil
supplied from the hydraulic pump (front) is ● The principle is the same when travel on
introduced into the left travel motor via port the opposite side is operated (when pres-
Btl. PD sure at pilot port XAtr and XAtl rises).
XAtr XBtr
IO
Atr Btr
Travel motor ZX225-1102012

4.5.2.3 Arm
(1) Arm OUT
[Pilot circuit] and is supplied into the arm cylinder rod

end (R) via port As.
● When the arm 2 spool (306) is switched,
the side path is closed and pressure at port ● On the other hand, working oil from port
Px (work equipment signal port) rises. P1 is introduced into neutral bypass (2) via
main passage (1). Neutral bypass is cut off
[Main circuit] by switching the arm 2 spool (306). There-
fore, working oil in the parallel passage
● When arm OUT is operated, pilot pres- pushes open the logic cone valve (256-101)
sure oil is supplied into port XAa1 and port of the arm 2 logic valve GP, and working oil
XAa2. When pilot pressure oil is applied at from neutral bypass pushes open the cone
the two sides of port XAa1 and port XAa2, valve (511) of the check valve and flows
arm 1 spool and arm 2 spool are switched
PD into the arm 2 spool (306) via the U pas-
to the left as shown in the illustration. As sage. Then, it merges with port As via the
a result, working oil from P2 is introduced inner passage of arm 2 spool (306) and is
into neutral bypass (2) via main passage supplied into the arm cylinder rod end (R).
(3). Neutral bypass is cut off by switching
arm 1 spool (302). Therefore, working oil ● Return oil from the arm cylinder head end
in the parallel passage pushes open the (H) via port Ba flows into the tank circuit of
cone valve (511) of the check valve, and arm 1 and arm 2, and returns to working oil
flows into the arm 1 spool (302) via the U tank via tank port (R1).
passage. Then, it flows into the periphery
IO
of arm 1 spool (302) and arm 2 spool (306)

R H
Aa 256-101
511
PD XAa2
XAa1
IO
Ba
511
ZX225-1102013

(2) Arm IN
[Pilot circuit] from neutral bypass pushes open the cone

valve (511) of the check valve and flows
● When the arm 2 spool (306) is switched, into the arm 2 spool (306) via the U pas-
the side path is closed and pressure at sage. Then, it merges with port Ba via the
port Px (work equipment signal port) rises. inner passage of arm 2 spool (306) and is
At the same time, pressure oil is supplied supplied into the arm cylinder head end (H).
to port PaL and the release signal of lock
valve option set (252) is sent out. ● On the other hand, pressure of the return
oil from the arm cylinder rod end (R) rises
[Main circuit] under the weight the arm, and the return
oil returns to port Aa. Working oil that re-
● When arm In is operated, pilot pressure oil turns to port Aa flows into the inside of the
is supplied to port XBa1 and port XBa2. valve spool via the holes on the periph-
When pilot pressure oil is applied at the ery of the arm 1 spool (302), and pushes
two sides of port XBa1 and port XBa2,
PD open the cone valve (302-317) in the spool
arm 1 spool and arm 2 spool is switched to only under light load. It merges with port
the left. As a result, working oil from P2 is Ba through the holes on the spool. This is
introduced into the neutral bypass (2) via called the regeneration function of the arm.
main passage (3). Neutral bypass is cut off
by switching arm 1 spool (302). Therefore, ● If the pressure at the arm cylinder head
working oil flown into the parallel passage end and in the U passage rises, arm re-
pushes open the cone valve (511) of the generation check valve spool (257-211)
check valve and flows into the arm 1 spool switches to the left. And, at the same time,
(302) via the U passage. Then, it flows into the back pressure of the cone valve (302-
the periphery of arm 1 spool (302) and is 317) in the spool is closed. Therefore,
IO
supplied into the arm cylinder head end (H) arm regeneration function is released and
via port Ba. return oil from the arm cylinder rod end
(R) flows into the spool via the hole (a) on
● On the one hand, working oil from port P1 the periphery of arm 1 spool (302). Then,
is introduced into neutral bypass (2) via it flows into arm regeneration check valve
main passage (1). Neutral bypass is cut off set (257) via hole (c) on the periphery of
by switching the arm 2 spool (306). There- arm 1 spool (302), and returns to the work-
fore, working oil in the parallel passage ing oil tank via tank port R1.
pushes open the logic cone valve (256-101)
of the arm 2 logic valve GP, and working oil

● Light load
Arm weight
R H
Aa
PD
XBa2
(302-317)
IO
XBa1
(b)
(a) Ba
ZX225-1102014

● When pressure at arm cylinder head end (H) rises
R H
Aa
PD
XBa2
IO
(302-317)
XBa1
(c)
(257-211) Ba
(a)
ZX225-1102015

4.5.2.4 Boom
(1) Boom UP
[Pilot circuit] ● At the same time, pilot pressure oil is also

supplied to port XAb2 and boom 2 spool
● When the boom 1 spool (303) is switched, (307) moves to the right. Working oil from
the side path is closed and pressure at port port P2 is introduced into neutral bypass.
Px (work equipment signal port) rises. Neutral bypass is cut off by switching the
boom 2 spool (307). Therefore, working
[Main circuit] oil in the parallel passage flows into boom
2 spool (307) via the U passage. Then, it
● When boom UP is operated, pilot pressure pushes open the cone valve (511) of the
oil is supplied into port XAb1 and boom 1 check valve and merges with port Ab and
spool (303) moves to the left. Working oil is supplied into the boom cylinder head
from port P1 is introduced into neutral by- end (H). This is called the boom conflu-
pass (2) via main passage (1). Neutral by- ence function.
PD
pass is cut off by switching boom 1 spool
(303). Therefore, working oil in the parallel
passage pushes open the cone valve (511)
of the check valve, and flows into the boom
1 spool (303) via the U passage. Then, it
flows into the periphery of boom 1 spool
● On the other hand, return oil from the
boom cylinder rod end (H) via port Bb flows
into the periphery of boom 1 spool (303)
and returns to the working oil tank via tank
port (R1).
(303) and is supplied into the boom cylin-
der head end (H) via port Ab.
IO

H R
511
Ab
Bb
XAb2
PD XAb1
IO
511
ZX225-1102016

(2) Boom DOWN
[Pilot circuit] passage. Then, it flows into the periphery

of boom 1 spool (303) and is supplied into
● When the boom 1 spool (303) is switched, the boom cylinder rod end (R) via port Bb.
the side path is closed and pressure at
port Px (work equipment signal port) rises. ● On the other hand, return oil from the
At the same time, pressure oil is supplied boom cylinder head end (H) passes the
to port PbL and the release signal of lock hole (a) and the periphery of boom 1 spool
valve option set (252) is sent out. (303).
[Main circuit] ● Return oil pressure rises due to the self

weight of the boom. Cone valve (303-317)
● When boom DOWN is operated, pilot pres- in the spool is pushed to the right. Return
sure oil is supplied to port XBb1. Boom 1 oil flows to the outside of spool. The pres-
spool (303) moves to the right. As a result, sure oil is supplied into the boom cylinder
working oil from P1 is introduced into the rod end (R) as the working oil for boom
PD
neutral bypass (2) via main passage (1).
Neutral bypass is cut off by switching boom
1 spool (303). Therefore, working oil flown
into the parallel passage pushes open the
cone valve (511) of the check valve and
flows into the boom 1 spool (303) via the U
DOWN operation. This is called the boom
regeneration function. Part of the oil that
flows into the inside passage of the spool
via hole (a) returns to the working oil tank
via hole (b).
IO
H R
511
Ab Bb
XBb1
(b) (a)
(303-317)
ZX225-1102017

4.5.2.5 Bucket
(1) Bucket DIG

[Pilot circuit] Then, it flows into the periphery of bucket
spool (304) and is supplied into the bucket
● When the bucket spool (304) is switched, cylinder head end (H) via port Ak.
the side path is closed and pressure at port
Px (work equipment signal port) rises. At ● On the other hand, return oil from the buck-
the same time, pressure oil is supplied at et cylinder rod end (R) flows in via port Bk.
port XBp2. Then, it flows to oil tank port (R1) via the
spool periphery and returns to working oil
[Main circuit] tank.
● When bucket DIG is operated, pilot pres- ● When boom UP and bucket DIG are oper-
sure oil is supplied into port XAk and buck- ated simultaneously, pilot pressure oil is
et spool (304) moves to the right. Working supplied to port Pck. Therefore, the stroke
oil from port P1 is introduced into neutral
PD of bucket spool is not limited at stroke end,
bypass (2) via main passage (1). Neutral but on any position halfway. As a result,
bypass is cut off by switching bucket spool bucket cylinder passage is throttled and
(304). Therefore, working oil in the paral- working oil flows into boom 1 spool (303)
lel passage pushes open the cone valve via bucket spool (304). In this way, boom
(511) of the check valve, and flows into UP operation takes precedence.
the bucket spool (304) via the U passage.
H R
IO
Ak Bk
H
XAk
Pck
ZX225-1102018

(2) Bucket DUMP
[Pilot circuit] tral bypass is cut off by switching bucket

spool (304). Therefore, working oil in the
● When the bucket spool (304) is switched, parallel passage pushes open the cone
the side path is closed and pressure at port valve (511) of the check valve, and flows
Px (work equipment signal port) rises. At into the bucket spool (304) via the U pas-
the same time, pressure oil is supplied at sage. Then, it flows into the periphery of
port XBp2. bucket spool (304) and is supplied into the
bucket cylinder rod end (R) via port Bk.
[Main circuit]
● On the other hand, return oil from the buck-
● When bucket DUMP is operated, pilot et cylinder head end (H) flows in via port
pressure oil is supplied into port XBk and Ak. Then, it flows to oil tank port (R1) via
bucket spool (304) moves to the left. Work- the spool periphery and returns to working
ing oil from port P1 is introduced into neu- oil tank.
tral bypass (2) via main passage (1). Neu-
H
PD R
Ak Bk
IO
XBk
ZX225-1102019
(3) Bucket confluence
● When bucket DIG is operated, pilot pres- switching neutral bypass valve spool (310).
sure oil is supplied into port XBp2 and the Therefore, working oil pushes open the
neutral bypass cutoff valve spool (310) is check valve, and interconnects with the U
switched. Working oil from port P2 is in- passage via the inside path, and converg-
troduced into neutral bypass (2) via main es with bucket spool (304).
passage (3). Neutral bypass is cut off by

4.5.2.6 Swing
(1) Swing operation
[Pilot circuit] (305). Therefore, working oil in the parallel

passage pushes open the logic cone valve
● When the swing spool (305) is switched, (2540-101) of the swing logic valve GP,
the side path is closed and pressure at port and flows into the swing spool (305) via the
Px (work equipment signal port) rises. U passage. Then, it flows into the periph-
ery of swing spool (305) and is supplied
[Main circuit] into the swing motor via port As (or Bs).
● When swing is operated, pilot pressure ● On the other hand, return oil from the
oil is supplied into port XAs (or XBs) and swing motor flows in via port Bs (or port
swing spool (305) is switched. Working As). Then, it flows into tank port (R1) via
oil from port P2 is introduced into neutral the spool periphery and returns to the
bypass (2) via main passage (3). Neutral working oil tank.
XBs
PD
bypass is cut off by switching swing spool
XAs
IO
As Bs
(254-101)
Swing motor ZX225-1102020

(2) Swing priority function
[Pilot circuit] ● Switch swing priority spool (311). The

opening area of the swing priority reduces.
● Pilot pressure oil is supplied to port Psp As a result, working oil from arm 1 spool
and swing priority spool (311) is switch. (302) flows into swing spool (305) and
swing operation takes precedence.
[Main circuit]
Psp
PD
ZX225-1102021
IO

4.5.2.7 Option
Option spool is used to control optional work equipment attachment.

(1) Operation
[Pilot circuit] (309). Therefore, working oil in the parallel
passage pushes open the cone valve (511)
● When the option spool (309) is switched, of the check valve, and flows into the op-
the side path is closed and pressure at port tion spool (309) via the U passage. Then,
Px (work equipment signal port) rises. it flows into the periphery of option spool
[Main circuit] (309) and is supplied into the optional
equipment via port Ao (or Bo).
● When option is operated, pilot pressure
oil is supplied into port XAo (or XBo) and ● On the other hand, return oil from the op-
option spool (309) is switched. Working tional equipment flows in via port Bo (or
oil from port P2 is introduced into neutral port Ao). Then, it flows into tank port (R1)
bypass (2) via main passage (3). Neutral via the spool periphery and returns to the
PD
bypass is cut off by switching option spool working oil tank.
XAo
XBo
IO
Ao Bo
ZX225-1102022
(2) Option confluence Neutral bypass is cut off by switching by-

pass valve spool (310). Therefore, work-
● To achieve option confluence, pilot pres- ing oil pushes open the cone valve (514)
sure oil is supplied into port XBp1 and the of check valve, and converges with option
bypass cutoff valve spool (310) is switched. spool (309) via the inside path and the U
Working oil from port P1 is introduced into passage.
neutral bypass (2) via main passage (1).

4.5.2.8 Travel straight
When travel spool (301) and other spool are [Main circuit]
operated simultaneously.
● When straight travel spool (308) is
The following case shows when travel spool switched, the right/left travel spool (301)
(301) and swing spool (305) are operated si- are interconnected with port P2. The paral-
multaneously. (When pilot pressure oil is sup- lel passage of swing/boom 2/option/arm
plied to port XAtL, port XAtr and port Xas) 1 circuit and boom 1/bucket/arm 2 circuit
are interconnected with port P1. Therefore,
[Pilot circuit] working oil supplied from port P2 flows into
port Atl and port Atr, and is supplied to the
● The side path of right/left travel spool (301) two travel motors equally.
and the side path of the swing spool (305)
at the downflow side are closed. ● On the other hand, working oil from port P1
is supplied to the swing motor via port As.
● Pilot oil from port PG is supplied to port
PD
PTa and straight travel spool (308) is ● When oil pressure at port P2 is lower than
switched. that at port P1, part of the working oil form
port P1 is supplied to port P2. In this way,
sharp decrease of travel speed is averted.
P1 P2
IO
PTa
ZX225-1102023

4.5.2.9 Lock valve function
● The lock valve option set (252) is installed ● When boom 1 spool (303) is in neutral po-
between the arm cylinder rod end (R) and sition, spool (252-511) in the lock valve op-
arm 2 spool (302) and arm 2 spool (306). tion set is pressed against the valve seat
It is used to reduce the internal leakage of of the valve sleeve (252-541) inside the
the spool due to cylinder pressure. lock valve option set, as shown in the illus-
tration, via the spring force of spring (252-
● Likewise, lockout option set (252) is also 321).
installed between boom cylinder head end
(H) and boom 2 spool (303) to reduce the ● At this position, working oil at the boom
internal leakage of he spool due to cylinder cylinder head end (H) flows in via hole (a)
pressure. and flows out from hole (b) through the
periphery of the lock valve option set spool
(1) Spool in neutral position (252-511), pressing the cone valve (513)
against the valve seat of the valve block
● The following shows when boom 1 spool
PD via hole (b). By this means, oil leakage is
(303) is in neutral position. (The same is reduced.
with arm 2 spool (306))
252-321 252-511
252-541
(b)
IO
513
(a)
ZX225-1102024

(2) Boom DOWN operation
● When boom DOWN is operated, pilot pres- in the spring chamber (RH) flows into drain
sure oil is supplied to port PbL and port circuit via hole (b). In this way, the cone
XBb1. Spool (252-511) inside the lock valve (513) is pushed up by the pressure
valve option set moves to the top by via pi- at boom cylinder head end (H) and the
lot pressure oil. Through the movement of function of the lock valve option set (252)
spool (252-511) inside the lock valve option is released.
set, hole (a) is cutoff and working oil from
boom cylinder head end (H) does not flow
into spring chamber (RH). In addition, oil
252-511
(b) (RH)
PD 513
(a)
PbL
IO
XBb
ZX225-1102025
(2) Boom UP operation

● When boom DOWN is operated, pilot pres- boom 1 spool (303) and working oil flows
sure oil is supplied to port XAb1. The cone into port Ab.
valve (513) is pushed ope by the oil from

4.5.2.10 Main relief valve function
The main relief valve is installed on the valve and enters low-pressure path (R).
block A (101). Its function is described below:
● Opening of cone valve (611) causes pres-
● Working oil flows into chamber (a) from sure in chamber (a) to drop and valve rod
passage (P) via the hole of valve seat (541) (512) is open. In this way, working oil in
and hole on valve rod (512). Valve rod (512) passage (P) flows into low-pressure path
is pressed against valve seat (541), form- (R) directly.
ing a tight seal.
● When pressure oil high than 3MPa is sup-
● When pressure in passage (P) exceeds plied to port Pz, this pressure oil pushes
the elastic force of spring (621), cone valve plunger (614) to the left. The set load of
(611) is pushed open. Therefore, working spring (621) is changed and pressure of
oil flows through the hole on valve sleeve the main relief valve rises.
(103) via the periphery of cone valve (611)
541
PD 611 621
P
IO
R
Pz
512 (a) 103 614

ZX225-1102026

4.5.2.11 Port relief valve function
The port relief valve is installed between the

tank port and low-pressure path. In addition
to the function as relief valve, it has also the
function of anti-cavitation oil complement
check valve. Its function is described below:
(1) Relief valve function
● Working oil flows into chamber (B) via the

hole (A) on plunger (301). Valve rod (511)
is pressed against valve seat (541), and
valve seat (541) is pressed onto the valve
seat of the valve block, forming a tight seal.
A
B
PD
P
IO
R
301 511 541
ZX225-1102027
A B
301 R
511 541
ZX225-1102028

● When pressure in passage (P) exceeds

the elastic force of spring (621), cone valve
(611) is pushed open. Therefore, working
oil flows through hole (C) via the periphery
of cone valve (611) and enters low-pres-
sure path (R).
R
PD 611 621
ZX225-1102029
C
IO
P
R
621
611
ZX225-1102030

● Opening of cone valve (611) causes pres-

sure in chamber (B) to drop and valve rod
(511) is open. In this way, working oil in
passage (P) flows into low-pressure path
(R) directly.
R PD
511 611
ZX225-1102031
B
IO
P
R
511 611
ZX225-1102032

(2) Anti-cavitation oil complement check

valve
● When negative pressure is formed in path

(P), working oil is supplied from path (R).
When pressure in path (R) gets higher
than pressure in path (P), valve seat (541)
moves to the right direction. Therefore,
working oil is supplied from path (R) to
path (P) via the periphery of valve seat
(541) in order to prevent cavitation.
R
PD
541 ZX225-1102033
IO
R
541 ZX225-1102034

4.5.3 Section view
B A 273×10
153
(Po)
XAtr
561 TRAVEL
TRAVEL R STRAIGHTC
C 273×12 HR
XBs XAtl TRAVEL L

SWING 252
D D
Dr8 PnS XAb2 XBbl

BOOM1
BOOM2 977
978×2 E
E
AbR
XAk
XBo BUCKET
OPTION
F F
AoR AkR
XBa1 XBa2
ARM1 PD ARM2
G AR G
(BYPASS CUT1) (XBp1)

PnA2 Dr7
H BYPASS CUT2
O AaR O 252
PCV1 H AaR
602
A
B
XBa2
(XBp1)
Dr3
IO
View O-O
274×4
CCo
Pns (P5)
Dr6 Dr7
PnA2
CCk P P
210
153 561
(P5)
Viw P-P
XAa2
273×12 XBk 273×10
XBp2 PCk
ZX225-1102035

Section A-A, N-N
N
543
101 159 541 542 166
550
(PTa)
XAtL XBtL
XBb1
XAk
PD XAbL
PCk
XBk
XBa2 XAa2
IO
CCo CCk
514 521 561 551 551 561 521 514
View A-A
151 168 151 168 151

168
PB 156
2-156
View N-N
ZX225-1102036

Section B-B
153 561 102

P2 (P3) R1
975 975
XBtr XAtr
975
XAs XBs
975
Psp XAb2
975
(XAo)
975
PD (XBo)
975
XAb1 XBa1
975
XBp2 (XBp1)
IO
975
975
165 165 165
ZX225-1102037

Section C-C (Travel right, travel straight)
154
164
201 TRAVEL TRAVEL 201
RIGHT STRAIGHT
336 336
332 XAtr 332
335 323
321 335
320
332
332
332 MR
261
261
308
163 601
314
165
163
511
Atr
PD Pz
512
522
553
521
551
CP1 CMR1
561 562
IO
165 562
163
163 Btr
CMR2
163
553
522
512
159
264 159
264
204
XBtr (PTa) 204
164
Viw C-C
154
ZX225-1102038

Section D-D (Swing, travel left)
201
SWING TRAVEL LEFT 336
201
336 332
XBs XAtL
332 335
335
321
321
320
320
332
261
332
314
261
305
161 PD
163
163 AtL
As
254 511
521
C2
551
561
IO
BtL
251
Bs
165
Dr2
264
264
XAs XBtl
204
204
163 163
View D-D
ZX225-1102039

Section E-E, L-L (Boom 1, boom 2)
202 BOOM2 BOOM1

336 201
332 XAb2 XBb1 336
339 332
327 335
321
326
320
602
332
332 261
261
L L
161 158
511 Dr1
521 PbL
551
561
165
CCb
PD CRb
523
552
561
513
511
307 521
LCb
163
Xb2
551
551 561
IO
561
Bb
311
161 303
163
264
261 602
332 XAb1 204
BbR
320
329 158
339
332
336
202 Psp
SWING
PRIORITY
View E-E View L-L
ZX225-1102040

Section F-F (Option, bucket)
259
164
201
201
OPTION BUCKET 336
336
(XBo) 332
332
335 335
321 321
320 320
602
332 AkR 332
261 261
604 304
163
209
971×4
165
309
163 (Ao)
PD Ak
163
511 511
521
521
LCo
IO
551
551
561
561
(Bo)
Bk
163
165
971×4
209
163
264 602
604 264
(XAo) 206
204 BkR
211
164 BoR XBk
561
154 258
PCk
View F-F ZX225-1102041

Section G-G (Arm 1, arm 2)
201
201 336
336
332
332 XBa1 XBa2
335
335
321 321
320 320
257 Dr3
AR 332
332
261
261
306
L L
158
163
165
162
152
165
162
152
PD CRa
513
523
561
552
251
302
511
521
551 LCAT2 256

IO
561
551
163 561
R2 521
511
165
163
264 264
602 XAa2
XAa1
BaR 204
205
View G-G
ZX225-1102042

Section H-H (Bypass cut 1, bypass cut 2)
612 169 162 152 158 154 164 152 162 162 152 164 154 158 152 162 164 154 169 612 162 152
PCV2 PCV1
XBp2
(XBp1)
203 333 331 372 373 337 331 262 310

PD 165
View H-H
165 310 163 262 331 337 373 372 331333 203
ZX225-1102043
IO

Mounting Mounting
NO. Part name Q’ty NO. Part name Q’ty
torque (N·m) torque (N·m)
SPOOL ASS’Y, travel
101 BLOCK, valve A 1 308 1
straight
102 BLOCK, valve B 1 309 SPOOL, option 1
13~17 151 PLUG 3 310 SPOOL, bypass cut 2
34~39 152 PLUG 7 311 SPOOL, swing priority 1
220~250 153 PLUG 3 320 SPRING 9
69~78 154 PLUG 6 321 SPRING 8
7.4~9.8 156 PLUG, orifice 3 322 SPRING 1
7.5~10 158 PLUG 5 323 SPRING 1
10~14 159 PLUG 3 326 SPRING 1
161 O-RING 3 327 SPRING 1
162 O-RING 7 329 SPRING 1
163 O-RING PD 21 331 SPRING SEAT 4
164 O-RING 7 332 SPRING SEAT 22
165 O-RING 14 16~18 333 FLANGE SOCKET 2
166 O-RING 1 335 STOPPER 9
168 O-RING 3 16~18 336 FLANGE SOCKET 11
169 O-RING 2 337 STOPPER 2
201 COVER, spring 9 339 STOPPER 2
202 COVER, spring 2 372 SPRING 2
203 COVER, spring 2 373 SPRING 2
IO
204 COVER, spool 7 511 VALVE, cone 8
209 FLANGE 2 514 VALVE, cone 2
210 PLATE 1 521 SPRING 10
211 PISTON 1 522 SPRING 2
49~65 251 VALVE, logic control 2 523 SPRING 2
OPTION ASS’Y, lock
9.8~14 252 2 541 BALL 1
valve
254 VALVE GP, swing logic 1 542 SPRING SEAT 1
256 VALVE GP, arm 2 logic 1 543 SPRING 1
CHECK VALVE ASS’Y,
69~78 257 1 25~29 550 PLUG 1
arm regeneration
258 PLUG 1 230~260 551 PLUG 11
259 PLUG 1 230~260 552 PLUG 2
261 O-RING 11 130~150 553 PLUG 2

Mounting Mounting
NO. Part name Q’ty NO. Part name Q’ty
torque (N·m) torque (N·m)
262 O-RING 2 561 O-RING 17
264 O-RING 9 562 O-RING 2
25~34 273 SCREW, hex, S,H,C 44 69~78 601 VALVE, main relief 1
98~120 274 SCREW, hex, S,H,C 4 69~78 602 VALVE, port relief 6
301 SPOOL, travel 2 120~140 604 VALVE, port relief 2
302 SPOOL ASS’Y, arm 1 1 69~78 612 PLUG 2
303 SPOOL ASS’Y, boom 1 1 49~65 971 SCREW, hex, S,H,C 8
304 SPOOL, bucket 1 140~180 975 SCREW, hex, S,H,C 10
305 SPOOL, swing 1 977 PLATE name 1
306 SPOOL, arm 2 1 978 PIN 2
307 SPOOL, boom 2 1
PD
IO

4.6.1 Swing motor

NOTE: For the location of the swing motor on the machine, see “Hydraulic equipment layout” on
page 4-24.
L
PD SH PG
PB
B
IP
PA A
1
M DB
IO
2
ZX215-1002081
A: Main oil port 1. Relief valve

B: Main oil port 2. Reverse prevention valve
M: Oil complement port
For more technical information about the
PA: Pressure detection port
swing motor, see “Swing motor” on page 3-5.
PB: Pressure detection port
DB: Lubricating port
PG: Brake release port
SH: Brake direction port
L: Oil level stick
IP: Gear oil feed port

7
6
A-A
5
A
PD 8 9
4
IO
10
11
3
12
2
13
1
ZX215-1002082
1) Spacer 6) Check valve spring 11) Plate

2) Casing 7) Check valve 12) Piston
3) Disc 8) Oil distribution plate 13) Drive shaft
4) Brake spring 9) Cylinder
5) Shell 10) Brake piston

4.6.2 Swing holding brake
● Port PG is connected with the pilot gear pump directly, and a pressure of 3.9MPa is main-
tained.
M
Pump a
1
Main valve
7
PX
PG
6
SH
PD 5
ZX215-1002083
● Port SH is connected with port PX of the main valve. Once any movement other than travel
is applied on the main valve, pressure will be generated at port PX, and port PG is intercon-
nected with chamber a beneath piston 7. The pressurized oil compresses brake spring (1)
and pushes the brake piston up. Disc (5) is separated from plate (6), releasing the brake.
IO
M
Pump a
1
Main valve
7
PX
PG
6
SH
ZX215-1002084
● Otherwise, no pressure is generated at port PX, and port PG is shut off from chamber a be-
neath piston (7). Brake piston (7) is pushed down by brake spring (1). Disc (5) and plate (6)
are pushed together, and the brake is applied.

4.6.3 Relief valve portion
NOTE: For the location of the relief valve on

the swing motor, see “Swing motor” on page 4-81.
Structure
● The relief valve portion consists of relief

valves (1) and (2), 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 contin-
ues due to inertial force. The motor output,
therefore, is abnormally increased, result-
ing in motor damage.
PD
● In order to avoid the motor damage, the
relief valve relieves the abnormally high
pressure to port (M) from the motor outlet
side (high-pressure side) of the motor.
IO

Operation
1. When swing begins (suppose pressur- From port M

ized oil enters Port A) 1 2
● When the swing control lever is operated

for right swing, pressurized oil from the
pump is supplied to port (A) via control
valve (5).
● The pressure on port (A) rises, the starting

torque is generated in the motor, and the 4
3
motor is activated.
● The pressurized oil from the outlet port of C

the motor passes from port (B) through the A B
control valve (5) and returns to the tank.
PD 5
ZX215-1002085
2. When swing stops
● When the swing control lever is neutral-

From port M
ized, the supply of pressurized oil from the 1 2
pump to port (A) is cut off.
● The pressurized oil from the motor outlet

can't return to the tank since the return cir-
IO
cuit to the tank is closed from control valve
(5). Thus, pressure at port (B) rises.
● Swing resistance is generated on the mo-

tor and hence the brake starts working. 4
3
● Pressurized oil will be relieved when the C

pressure on port (B) rises to the set pres-
sure of relief valve (2). A B
● A high braking torque is applied on the mo- 5

ZX215-1002086
tor, thereby stopping the motor.
● When relief valve (2) is being actuated, the

relieved pressurized oil and the pressur-
ized oil from port (M) are fed to port (B) via
check valve (4).
● Above prevents cavitation on port (B).

4.6.4 Reverse prevention valve
4.6.4.1 Operation drawing
NOTE: For the location of the reverse prevention valve on the swing motor, see “Swing motor” on
page 4-81.
A T1
T2 B
1 PD
2
3 4
7 6 5
Swing
motor T
IO
B A
Swing control valve

ZX215-1002087
1) Valve body 5) Spool (B side)

2) Spool (A side) 6) Spring (B side)
3) Spring (A side) 7) Plug
4) Plug

4.6.4.2 Explanatory drawing of effects
:With reversal prevention valve
:Without reversal prevention valve

Reversal pressure
Pressure MA
Containment pressure
Reversal pressure
Pressure MB
1st reversal
2nd reversal
Motor speed
Start
PD Brake Reversal
Time
ZX215-1002088
Outline
● Inertia of the swing body, the backlash and A

rigidity of the machinery system, and the T
compression of the hydraulic oil all may c e D4 a D3
IO
cause the machine to shake during swing
operation. The reverse prevention valve is
designed to reduce this effect. The valve
contributes in preventing collapsing of load
when the swing is stopped and also con-
tributes in reducing cycle time (enhances
the positioning performance, enabling you
D1 d Notch D2 B b f
to proceed to the next work quicker than
T
ever).
ZX215-1002089

Operation
1. When port (B) brake pressure is gener-

ated
● Pressure (MB) is conducted to chamber (d) A

T
via the notch. The pressure compresses c e D4 a D3
spring (6) by use of the difference in areas
of circles (D1 > D2) of spool (5) and moves
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
the pressurized oil is stopped by spool (2).
Thus the braking force is ensured. D1 d Notch D2 b f
B
T
ZX215-1002090
2. When motor is stopped

PD
● The motor rotation is reversed by the clos-
ing pressure generated at port (B). (1st
time: reverse rotation) Reversing pressure
T
A
a 2 3
is generated on port (A). Pressure (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
IO
is interconnected with f via the orifice on
spool (5), and reversing pressure on port A
is bypassed to port T, preventing the sec- 5 d B b f
ond reverse rotation. T
ZX215-1002091

4.6.5 Center swivel joint
NOTE: For the location of the central swivel joint on the machine, see “Hydraulic equipment lay-
out” on page 4-24.
Z
7 8 13 9 10
6 H
11
5 12
4 D
PDB
A
3
F1
IO
G1 H-H H
G
D1
A1
B1
C1
Z
ZX215-1002092
1) Swing shaft 8) Plug (ZG3/4)

2) Dust seal 9) Plug (ZG1/4)
3) O-ring 10) Cover
4) Swing body 11) Spacer
5) Rotating seal φ100x5 12) Gasket
6) Gasket 13) Gasket
7) Retaining ring φ 90

A: From main valve BTL

B: From main valve BTR
C: From main valve ATL
D: From main valve ATR
A1: To L. travel motor port (P1)
B2: To R. travel motor port (P2)
C3: To L. travel motor port (P2)
D4: To R. travel motor port (P1)
G: To swing motor port DB
G1: From travel motor final drive assembly oil drain port (D1,D2)
F: From solenoid valve port A2
F1: To travel motor reducer Hi/Lo speed switching port (P)
PD
IO

4.6.6 Travel motor
NOTE: For the location of the travel motor on the machine, see “Hydraulic equipment layout” on
page 4-24.
Ps Pm1 Tin 1 Dr P1 A
Pm2
PD
Pp 2 P2 B
ZX215-1002132
Ps: Duo speed pilot hose port A. Mounting surface with sprocket
Pm1: Pressure detection port B. Mounting surface with undercarriage
Pm2: Pressure detection port 1. Mounting hole with sprocket
IO
Tin: Motor case inner oil port 2. Mounting hole with undercarriage
Pp: Brake release port
Dr: Oil drain port
P1: Main oil port
P2: Main oil port
NOTE: For more technical information about the travel motor, see “Travel motor” on page 3-6.

Connected to sprocket
Mounted on the undercarriage 5 4 2-1 1-4 1-3
Piston motor shaft

1-5
1-6
PD 1-2
1-1
3
IO
2-4 2-3 2-2 2-6 2-5
ZX215-1002093

4.6.6.1 Operation of components
Counterbalance valve
Function
● When external load makes the rotating

speed of the piston motor faster than the
rated rotating speed of supplied delivery,
this valve controls the speed of the motor
and prevent over-speed of the motor in re-
lation with the supplied delivery.
● The counterbalance valve and the relief

valve constitute the braking circuit. The
braking circuit applies braking force onto
the rotating motor and stops the motor
PD
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 counterbalance

valve is shown as below. The following in-
formation describes the operating principle
of a standard counterbalance valve.
IO

A. Stopped state
● When the main valve is neutralized (motor pressure is generated at port P1 and port
stopped), port M1 and port M2 are shut off P2. The motor is not rotating.
by spool (1) and check valve (2) since no
8-1
8-2
Circuit B
Circuit C2
Circuit C1
Orifice D1
Damper chamber A1
Orifice D2
M1 PD M2
Orifice D3
Damper chamber A2
Orifice D4
Spring chamber 2
Spring chamber 1
P1 P2
6-1 6-2
IO
7-1 7-2
5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002094

B. When the motor is activated
● When hydraulic oil from the main pump damper chamber (A1) via orifice (4-1) and
enters port P1 of the counterbalance valve, check valve (5-1). The force generated in
spring (3) is pushed to the left by check this way pushes spring (7-2) on the other
valve (2-1), opening circuit C1. The hy- side and moves piston (1) to the right. At
draulic oil enters the piston motor via port this time, return oil from port M2 passes
M, trying to make the motor rotating. At the through circuit of the notch on the periph-
same time, return oil from the piston motor ery of piston (1), and through port P2 when
enters the counterbalance via port M2, but pressure is generated at port M2, and en-
it is stopped by check valve (2-2). The out- ters the tank via the main valve finally. The
put pressure of the main pump increases motor is activated at this time.
as a result, and the hydraulic oil works
on the inside of spring chamber (1) and
8-2
8
8-1
PD
Circuit B
Circuit C2
Circuit C1 M1 M2
Orifice D3
Orifice D1
IO
Damper chamber A2
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
P1 P2
6-2
6-1
7-1 7-2
5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002095

C. Counterbalance function
● When the engine runs at an excessively

high speed because of external force ap-
plied 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, pison (1) moves to the
left under the force of spring (7-2), closing
circuit B. Circuit at the suction side is also
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
piston (10 to the right again. In this way,
when external load generates pump effect,
PD
slight movement of piston (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.
IO

D. Braking of motor
● The counterbalance valve and the relief braking force of motor rotation. When the
valve forms the braking circuit. When the pressure at port M2 reaches the set pres-
main valve is neutralized position, hydrau- sure of relief valve (8), cone valve (8-1) at
lic oil from the main pump is cut off, and port M1 overcomes the force of spring (8-
pressure at port P1 and P2 is the same. 2) and moves to the left, and hydraulic oil
As a result, piston (1) moves to the neutral flows the port M1. In this way, the impact-
position, and the opening area of circuit B ing force due to inertia at port M2 is under
decreases. At the same time, because of control, and vacuum at port M1 is avoided.
the inertia of external force, the motor does
not stop rotating (pump effect), and pres-
sure at port M2 rises and serves as the
8-2
8
8-1
PD Circuit B
Circuit C2
Circuit C1 M1 M2
Orifice D3
Orifice D1
Damper chamber A2
IO
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
P1 P2
6-1 6-2
7-1
7-2
5-1 3 4-1 2-1 1 2-2 4-2 5-2

ZX215-1002096

E. Shuttle valve function for high pressure

selection
● The counterbalance valve can function ber E to release travel brake. In addition,
as a shuttle valve to release travel brake. piston (1) moves to neutral position, as
When hydraulic oil is fed to port P1, piston shown in fig 5 when motor stops. Circuit D
(1) moves to the right, as shown in fig. 4. is closed and drain circuit F of motor body
At this time, drain circuit F of motor body is connected. Hydraulic oil in travel brak-
is cut off, and circuit D leading to cylinder ing cylinder chamber E is conducted to the
chamber E for travel braking is connected. drain circuit of motor body, and travel brake
Hydraulic oil flows to circuit G via the ori- is applied.
fice, and enters travel brake cylinder cham-
1
Circuit D
PD Circuit D
Orifice
Circuit F
Circuit F
Circuit D Circuit G Circuit G
Cylinder chamber E
ZX215-1002097
IO
1
Circuit D
Circuit D
Orifice
Circuit F
Circuit F
Circuit D Circuit G Circuit G Cylinder chamber E
ZX215-1002098

Operation of parking brake
1) When travel begins
● As the travel lever is operated, pressurized

oil from the pump activates counterbalance 10
valve spool (10), opens the parking brake
circuit, and flows to chamber A of brake
piston (12). Pressurized oil overcomes the
force of spring (11) and pushes piston (12)
toward the left.
● Since the pushing force to plate (13) and

Travel control valve
disc (14) disappears, plate (13) is sepa-
rated from disc (14) and the brake is re-
leased. A M
2) When travel stops

PD 11 14 13 12 22
ZX215-1002099
● As the travel lever is placed in neutral,

counterbalance valve spool (10) returns to 10
the neutral position and closes the park-
ing brake circuit. The pressurized oil in
IO
chamber (A) of brake piston (12) passes
through the orifice of the brake piston and
is drained to the motor case. Brake piston
(12) is pushed to the right by spring (12).
Plate (13) and disc (14) are pushed to- Travel control valve
gether, and the brake is applied. As brake
piston (12) returns, flow of pressurized oil
is reduced with slow return valve (22). The A M
time delay will be set to activate the brake 11 14 13 12 22
ZX215-1002100
only after the machine has stopped.

Brake valve operation
● The brake valve consists of suction safety

valve (8A) and counterbalance valve (18). Travel control valve
Functions and operations of respective PA PB

components are described below.
8A
18
MA MB
PD
1) Counterbalance valve and check valve
Function
ZX215-1002101
● When the machine is travels downhill, the

weight of the machine tends to make the
PA PB
travel speed faster than the motor speed. 8B
If the machine travels with the engine at
IO
low speed, the motor may rotate at zero 8A
load, resulting in run away and inviting a
very dangerous situation. These valves are
used to avoid such a situation by control-
ling the machine to travel as per the engine
speed (pump delivery).
19 MA MB
Operation when pressurized oil is supplied
ZX215-1002102
● Operating the travel lever conducts the
pressurized oil from the control valve to
port (PA). The pressurized oil opens suc-
tion 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.

● The pressurized oil on the supply side

flows to chamber (S1) via orifice (E1) and
orifice (E2) of the spool (19). As the pres-
PA PB
sure in chamber (S1) goes above the spool
selector pressure, spool (19) is pushed
toward the right. Port (MB) and port (PB)
are connected, the motor outlet port side
opens and the motor starts rotating.
S1
19
MA MB
E1 E2
ZX215-1002103
Operation of brake during downhill travel

PD
● 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)
is released via orifices (E1) and (E2). As
PA PB
20
the pressure in chamber (S1) goes below

the spool selector pressure, spool (19)
is returned to the left by spring (20) and
S1
outlet port (MB) is throttled. The pressure
IO
at the outlet port side rises, generating ro-
tation resistance on the motor to prevent 19
the machine from losing control. On the
other hand, the spool moves to a position MA MB
where the pressure on outlet port (MB) can E1 E2
ZX215-1002104
be balanced 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.

2) Safety valve
Function
● When the machine travel is stopped (or it

is travelling downhill), the counterbalance
valve closes the inlet and outlet circuits of
the motor. Since the motor is rotated by
inertial force, pressure in the motor outlet
port side is abnormally increased, poten-
tially resulting in damages on the motor
and piping. The safety valve releases this
abnormal pressure to the inlet port side of
the motor in order to prevent damages to
the equipment.
Operation PD Travel control valve

1. When travel is stopped (or when travelling PA PB
downhill) (Right swing) 20
● Reduction of the pressure at motor inlet

(PA) decreases the pressure in chamber
(S1). When it drops beyond the spool
S1
switching pressure, the spool is returned to
the left by spring (20), reducing the pres-
IO
sure at outlet passage (B1). At this time,
the motor continues rotating due to its iner-
tial force, thus pressure on the outlet port MA MB
(MB) is increased. A1 B1 ZX215-1002105
● 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 op-
posite side.
Spool MB MA
ZX215-1002107

2. When starting travel (or when traveling at a

constant speed) Travel control valve
PA PB 8B
● As the travel lever is operated, the pres-
surized oil from the pump moves spool (19) 8A
toward right. The passage to the suction
safety valve functions as a circuit which
passes through notch (B2) of spool (19),
S1
producing large differential pressure. The
pump pressure rises, providing a large
tractional force to the valve. 19
MA MB
E1 B2
ZX215-1002106
3) Relief valve PD
● The structure of the relief valve is shown
in the right figure. This valve is area dif-
ference and direct flow type. It has impact
damping function during starting and brak-
ing.
ZX215-1002108
IO
A. Operation principle and function
● When the main valve makes the motor 2-9-2 2-9-5

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
pressure side. The impact due to inertia 2-9-3 ZX215-1002109
energy at the high pressure side is put un-
der control and vacuum is prevented from
occurring at the low pressure side through
bypassing pressurized oil to the low pres-
sure side.

B. Damping function
● When the relief valve begins to function,

2-9-2 Area S2 2-9-5
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 it is
much larger than the normal 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 2-9-3 Area S1 2-9-9 Spring chamber D
ZX215-1002110
at 1/3 of normal set pressure in order to
absorb the impact at the high pressure
circuit side due to inertia energy. When
the movement of damping piston stops,
pressure in spring chamber D rises. Pres-
sure at both side of cone valve (2-9-2) is
PD
the same, and the relief valve is working at
normal set pressure. In this way, the relief
valve reduces the impact during motor start
and brake by a two-stage action to provide
excellent performance.
Pressure
IO
Damping method Time

ZX215-1002111

4.6.7 Valve control system
4
7
6
1 2
5
PD 10
3
5 9
6 7
11 12
8 10
IO
13
4
11
1 12
ZX215-1002112

Control lever position
1. Travel PPC valve (1) HOLD

2. L. travel control lever (2) Boom UP
3. R. travel control lever (3) Boom DOWN
4. Right PPC valve (4) Bucket DUMP
5. Right joystick (5) Bucket DIG
6. Accumulator (6) HOLD
7. Transition block (7) Arm IN
8. Hydraulic pump (8) Arm OUT
9. Main control valve (9) Right swing
10. Solenoid valve (10) Left swing
11. Left joystick (11) Neutral
12. Left PPC valve (12) Reverse travel
PD (13) Forward travel
IO

4.6.8 Pilot valve
4.6.8.1 Work equipment and swing pilot valve
P3
P2
A
T
P
2
3
P
1
4
P4
PD
64~73.5Nm
A
19~22Nm
P1
IO
ZX215-1002113
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

6
7
3
PD 9
10
2
IO
1
A-A ZX215-1002114
1) Plunger 6) Nut (for lever connection)

2) Metering spring 7) Joint
3) Centering spring 8) Plate
4) Piston 9) Retainer
5) Disc 10) Valve body

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 D
(f) in plunger (1).
f
2. Fine control (Neutral to fine control)

1 T
● When piston (4) is pushed by disc (5),

retainer (9) is pushed, plunger (1) is also P
pushed by metering spring (2), and moves
down.
● When orifice (f) is shut off from drain cham-

PD Pilot
pump P1 P2
ber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
Pilot pressurized oil of the control pump is
led to port (A) from port (P1) via orifice (f). A M M B
When the pressure at port (P1) becomes Control valve
higher, plunger (1) is pushed back and ZX215-1002115

orifice (f) is shut off from pump pressure
chamber (PP). At almost the same time, it
is connected to drain chamber (D) to re-
IO
lease the pressure at port (P1). As a result,
plunger (1) moves up and down until the
force of metering spring (2) is balanced
with the pressure at port (P1). D
f
● The relationship of the position of plunger
(1) and body (10) [orifice (f) is in the middle
between drain chamber (D) and pump 1 T
pressure chamber (PP)] does not change
until retainer (9) contacts plunger (1). Me- P
tering 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 Pilot
pump P1 P2
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 A M M B
are balanced. Control valve
ZX215-1002116

3. During fine control (When control lever

is returned)
● When disc (5) starts to return, plunger

(1) is pushed up by the force of centering
spring (3) and the pressure at port (P1). D
● Because of this, orifice (f) is connected to f

drain chamber (D), and the pressurized oil
at port (P1) is released.
1 T
● If the pressure of port (P1) is lowered ex-

cessively, plunger (1) is pushed down by P
metering spring (2).
● Orifice (f) is shut off from drain chamber f1

(D), and it is almost simultaneously in- Pilot
pump P1 P2
terconnected to pump pressure chamberPD PP
(PP). Pump pressure is supplied until the
pressure at port (P1) recovers to the level
equivalent to the lever position.
A M M B
Control valve
● When the spool of the control valve re-
ZX215-1002117
turns, the oil in drain chamber (D) flows in
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.
IO
4. At full stroke D
● Disc (5) pushes down piston (4), and re- f

tainer (9) pushes down plunger (1).
● Orifice (f) is shut off from drain chamber (D), 1 T
and is interconnected to pump pressure

chamber (PP). P
● Therefore, the pilot pressure oil from

the self pressure reducing valve passes f1
through orifice (f) and flows to chamber Pilot
pump P1 P2
(A) from port (P1) to push the control valve
PP
spool.
● The oil returning from chamber (B) passes

from port (P2) through orifice (f) and flows A M
Control valve M B
to drain chamber (D).
ZX215-1002118

4.6.8.2 Travel PPC valve
P
P
P2
P5
PD P1
P5 A
P6
IO
2 1
4 3
P4 P3
ZX215-1002119
P: From pilot pump P4: R.H. forward

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

37~30Nm
B
65~45Nm
1 8~6Nm
5 PD
6
C C
7
B-B
2，4 1，3
B
13~11Nm
IO
C-C
8~6Nm
ZX215-1002120
1) Plate 5) Centering spring

2) Body 6) Metering spring
3) Piston 7) Valve
4) Collar

Operation
1. When in neutral
● Ports (A) and (B) of the control valve and

ports (P1) and (P2) of the Pilot valve are D
connected to drain chamber (D) via orifice
(f) in plunger (1). f
T
2. Fine control (Neutral to fine control) P
● When piston (4) is pushed by lever (5),

1
retainer (9) is pushed, plunger (1) is also
Pilot pump
pushed by metering spring (2), and moves P1 P2
down. When orifice (f) is shut off from drain
chamber (D), it is almost simultaneously
A B
interconnected to pump pressure chamber Control valve
(PP). PD ZX215-1002121
● 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
orifice (f) is shut off from pump pressure
chamber (PP). At almost the same time, it
is connected to drain chamber (D) to re- 5
lease the pressure at port (P1). 4

IO
● As a result, plunger (1) moves up and 9 D
down until the force of metering spring (2) 2
is balanced with the pressure at port (P1). f
T
● The relationship of the position of plunger P
(1) and body (10) [orifice (f) is in the middle
between drain chamber (D) and pump 1
Pilot pump PP
pressure chamber (PP)] does not change
P1 P2
until retainer (9) contacts plunger (1). 10
● Metering spring (2) contracts in proportion A

Control valve B
to the stroke of the control lever.
ZX215-1002122
● 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 cham-
ber (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 is

returned)
● When lever (5) starts to return, plunger

(1) is pushed up by the force of centering
spring (3) and pressure at port (P1). 5
● Because of this, orifice (f) is connected to

drain chamber (D), and the pressurized oil 3 D
at port (P1) is released. 2
f T
● If the pressure of port (P1) is lowered ex-
P
cessively, plunger (1) is pushed down by f’
metering spring (2).
1
Pilot pump PP
● Orifice (f) is shut off from drain chamber (D), P1 P2
and it is almost simultaneously intercon-
nected to pump pressure chamber (PP).PD A Control valve B
● Pump pressure is supplied until the pres- ZX215-1002123

sure at port (P1) recovers to the level
equivalent to the lever position.
● When the spool of the control valve re-

turns, the oil in drain chamber (D) flows in
from orifice (f) in the valve on the side that
5
is not working. The oil passes through port 4
(P2) and enters chamber (B) to replenish
IO
the chamber with pressurized oil. 9 D
4. At full stroke f
T
● Lever (5) pushes down piston (4), and re- P
f’
tainer (9) pushes down plunger (1).
1
● Orifice (f) is shut off from drain chamber (D), Pilot pump PP
and is interconnected to pump pressure P1 P2
chamber (PP).
A Control valve B
● Therefore, the pilot pressure oil from
ZX215-1002124
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).

4.6.9 Solenoid valve
Pilot valve lock, travel speed, bucket confluence, swing priority
P1
P2
T1
A8 A7 A6 A5 A4 A3 A2 A1
5 4 3 2 6
P T2
P2
A8
A7
PD A6 A5 A4 A3 A2 A1
1
T1
P1
P2
ZX225-1102044
1) Travel hi/lo speed solenoid valve T: To oil tank

IO
2) Swing priority solenoid valve P: From accumulator and pilot pump
3) Bucket confluence solenoid valve A3 To center swivel joint port
4) Boom to arm priority solenoid valve A4 To main valve port PsP
5) Pilot lockout solenoid valve A5 To main valve port Xbp2
6) Secondary boosting solenoid valve A6 To main valve port PnA2
A7 To pilot valve block P
NOTE: For the location of the solenoid valve on the machine, see “Hydraulic equipment layout”
on page 4-24.

4.6.10 Accumulator
6
PD ZX215-1002126
1) Gas plug Specifications

2) Shell
3) Poppet Gas capacity: 300 cm³
IO
4) Holder
5) Bladder
6) Oil port

4.6.11 Pilot oil filter
1
K
2
Model
Pressure
Precision
3
PD 5
6
IO
3
ZX215-1002127
Specifications
1) Name plate Max. delivery: 40 L/min

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

4.6.12 Pump oil pressure sensor
1 2 3
A B
4
ZX215-1002128
1) Pressure connector
2) Name plate
3) Connector
4) Vent hole
Function
PD
● This sensor measures pump oil pressure
and uses it to control various machine op-
erations. When oil pressure compresses
the diaphragm, it deforms and this is de-
tected in the form of electric signals.
IO

4.6.13 Hydraulic cylinder
5340±50N·m
2 1 544.9±5.1kgm 3
56.9±10.7N·m
267±35N·m 5.8±1.1kgm
27.2±3.6kgm
ZX215-1002129
PD 7900±50N·m
2 1 806.1±5.1kgm 3
56.9±10.7N·m
367±35N·m
5.8±1.1kgm
37.4±3.6kgm
ZX215-1002130
IO
5480±50N·m
2 1 559.2±5.1kgm
3
56.9±10.7N·m
267±35N·m
5.8±1.1kgm
27.2±3.6kgm
ZX215-1002131

100/500 hours greasing
Unit: mm
Cylinder
size Shaft Hole clearance limit
-0.036 +0.222
Clearance between pis- Boom 85 0.083 – 0.312 0.412 Replace
1 -0.090 +0.047
ton rod and bushing -0.036 +0.222 bushing
Arm 95 0.083 – 0.312 0.412
-0.090 +0.047
-0.036 +0.258
Bucket 80 0.078 – 0.334 0.434
-0.076 +0.048
-0.030 +0.246
Boom 80 0.230 – 0.322 1.0
Clearance between pis- -0.076 +0.200
-0.030 +0.246
2 ton rod support pin and Arm 80 0.230 – 0.322 1.0
-0.076 +0.200
bushing -0.030 +0.246
Bucket PD70 0.230 – 0.322 1.0 Replace
-0.076 +0.200
pin or
-0.030 +0.246
Boom 70 0.230 – 0.322 1.0 bushing
Clearance between cyl- -0.076 +0.200
-0.030 +0.246
3 inder bottom support pin Arm 80 0.230 – 0.322 1.0
-0.076 +0.200
and bushing -0.030 +0.246
Bucket 70 0.230 – 0.322 1.0
-0.076 +0.200
IO

4.6.14 Work equipment
F
D
G E
,
PD A
K H B
ZX215-1002133
IO
1
6
3 ,-,
A-A
C-C
5
B-B
2 4 J-J
G-G
H-H
E-E D-D F-F K-K

ZX215-1002134

100 hour greasing
Unit: mm
Standard Tolerance Standard clear- Clearance

Clearance between pin connect-
size Shaft Hole ance limit
1 ing boom and revolving frame and
–0.036 +0.140
bushing 90 0.141 ~ 0.211 1.0
–0.071 +0.105
Clearance between pin connecting –0.036 +0.174
2 90 0.140 ~ 0.345 1.0
boom and arm and bushing –0.071 +0.104
Clearance between pin connecting –0.030 +0.335 Replace

3 70 0.305 ~ 0.395 1.0
arm and rocker and bushing –0.060 +0.275

4 80 0.300 ~ 0.384 1.0
arm and bucket and bushing PD –0.060 +0.270
5 80 0.303 ~ 0.433 1.0
linkage and bucket and bushing –0.060 +0.273
6 70 0.305 ~ 0.395 1.0
linkages and bushing –0.060 +0.275
500 hour greasing
Unit: mm

IO
Standard Tolerance Standard clear- Clearance
Clearance between pin connect-
size Shaft Hole ance limit
1 ing boom and revolving frame and
–0.036 +0.131
bushing 90 0.110 ~ 0.202 1.0
–0.071 +0.074
2 90 0.110 ~ 0.237 1.0
boom and arm and bushing –0.071 +0.074
Clearance between pin connecting –0.030 +0.158 Replace

3 70 0.108 ~ 0.218 1.0
arm and rocker and bushing –0.060 +0.078

4 80 0.104 ~ 0.197 1.0
arm and bucket and bushing –0.060 +0.074
5 80 0.116 ~ 0.226 1.0
linkage and bucket and bushing –0.060 +0.086
6 70 0.104 ~ 0.214 1.0
linkages and bushing –0.060 +0.074

Arm dimension
11
B 19
12 5
A C D
A
D 6
B 14 C
10
8 7
13
PD
18
16
IO
17 15
A-A B-B
3 2
1
4
C-C D-D
ZX215-1002135

Unit: mm
SY195C-9 SY205C-9 SY215C-9
No. Standard Standard Standard
Tolerance Tolerance Tolerance
size size size
+0.1 +0.1 +0.1
1 φ80 φ80 φ80
0 0 0
2 ±0.5 ±0.5 ±0.5

109 109 109
0 0 0
3
310 -0.5 310 -0.5 310 -0.5
+0.174 +0.174 +0.174
4 φ90 φ90 φ90
+0.104 +0.104 +0.104
5 486 ±1 365.6 ±1 365.6 ±1
6 195 ±0.5 187.2 ±0.5 187.2 ±0.5
7 850 ±1 829.1 ±1 829.1 ±1
8
9
10
11
2,700
2,631.3
411
640
—
—
PD
±1
±0.2
2,919
2,631.3
411
640 ±0.2
—
±1
—
2,919
2,631.3
411
640 ±0.2
—
±1
—
12 600 ±0.5 600 ±0.5 600 ±0.5

13 458 — 458 — 458 —
14 1,504.1 — 1,500 — 1,504.1 —
+0.373 +0.373 +0.373
15
IO
φ80 φ80 φ80
+0.273 +0.273 +0.273
16 326.5 ±0.5 326.5 ±0.5 326.5 ±0.5
+0.1 +0.1 +0.1
17 φ80 φ80 φ80
0 0 0
0 0 0
Arm itself
311 -0.5 311 -0.5 311 -0.5
18 When press fit-
325 — 325 — 325 —
ting bushing
Min. 1,680 — 1,680 — 1,680 —
19 Max. 2,800 — 2,800 — 2,800 —

Bucket dimension
2 5
A
18 17
6
1 4
16
19 PD
7
21 20 10
15 8 14
IO
13
14 8
11 9 10
12
A-A ZX215-1002136

Unit: mm
SY195C-9 SY205C-9 SY215C-9
No.
Standard size Tolerance Standard size Tolerance Standard size Tolerance
1 457.5 ±0.5 457.5 ±0.5 457.5 ±0.5
2 22 ±0.5 22 ±0.5 22 ±0.5
3 92°45’ — 92°45’ — 92°45’ —
4 458.1 — 458.1 — 458.1 —
5 1490 — 1490 — 1490 —
6 164 — 164 — 162.9 —
7 45° — 45° — 45° —
+0.2
8 φ80 ±0.2 φ80 ±0.2 φ80
0
9 326.5 ±1 326.5 ±1 326.5 ±1
10 57 — 57 — 57 —
11 107 — PD 107 — 107 —
12 471.5 — 471.5 — 471.5 —
13 φ23.5 — φ23.5 — φ23.5 —
14 φ136 — φ136 — φ136 —
15 φ190 — φ190 — φ190 —
16 130.9 — 130.9 — 132.3 —
17 125 — 125 — 125 —
18 107 — 107 — 110 —
IO
19 82 — 82 — 82 —
+1 +1 +1
20 348.5 348.5
0 0 348.5 0
21 37 — 37 — 37 —

4.7 Air Conditioning System
1
2
C
PD C
C B 6
IO
C
8
ZX215-1002137
1) Hot water piping A. Fresh air

2) A/C compressor (DENSO.2)
3) Refrigeration piping B. Recirculated air
4) Condenser (SG447750-A040)
C. Warm air/cool air
5) Receiver tank (DENSO.4)
6) Hot water return piping
7) A/C unit assembly (SG443180-9320)
8) Air duct

4.7.1 A/C components layout drawing
2
1
3
4
PD
IO
7 6
ZX215-1002138
1) Sunlight sensor 5) Compressor

2) Control panel 6) Fresh air sensor
3) Air conditioning unit 7) Recirculated air sensor
4) Condenser

4.7.2 Control panel
1 2 3 4 5
Monitor
OFF
MODE AUTO
FULL AUTO AIRCONDITION
TEMP
A/C 9
6 7 8
ZX215-1002139
1) OFF switch PD 6) Air circulation control switch

2) Fan speed control switch 7) LCD display
3) Temperature control switch 8) A/C switch
4) Air outlet mode switch 9) Sunlight sensor
5) Auto mode switch
IO

ZX215-1002140
SW
1.25R
7
FURM B G1 G2 ACC M ST
PD
3
FL1
3 8
H
FUCD 20A FUM OFF
60A 15A 8
1.25R 5A ACC
2 13 ON
START MRF
8 8
2
CMB RLCD RLCC RLBM
13 15 13
M
RLCC RLCD RLBM

9 10
GND
REC
FFE
1
Vz
2RL 1.25RL
Pt
10 1.25L 15
16 16 19 25 24 22 26 25
1
D MR
FLZ
MCD SPCD M 200W
RLSF 5 2 40A
M 11
1.256 10 2G 13 +B 16 19 25 24 26
5
80W 10 BLCM
6 16 19 22 23 1
10
5
G
1
BAT
4
CMB
ACC
SW
7
7
4
4
6
D1
D2
02
1.25B
RCD RLCH
02 02
RLCH
03
9
ECC
40W
BLC
4
1
3
2
RLCH
12 12
G
8
12
28 15
14
15
IO 14
17
THAM THW THI THF
15
18
15
12
20
15
13 3
22 21
22
16
SSD
27 4
15 23
21
27
ACM
28
20
29
2 24
30
30
25
31
31 22 32
32
9
15
38
32
33
26
34 35
34 35 35 22
10
1.25B
3
SPHL
CM
0.85B
0.50
02 02
M M M
2B
4.7.3 Circuit diagram
06 0.5B
2B 2B
01 02
06
03
MAM MV1 MV2
4-130
Wire No. Diameter/Color code Wire color Wire No. Diameter/Color code Wire color
B Black 0.5VW Violet+white
Br(R) Brown 0.5YB Yellow+black
0.85W White 0.5WO White+orange
RL Red+blue 0.5PB Pink+black
G Green 0.5VR Violet+red
0.5BL Black+blue 0.5BG Black+green
0.5R Red+blue 0.5WY White+yellow
0.5Y Yellow 0.5WR White+red
0.5BR Black+red 0.5BrW Brown+white
0.5BrY Brown+yellow 0.5GO Green+orange
0.5BY Black+yellow 0.5Sb Sky blue
0.5GW Green+white 0.5OW Orange+white
0.5LO Blue+orange
PD 1.25V Violet
0.5PG Pink+green 1.25RG Red+green
0.5RY Red+yellow 1.25RW Red+orange
0.5BW Black+white 0.85GL Green+Blue
0.5LgR Light green+red
Code Name Code Name Code Name

IO
Condenser high speed
ACM A/C amplifier FUCD Condenser fuse RLCH
relay
BAT Battery FUM A/C main fuse RLSF Protective relay
BLC Speed regulating resistor G Alternator SSD Sunlight sensor
Condenser pressure
CMB Battery relay MAM A/M servo motor SPCD
switch
D Diode MB Blower motor SPHL HI/LO pressure switch
D1 Diode 1 MCD Condenser motor SW Switcher
Internal/External air servo
D2 Diode 2 MRF THAM External air thermistor
motor
ECC Compressor clutch MV1 Air outlet servo motor THF Anti-frosting thermistor
FL1 Fuse MV2 FRONT outlet servo motor THI Internal air thermistor
FL2 Fuse RCD Condenser resistor THW Water temp. thermistor
FUBM Blower fuse RLBM Blower main relay
RLCC Compressor relay RLCD Condenser relay

4.7.4 Refrigeration principle
4.7.4.1 Refrigeration cycle diagram
Cool air Expansion valve
Lo temp\Lo press liquid (Mist)

Evaporator
Lo temp\Lo press gas
Hi temp\Hi press liquid

Cooling fan
Blower
Air in cab
Out side fresh air
Hi-temp hi-pres gas
Receiver
Lo-pres.
side
Compressor
Hi-pres.
side
PD
Hot air
Lo-pressure portion Hi-pressure portion
ZX215-1002141
IO
4.7.4.2 Heating cycle diagram
Radiator Water valve control
Water pump Hot air
Engine
Blower motor
Internal air
Low tempr water

High temp water ZX215-1002142

4.7.5 Compressor
3 4
1 2
16
15
14
13
PD 5
12
IO
11 10 9 8 7
ZX215-1002143
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) Hub
8) Swash plate 16) Rotor

Operating principle
Compressor type: 10S15C. This compres- back and forth and transforms the refrigerant
sor has 5 plungers in total with a piston on sucked from the evaporator from low tempera-
both sides of each plunger. The rotation of ture and low pressure gas state to high tem-
the swash plate drives the pistons to move perature and high pressure state.
Process 1 Process 2
HI press.end pipe LO press.end pipe HI press.end pipe LO press.end pipe
Valve plate
Outlet valve disc
Main shaft and swash plate
Process 6
Intlet valve disc
PD Process 3

IO
Process 5 Process 4
ZX215-1002144

4.7.6 Clutch
1) Rotor
1
2) Stator coil
2
3) Snap ring
3
4) Ball bearing 4
5) Stator
6) Center piece
● The electromagnetic clutch is used to

transmit moment of torsion. When the en-
6
gine is operating, the compressor may not ZX215-1002145
be working. The clutch controls the opera-
tion of the compressor only when the air
PD
conditioner is under refrigerating mode.
● Operating principle
When the A/C switch is turned on, the

clutch coil with an electromagnet gener-
ates a magnetic field and attracts the metal
piece. The stator and rotor of the clutch are
engaged and drives the main shaft of the
IO
compressor into rotation.

4.7.8 Condenser
1
4
2
1)
2)
3)
Condenser core
Bracket
Bolt with gasket
PD 4)
5)
Refrigerant inlet
Refrigerant outlet
ZX215-1002146
Function
● The condenser converts high-temperature,

IO
high-pressure gas refrigerant (16Kg/cm²,
about 80°C) to high-temperature and high-
pressure liquid refrigerant (16Kg/cm², be-
low 60°C) through radiating.
4.7.7 Expansion valve

Evaporator
1) Spring 2
2) Diaphragm
1
3) Probe
4) Needle valve
Operating principle
3
● Refrigerant from the receiver tank spurts
out via the orifice, turns into low-temper-
ature, low-pressure liquid (mist) after ex- 4 Compressor
panding, and enters the evaporator. Reservoir
ZX215-1002147

4.7.9 Evaporator
1) Expansion valve
2) Evaporator
Operating principle
● The evaporator is a kind of heat exchanger

that looks like a condenser. Hot air in the
cab is conducted into the evaporator via
the blower motor and undergoes heat ex-
change with the surface of the evaporator. 2
1
Heat is absorbed and hot air turns into
cold air, which flows into the cab through
ZX215-1002148
the air ducts. Evaporator surface absorbs
heat→Refrigerant in the evaporator ab-
sorbs heat → Refrigerant evaporates .
PD
Evaporated refrigerant (gas) is absorbed
by the compressor.
4.7.10 Receiver tank
1) Inlet 2
1
2) Outlet
3) Receiver/dehydrator
IO
4) Desiccant
Function
3
● Temporary storage of refrigerant
● Dehydration of refrigerant 4
● Dust removal from refrigerant
● Measure the volume of refrigerant
ZX215-1002149

4.7.11 Pressure switch
1) O-ring
Pressure
2) Mobile contact point
3) Hood
1
4) Plug and fixed contact 7
5) Spring 2
6
6) Chamber
7) Diaphragm
Function 3
5
● The pressure switch is installed between

the receiver tank and the expansion PD 4
valve (hi-pressure pipe). It is a combina-
tion switch (Hi-Lo pressure combination
switch). ZX215-1002150
● When pressure is excessively high, the

compressor stops.
● When pressure and temperature is very

low, the compressor stops.
IO
Operating features
Feature
DIFF DIFF
HI pressure ON
operating value Above 0.02 MPa 0.59±0.2 MPa
OFF
LO pressure 0.196±0.02 MPa 0.196~0.250 MPa 2.94~3.19 MPa
operating value
ON
MID pressure
operating value OFF
1.23±0.1 MPa 1.52±0.08 MPa

4.7.12 Fresh air sensor
The fresh air sensor is installed beside the

condenser or around the fresh air inlet. It mea-
sures the temperature of outside air and it is
12
composed of thermistors.
/KΩ
10
Resistance value
Technical specifications
8
Item Specification 6
Service voltage range 4.4~5.6 V 4

Service temp range -30~60 °C 2
Storage temp range -40~90 °C
Resistance value 1700±85Ω -10 0 10 20 30 40 AT
ZX215-1002151
B constant 3900±195 K
Allowable operating current
4.7.13 Refrigerant
PD
1.6 mA (MAX)
WARNING
● Obey local material disposal regula-
tions. Never discharge refrigerant di-
rectly into the air.
IO
● 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.
1. General property
● High heat absorption and easy liquefaction

● Non-flammable, nonexplosive
● Stable chemical composition
● Non-toxic
● Non-corrosive
● No hazard to clothing

2. Refrigerant cycle
● After evaporation in the evaporator, refrigerant turns from gas into liquid via the compressor
and the condenser, which finishes a refrigerant cycle.
Compressor LO press. side (inlet): LO temp\LO press.\Gas

Compressor Pressure/Temperature: 2Kg/cm²，approx. 8℃
Evaporator
Intake→Discharge Absorb heat→Emit cold air
Compress HI press. side(outlet): HI temp\HI press.\Gas

Pressure/Temperature:16Kg/cm²，approx. 80℃
Condensor (outlet): LO temp\LO press.\Mist

Pressure/Temperature: 2Kg/cm²，approx. 0~2℃
Condensor (outlet)：HI temp\HI pressure\Liquid Expansion valve

Condensor
Via radiating: Gas refri-
gerant→Liquid refrigerant
● Refrigerant cycle principle (pressure - enthalpy diagram)

PD
Pressure/Tempterature：16Kg/cm²，Below 60℃
Hi pressure→Lo pressure
Hi temp→Lo temp
Liquid→Mist
lgp
Liquefaction completed Refrigerant cyclic curve
IO
Liquefaction starts
Throttling point Condensor
Condensing process
Liquid
Expansion throttle
Compressing
Expansion valve process Compressor
Evaporating process
Evaporator
Gas-liquid mixture Gasification completed
h=u+Apv(kJ/kg)
U-Internal energy p-Pressure V-Special volume A-Joule equivalent

ZX215-1002152

3. Feeding of refrigerant
● Filling method and volume:
1) Refrigerant: HFC-134a
2) Feeding volume: 850±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.
ZX215-1002153
PD
● Inspect the state of the refrigerant in the
A/C circulation system through the sight
glass:
Sight glass
1) Correct feeding: Foam is hardly observed

when the refrigerant is flowing. When en-
gine speed increases from idling to 1500
IO
rpm, foam disappears and the refrigerant Proper filling
turns clear.
2) Over-feeding: No foam can be observed

when refrigerant is flowing.
Inadequate filling
3) Under-feeding: Foam is always observed ZX215-1002154
when refrigerant is flowing.

4. Evacuation
● No moisture shall exit in the air condition-

ing unit. Refrigerant (R134a) is soluble in
water. Very small amount of moisture in
the unit can cause the orifice of the expan-
sion valve to ice up, or cause the compres-
sor valve to rust. To avoid such problems,
moisture in the system shall be removed
before refrigerant is added. To minimize
the residual moisture in the system, mois-
ture in the system can evaporate through
evacuating.
Evacuating steps
Step 1: Connect the manifold pressure gauge

PD
1) Close the high-pressure valve (HI) and Valve
Lo-pres.gauge
LO HI LO HI
above 750mmHg
low-pressure valve (LO) of the manifold Lo-pres. ON ON OFF OFF
gauge
pressure gauge. Hi-pres. gauge
2) Connect the hoses (red, blue) to the auxil-

Hi-pres. valve(ON)
iary valve of the compressor. Lo-pres. valve (ON)
Green
Red D
Red hose – High pressure side (Mark D)
Blue
IO
S
Blue hose – Low pressure side (Mark S)
Compressor
NOTE: Connect the end of the hose with a Vacuum pump (running)
ZX215-1002155
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.
3) Connect the green hose to the vacuum

pump.

Step 2: Evacuation
1) Open the high-pressure valve (HI) and low-

pressure valve (LO) on the manifold pres-
sure gauge.
2) Turn on the vacuum pump and evacuate

for about 15 minutes.
3) 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.
Step 3: Air - proof check

PD
1) 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 re-
Valve
Lo Hi
OFF OFF
Wait 5 min. or more Lo-press. gauge
Lo-press. gauge
returns to 0
turn to zero.
2) If the pointer returns to near zero, a leak-

age is available somewhere. Check and Pointer returns
to 0 Tighten pipe joint
adjust the pipe joint. Tighten the joint and
IO
conduct another evacuating operation until ZX215-1002156
no leakage is detected.

Step 4: Leak check
1) Connect the green hose that is previously Valve

connected to the vacuum pump to the Lo Hi
OFF OFF
fluorine cylinder.
2) Connect the other end of the green hose

to the pressure gauge. Open the valve of Vent valve
the cylinder and press the vent valve of the Release air
Open
pressure gauge. (Do not press the valve
with naked hand to avoid frostbite caused
by refrigerant). Release the air in the Blue
hose with the pressure of the refrigerant. Green
(Release the vent valve when you hear a Red R134a
squeezing sound).
To compressor Fluorine cylinder
ZX215-1002157
PD
3) Add refrigerant until pressure reading on
the Lo-pressure gauge is 1kgf/cm² . Hi-
pressure valve of the gauge is open at this Valve
Lo Hi Lo-press gauge Lo Hi
time. Close the Hi-pressure valve when OFF ON
at 1kgf/cm2
OFF OFF
feeding is finished. Lo-pres. gauge
reads1kgf/cm2
4) Use a leak detector to check if leakage is

Lo-pres.valve (OFF) Open Hi-pres.valve
available in the cooling system.
IO
Cylinder valve (ON)
D
5) Make necessary repairs (tightening) if leak-
age is observed. S
R134a
Compressor
Fluorine cylinder
ZX215-1002158

5. Refrigerant charging operation
● When evacuation is finished, add refrigerant into the cooling system as per the following in-
struction:
Add refrigerant kgf/cm2

Air-proofness check
Performance testing
Evacuation starts
Evacuation ends
Add refrigerant
Air leak check
Air leak check

75cm-Hg or more
More than 15 min. Wait 5 min. Pres. gauge

normal
Pres. gauge
Tighten pipe joint abnormal (1) Compressor stopped, charge at hi-press end
Check leak point (2)Compressor running, add at lo-press end
Charge at the hi-pressure side Valve
1. Remove the green hose of the manifold

pressure gauge from the vacuum pump
and connect it to the fluorine cylinder.
PD Vent valve
Lo
OFF OFF
Hi
2. Loosen the cylinder valve and press the

vent valve on the gauge. Use the pressure Open
Loosen
of the refrigerant to release the air in the this nut
hose. Blue
IO
Green
NOTE: Release the vent valve when you Red R134a
hear a hissing sound.

To compressor Fluorine cylinder
CAUTION ZX215-1002159
Do not press the valve with naked hand to

avoid frostbite.
3. Open the hi-pressure valve of the manifold Valve

Lo Hi A cylinder Lo Hi
pressure gauge and the cylinder valve with OFF ON
(about 600g)
OFF OFF
the engine stopped. Fill about 600g of re-
frigerant. ·Do not operate compressor
Lo-press. ·Do not open Lo-pressure valve
4. Close the hi-pressure valve of the pressure valve (OFF) Open Hi-press. valve
gauge and shut the cylinder valve. Fluorine cylinder
valve (ON)
D
S
R134a
ZX215-1002160

CAUTION
● Do not operate the compressor when
refrigerant charging is in progress.
Otherwise, refrigerant will counterflow
and cause the cylinder and hoses to
explode.
● Operating the compressor with no re-

frigerant in the system will cause dam-
age to the compressor.
● Do not open the lo-pressure valve of

the manifold pressure gauge; other-
wise, the compressor will be damaged.
Charge at the lo-pressure side (refill)

PD
1. Check that the hi-pressure valve of the
manifold pressure gauge is closed.
Hi-press. valve (OFF) ON
2. Start the engine. Manifold pressure
gauge
3. Turn on the A/C unit. Adjust Temperature H I

control switch to minimum.
Start the engine
1300~1500rpm
4. Adjust engine speed to 1300 – 1500 rpm.
IO
ZX215-1002161
5. Open the Lo-pressure valve of the mani-

fold pressure gauge and the cylinder valve.
Add refrigerant until no foam is observed Valve
When no foam
Lo Hi Lo Hi
through the sight glass. ON OFF
is observed
OFF OFF
Lo-press. gauge
(1.5~2.5kgf/cm2) Hi-press. gauge
Remark: (13~17kgf/cm2)
Lo-press. Hi-press. valve (OFF)

Manifold pressure gauge reading (for refer- valve (ON) (Never open it)
Fluorine cylinder
ence): valve (ON)
HIGH pressure:
13~17kgf/cm² (when ambient temperature

Fluorine cylinder Compressor
is 30°C) (never placed upside down) running
ZX215-1002162
LOW pressure:
1.5~2kgf/cm² (when ambient temperature

is 30°C).

6. When refrigerant charging is finished,

close the Lo-pressure valve of the mani-
fold pressure gauge and the valve of the
fluorine cylinder.
7. Check carefully for air leaks with a leak

detector.
CAUTION
● Opening the Hi-pressure valve of the
pressure gauge will cause pressurized
gas to counterflow and cause the hoses
and the fluorine cylinder to explode, re-
sulting in serious damage.
● When engine is running and charging in

progress, placing the fluorine cylinder
PD
upside down will cause liquid refriger-
ant to be sucked directly into the com-
pressor and cause liquid compression,
resulting in equipment damage.
8. When ambient temperature is low

Valve
When refrigerant charging gets difficult Lo Hi When no foam Lo Hi
ON OFF is seen OFF OFF
due to low temperature, put the cylinder in
IO
warm water (max. 40°C).
Lo-pressure
Hi-pressure valve
9. When ambient temperature is high valve (ON)
(OFF)
Cylinder valve
(ON)
When ambient temperature is very high,
cool the compressor with an electrical fan.
Compressor
Water less than 40°C running
(Do not use hot water)
ZX215-1002163

Replace the fluorine cylinder
When the refrigerant in a cylinder is used up,

replace the cylinder as per the following in- Handle
struction:
1. Close the Hi- and Lo-pressure valves of

Air hose connector
the manifold pressure gauge.
Needle valve
2. Raise the needle and disc plate of the cyl-
inder and remove the empty cylinder. Gasket
Disc plate
3. Install a new cylinder onto the cylinder
valve. Refrigerant
cylinder
4. Release the air in the hose as per the fol- ZX215-1002164
lowing instruction: PD
1) Tighten the valve of the fluorine cylinder,
and then, loosen it a bit.
2) Open the Lo-pressure valve of the mani-

fold pressure gauge a bit.
3) Press the vent valve and allow a little re-

frigerant to come out. Immediately close
the valve of the cylinder and the Lo-
IO
pressure valve of the manifold pressure
gauge.
CAUTION Valve
Lo Hi
Do not press the valve with naked hand to Loose OFF
avoid frostbite. Close the Lo-pressure valve

once you hear the hissing sound
5. Turn the handle of the cylinder valve to

pierce the cylinder and continue charging
operation. Loosen the valve a bit
Lo-pressure
valve
Green
Blue
R-134a
Red
To compressor Refrigerant cylinder

ZX215-1002165

6. Fault testing 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°C
2) Engine speed: 1500 rpm
3) Fan speed: High
4) Temperature control: Minimum.
5) Air circulation mode: Recirculation

● Cooling system under normal condition
Gauge reading:
PD
Lo-pressure end: 0.15~0.25 Mpa (1.5~2.5 Kgf/cm²)
Hi-pressure end: 1.37~1.57 Mpa (14~16 Kgf/cm²)
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
IO
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
R134a
ZX215-1002167

● Moisture in the refrigerating system
Symptom: Intermittent refrigeration to non-refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
8 3
0
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
ZX215-1002168
Symptom
at the Lo-pressure
end unstable (some-
ices up at the expan-
sion valve causing
circular temporary
Cause
hydrator.
PD
● When the system is ● Moisture in the system ● Over-saturation of de- ● Replace receiver/
operating, pressure dehydrator
● Moisture in the system ● Remove the mois-

Analysis Remedy
times vacuum, stop. When ice melts, ices up at the expan- ture in the system
sometimes normal) the system becomes sion valve and hinders through constant
normal again. the circulation of the pumping.
refrigerating system.
IO
● Add proper volume
of new refrigerant.

● Insufficient refrigeration
Symptom: Insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
ZX215-1002169
Symptom
● Pressure at both Hi- and
Ho-pressure ends very
low
● Air leaks
somewhere
in the refrig-
erating sys-
Cause
PD Analysis
● Insufficient
refrigerant in the
system
● Check for air leakage with a leak
detector. Make necessary re-
pairs.
Remedy
● Foam is continuously ob- tem ● Leak of refriger- ● Add proper amount of refriger-
served via the sight glass ant ant.
● Insufficient refrigeration. ● When connected with the gauge,

if the reading is near zero, set
IO
the system under vacuum state
after inspection and repair.

● Defective refrigerant circulation
Symptom: insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
ZX215-1002170
Symptom
● Pressure at both
Hi- and Lo-pressure
sides very low
● Contaminant in the
Cause
reservoir hinders the

flow of refrigerant.
PD ● Blocked reservoir
Analysis Remedy
● Replace reservoir
● Frosting on the pip-

ing between parts
and reservoir
IO

● Refrigerant not circulating
Symptom: Non-refrigeration (intermittent refrigeration)
04 15 2
03 05
4 15 20
3 5
1
02 06 25
2 6 10 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
ZX215-1002171
Symptom
● Vacuum at Lo-pres-
sure side; pressure
at Hi-pressure side
extremely low
● Moisture or contami-
PD
Cause
nant in the refrigerant

hinders the flow of
refrigerant.
Analysis
● Refrigerant not
circulating and ERP.
Remedy
● Check the expansion valve
● Blow the contaminant in the

expansion valve or replace
● Frosting or conden- ● Air leak at the thermal the expansion valve if nec-
sation on the pipes pipe of the expansion essary.
around the expan- valve hinders the flow
IO
sion valve or receiv- of refrigerant. ● Replace the receiver
er/dehydrator
● Release internal air and
add refrigerant. If air leaks
from thermal pipe, replace
expansion valve.

● Over-charging of refrigerant or insufficient refrigeration of condenser
Symptom: Insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa
ZX215-1002172
Symptom
● Pressure at both Hi-
and Lo-pressure
sides very high
Cause
ant in the system. Re-

frigerating performance
inadequate.
ant
PD
● Condenser fins clogged
Analysis
● Over-filling of refriger- ● Over-filling of refriger- ● Clean the condenser
● Check the working

condition of fan mo-
Remedy
● No foam can be ob- or fan motor error. tor

served via the sight ● Insufficient refrigera-
glass even when tion of condenser ● If the two above
engine speed drops. items are normal,
IO
check the volume
of refrigerant. Add
refrigerant.

● Air is observed in the refrigerating system
Symptom: Poor refrigeration
NOTE: If refrigerant is added with no evacuation operation performed, the following gauge read-
ing will appear:
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
Symptom
● Pressure at both Hi- and ● Air enters the re-
PDCause Analysis
● Air enters the refriger-
ZX215-1002173
Remedy
● Check if compressor
Lo-pressure ends very frigerating system ant system oil is contaminated
high or inadequate.
● Insufficient evacuation
● Lo-pressure piping feel- ● Evacuate and add
IO
ing hot new refrigerant.
● Foam is observed
through the sight glass

● Improper installation of expansion valve/thermal pipe defect (wide opening)
Symptom: insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
ZX215-1002174
Symptom
● Pressure at both
Hi- and Lo-pressure
ends very high
● Expansion valve de-
Cause
fect, or improper instal-

lation of thermal pipe
PD
● Over-filling of
refrigerant in
Lo-pressure
Analysis Remedy
● Check the installation of
thermal piping
piping ● If thermal piping is normal,

● Frosting or conden- check the expansion valve.
sation on Lo-pres- ● Expansion Replace defective expan-
sure piping valve opening sion valve if observed.
very wide
IO

● Compressing error
Symptom: No refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1 5
01 07 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 - 01 35
MPa MPa
ZX215-1002175
Symptom
● Pressure at Lo-pressure
side very high
PD
● Compressor internal
leakage
Cause
● Compressing fault;
Analysis Remedy
● Repair or replace
compressor
● Leaking or damaged
● Pressure at Hi-pressure valve, loosened parts
side very low
IO

4.7.14 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:
Replaced component
Compressor Condenser Evaporator
Volume (ml) See "CAUTION" below 40 40
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
PD
the compressor is to be replaced, discharge the surplus oil in it.
● Over-filling of compressor oil will reduce the refrigerating capacity. Short of compres-
sor oil in the system will cause compressor abnormality.
● Protect pipe joints and O-rings from contamination when disassembling the compres-
sor.
IO

4.8 Engine Control
4 5
PD 6 7
9
8
1
IO
Z
ZX215-1002176
1) Battery relay Outline

2) Battery
3) Engine start switch ● Start and stop the engine only with the en-
gine start switch (3).
4) Fuel control dial
5) Start motor ● The controller (6) receives the signal from
6) Engine controller the fuel control dial (4) and transmits the
7) Fuel injection pump drive signal to the throttle motor (8) to
control the governor lever angle of fuel
8) Throttle motor
injection pump (7) and control the engine
9) Shutdown device
speed.
● When engine start switch (3) is turned to

the OFF position, the shutdown device (9)
closes the injection nozzle of the fuel injec-
tion pump and cuts the engine fuel supply.
Then, the engine stops.

4.8.1 System operation
Engine startup
● When the start switch is turned to the

START position, the starting signal is trans-
mitted to the start motor. Then, the start (Power)
motor rotates to start the engine. Fuel ctrl dial

Engine Start motor Starting relay
Start S/W
Lo s
(Starting signal)
S SW
Hi Hi Governor E
L B
motor Safety
When it happens, the controller checks the
s
relay
Throttle Off
P E
P
Lo B BR C
M B E
signal voltage from the fuel control dial and Throttle On P Alternator Lock
relay
(Starting signal)
sets the engine speed to the speed set by
(Potentiometer singal)
Drive signal
Shutdown Bat. relay
the fuel control dial. device Pilot S/W
Shutdown
relay
Controller
(Regulating signal)
(Start switch ON signal)
ZX215-1002177
Engine speed control

PD
● The fuel control dial sends a signal voltage
corresponding to the rotation angle to con- Engine Start motor
(Power)
Starting relay
Start S/W
troller. Hi
Fuel ctrl dial
Hi
Lo
Governor
s
E
(Starting signal)
S
L
SW
B
motor Safety s
relay
Throttle Off
P E
P
Lo B BR C
M B E
The controller sends a driving signal to the Throttle On

P Alternator Lock
relay
throttle motor according to the signal volt-
(Starting signal)
(Potentiometer singal)
Drive signal
Shutdown Bat. relay
age to control the fuel injection pump, and

Pilot S/W
IO
device
Shutdown
eventually controls the engine speed. relay
Controller
(Regulating signal)
ZX215-1002178
Engine shutdown
● When the start switch is turned to the OFF

position, the controller activates the shut- (Power)
down device to cut off the fuel supply and Fuel ctrl dial
Engine
Start motor Starting relay
Start S/W
Lo s (Starting signal) L
S SW
stops the engine. Hi Hi Governor B

motor E
Safety s
relay P
Throttle Off
E
P
Lo B E
B BR C
Alternator Lock
Throttle On
relay
(Starting signal)
Shutdown Bat. relay

device Pilot S/W
Shutdown
relay
Controller
(Regulating signal)
ZX215-1002179

4.8.2 Components
4.8.2.1 Fuel control dial
140°
9×10°
1
Level 1
Level 10
2 25°
Left limit Right limit

3
5
PD
6 Yellow
a 5V
IO
b Blue
VR
b
a c
Red
c 0V
ZX215-1002180
1) Knob 4) Ball
2) Dial 5) Potentiometer
3) Spring 6) Connector

Function
● Turning of the fuel control dial changes the （%）

resistance of the sliding rheostat inside the 100
dial and the voltage signal collected by the
Dial angle
controller. The controller calculates the col-
lected signals and drives the throttle motor
via signal output and controls the volume
of the injection pump so that the engine
can run at an optimal speed.
0 0.25 1.72 4.49 4.75 5（V）
Voltage（V）
● When throttle voltage is beyond the area,
ZX215-1002181
the controller sends out alarm code and
the engine runs at low idle. The area under
the sloping line is the abnormality detection
area.
Remark: PD
The left limit is 0%; and the right limit is 100%.
IO

4.8.2.2 Controller
Controller
PD TYPE
USE FOR
NO
ZX215-1002182
Controller port layout

IO
........
........ ...................
...................
........ ...................
........ ...................
A2 A1 ZX215-1002183

Input and output signals
A1 A1
Pin Input/ Pin Input/
Signal name Signal name
No. output No. output
1 Power ground 53 Rear pump pressure sensor Input
2 Power ground 54 Sensor power ground Input
3 Power ground 55 Sensor power ground Input
4 Power supply(24V constant) Input 56 Sensor power Output
5 Power supply(24V constant) Input 60 Monitor CAN Low
11 Fuel level sensor Input 61 Calibrator CAN High
15 Throttle position signal Input 62 Calibrator CAN Low
19 Engine speed signal Input 66 Coolant temp very high Input
22 RS232 ground 67 R. travel pressure sensor Input
23 RS232 receive 68 Swing pressure sensor Input
24 Enable 69 Bucket CURL pressure sensor Input
30 Coolant temperature sensor signal Input 70 Boom RAISE pressure sensor Input
31 Oil temperature sensor signal Input 71 Arm IN pressure sensor Input
33
34
38
41
42
43
Backup pilot pressure signal
Fuel dial signal
Engine speed signal ground
RS232 send
CPU mode
Enable
PD
Input
Input
72
73
74
75
76
77
Front pump pressure sensor
Sensor PWR ground
Sensor PWR
Sensor PWR
State indicator
Monitor CAN High
Input
Output
Output
48 Engine oil pressure switch Input 78 Monitor CAN Low

49 L. travel pressure sensor Input 79 Setting tool CAN Low
50 Bucket DUMP pressure sensor Input 80 Setting tool CAN shield wire
51 Boom LOWER pressure sensor Input 81 Setting tool CAN High
52 Arm OUT pressure sensor Input
IO
A2
Pin Input/
Signal name
No. output
82 Travel speed switching solenoid
88 Front pump solenoid valve
89 Rear pump solenoid valve
97 Swing priority solenoid valve
98 Bucket confluence solenoid valve
99 Boom priority 1
100 Boom priority 2
104 Motor drive signal +
113 Motor drive signal -
114 Power ground
115 Power ground
116 Power ground
117 Power ground
118 Power supply(24V constant)

4.9 Electrical Control System
4.9.1 Control function
Engine-Pump composite control function
Pump control function
Valve control function
Electronic control system

PD Dual travel speed control
Engine preheating/overheating alarm
Engine oil under-pressure alarm

IO
Auto-deceleration/acceleration control
Self-diagnosis function
NOTE: For detailed information about self-diagnosis function, see "Troubleshooting"

4.9.2 Machine control system diagram
Battery Battery relay Fuel control dial

Fuse
Power ON signal
Start switch
Power supply
Preheating signal
Starting signal
Swing priority signal

1
Power supply
Monitor panel
R. travel signal
Network signal 2
Working mode signal L. travel signal
Signal monitor info Travel spd select signal 3
Auto-deceleration signal Boom UP signal
Signal monitor info 4
Boom DOWN signal
5
Arm IN signal
6
Fuel level sensor
Hydraulic oil temp sensor

Fuel level signal
Hydraulic oil temperature signal

PD Controller
Arm OUT signal
Bucket CURL signal
Bucket DUMP signal

Swing signal
7
9
10
Travel spd select signal

11
Bucket confluence signal
17
IO
R.Pump EX press. signal
12
F. Pump EX press. signal 13
F. Pump control signal 14
R. Pump control signal
15
Relay 16
Throttle position feedback signal
Motor drive signal
Engine speed
PPC lock signal

Starting signal
Engine speed sensor Motor Potentiometer
Engine oil pressure

Oil pressure switch
Safety relay Coolant temp sensor
Coolant temp sensor
Charging indicator Alternator Engine
Starting signal
Starting motor
Heater relay Elct. intake air heater
Preheating signal ZX215-1002184

2 R. travel pressure sensor

3 L. travel pressure sensor
4 Boom UP pressure sensor
5 Boom DOWN pressure sensor

PPC
6 Arm IN pressure sensor Valve
7 Arm OUT pressure sensor
8 Bucket CURL pressure sensor
9 Bucket DUMP pressure sensor
10 Swing pressure sensor
F. Pump oil-feed device Work equipment actuator

11
17
PD PPC Basic pressure
13
12
PPC Lock Bucket Swing Travel
solenoid confluence priority speed
16 solenoid solenoid solenoid
valve valve valve
valve
IO
15
14 Control valve
ports
F. Pressure sensor
R. Pressure sensor
PnA2 XBp2
Proportional valve
Proportional valve
PsP
Main valve
Servo Servo
F R
Travel motor
Main pump
R. Pump oil-feed device Swing motor
Work equipment actuator Travel motor

ZX225-1102049
Remark:
The diagram above illustrates the electrical control system. For hydraulic circuit diagram, see Hy-
draulic System section.

4.9.3 Engine and pump composite control function
PPC valve Operator cab

Monitor
Travel Travel MAX
Boom UP/DOWN
Arm IN/OUT
Bucket DIG/DUMP
Swing
MIN
F1 F2 F3 F4 F5
ESC Enter
Fuel control dial
MC Controller input
Pressure Option pressure
H/S/L/B sensor
sensor
Auto-idle cancel
Pilot oil pressure

Travel speed swithing
Alarm output
PD Main control valve
Pressure Engine chamber

sensor
KC controller
P2
P1
IO
Engine
Oil-feed
Pump adjustment
Pump proportional
pressure reduce
solenoid valve
Throttle motor
CAN path
Potentio- Motor
meter
R. Pump control angle
F. Pump control angle
Engine speed
Calibrator
SW LED Actual throttle position feedback
MEMORYON
H S L A/I
Control motor
LED
DOWN UP
7 RPW
LED
SW
PWR resouce DC24V H S L A/I
Fuel, coolant temp and others
(Battery)
ZX215-1002186

Function
● This function allows the operator to select

a working mode according to the job to
be performed and change engine power
Engine torque T
output. Four different working modes are
available: H, S, L and B. To select a work- H
S
ing mode, use the working mode selector L
switch on the machine monitor.
● The main controller controls the pump so

that it can absorb all the torque at the out-
put points of the engine depending on the
Engine speed N
pump absorption torque specified for each ZX215-1002193
mode, rotation set by the fuel control dial,
and actual engine speed.
Specifications
H mode
Engine
speed
~1600
PD
1600~1800 1800~2250
Engine power KW
H
S
Power (KW) 60 84 115
S mode
Engine
~1600 1600~2250
IO
speed Engine speed N
ZX215-1002194
Power (KW) 60 84
L mode
Engine
2250
speed
Pump delivery Q
H
Power (KW) 60
S
Pump output pressure P

ZX215-1002195

Control method of each working mode
H mode
Engine torque T
● The matching point of H mode: rated
speed 114kW/2050rpm
● If pump load increases and pump pressure

rises, engine speed drops. In this case,
engine speed will rise to near the match-
ing point, allowing the pump controller to
reduce pump discharge. On the contrary, if
Engine speed N
pump load decreases and pump pressure
drops, pump controller will continue to in- ZX215-1002190
crease pump discharge until engine speed

reaches the matching point.
PD Engine power KW
IO
Engine speed N
ZX215-1002191
Pump delivery Q

ZX215-1002192

S mode/B mode/L mode
Power output rate of at each working mode
Engine torque T
Mode S L B H
S
L
Power output rate 90% 80% 70%
● At this time, the controller keeps the pump

oil-suction torque in line with the stabling
motor curve, and controls engine speed
through combined control of the engine Engine speed N
and pump. ZX215-1002193
H
PD Engine power KW S
Engine speed N
ZX215-1002194
IO
Pump delivery Q

ZX215-1002195

4.9.4 Pump control function
Engine Main Press.sensor Press.sensor

pump
Fuel injection Throttle
pump motor F R
M
P Speed
Servo Servo
sensor
(Throttle position feedback signal)
Proportional Proportional
Fuel control dial

PD valve valve
(Engine speed signal)
(Control signal)
(Control signal)
Hi
(Motor drive signal)
Lo
Monitor
IO
Controller
F1 F2 F3 F4 F5
(CAN bus)
ESC Enter
Bucket DUMP signal
Boom DOWN signal

Bucket DIG signal
Boom UP signal
Arm OUT signal
R. Travel signal
L. Travel signal
Arm IN signal
Swing signal
ZX215-1002196

4.9.4.1 Electrical positive flow control
Pump 1
delivery
amount
Boom RAISE PPC pressure

Pump 1
delivery
amount
Arm IN PPC pressure
Pump 1
delivery
amount
Arm OUT PPC pressure PD

Pump 1
delivery Corresponding
amount delivery output
MAX
Bucket CURL PPC pressure

Pump 1
delivery
amount
Bucket DUMP PPC pressure

Pump 1
IO
delivery
amount
Swing PPC pressure

Pump 1
delivery
amount
L. Travel PPC pressure
ZX215-1002197

Pump 2
delivery
amount
Boom RAISE PPC pressure
Pump 2
delivery
amount
Arm IN PPC pressure
Pump 2
delivery
amount
Arm OUT PPC pressure PD

Pump 2
delivery Corresponding
amount delivery output
MAX
Bucket CURL PPC pressure

Pump 2
delivery
amount
Bucket DUMP PPC pressure

IO
Pump 2
delivery
amount
Boom LOWER PPC pressure

Pump 2
delivery
amount
R. Travel PPC pressure
ZX215-1002198

Function
● Use the joystick pilot pressure signal di-

rectly as the hydraulic pump discharge
control signal. Pilot pressure is applied on
the valve stem and, on the other hand, is
collected by the controller. The controller
keeps the discharge amount of the hydrau-
lic pump at the specified value of the cor-
responding pilot pressure according to the
functional relation between the set hydrau-
lic pump discharge amount and pilot pres-
sure. During combined operation, the set
discharge amount of each operation shall
be added.
Operation
PD
● When the work equipment is operating, the
controller collects the signal of pilot pres-
sure sensor, and determines the control
discharge amount of pump 1 and pump 2
according to the pressure signal.
IO

4.9.4.2 Constant power control
Function
● Calculation of theoretical maximum dis-

charge amount of the pump. The system Q
applies constant power control. The two Flow Pump P-Q curve
adjustor act together hydraulically, and PMax

P0
keep two executing unit of the same speci-
fication and acting together in synchroni-
zation. The change of pump discharge is PMax
determined by the sum of operating pres-
sure of the two hydraulic pumps P∑ . When P
is met, the sum of the Pressure
ZX215-1002199
power of the two hydraulic pumps remains
constant below the power of the engine.
Operation
PD
● When the work equipment is working, the
controller collects the throttle gear signal,,
a constant current value is provided and
pump power control is achieved.
IO

ESS control
Function
● Changing of the engine speed due to load

change controls the pump power, and en-
gine 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.
PD
● The engine controller collects the actual
speed signal from the ECM, and preforms
a closed loop control with the target oper-
ating speed. Then, the controller involves
the output of closed-loop control with the
calculation of the solenoid valve control
signal, and sends the final adjusting cur-
rent signal to the pump proportional sole-
noid valve.
IO
● The solenoid valve feeds pilot pressure oil
to the pump adjustor according to the sig-
nal of the controller, and controls the pump
discharge amount.

4.9.5 Valve control function
Swing priortity Bucket Confluence
Main valve
Engine Press.sensor Press.sensor

Main
Fuel injection Throttle pump
pump motor F R
M
Speed
P Servo Servo
sensor
PD
Proportional Proportional
valve valve
Fuel control dial

(Engine speed signal)
(Control signal)
(Control signal)
Hi
Lo
IO
Monitor
Controller
F1 F2 F3 F4 F5
(CAN bus) ESC Enter

Boom DOWN signal
Bucket DUMP signal
Bucket DIG signal
Boom UP signal
Arm OUT signal
R. Travel signal
L. Travel signal
Arm IN signal
Swing signal
ZX215-1002200
Valve control function
● Bucket flow control
● Swing priority control

4.9.5.1 Bucket flow control
Function
Swash plate angle
● Control the pump swash plate angle ac-

cording to the operation of bucket control
Max
lever.
Min
Bucket control lever

PPC pressure ZX215-1002201
Operation Bucket confluence

proportional
valve current
● When the bucket control lever is operated,
PD
the controller collects the signal from the 750mA
bucket DUMP pressure sensor and bucket
CURL pressure sensor, and controls the
bucket confluence proportional valve.
300mA
Bucket control lever

PPC pressure ZX215-1002202
IO

4.9.5.2 Swing priority control
Function
● Pressurized oil from pump 1 bypasses

bucket 1 valve spool, and flows first to
swing motor valve spool to activate swing
first.
Operation
● When signals from pump 1 pressure sen-

sor, arm pressure sensor and swing pres-
sure sensor meet the following conditions,
the controller activates the solenoid valve.
The solenoid valve conducts pilot pressure
oil to arm flow controller and limits the al-
PD
ternate circuit of arm 1 valve spool. Swing
valve spool first ensures swing motor
power, preventing the counter acting force
when the arm is retracting from affecting
the positioning of the upper swing struc-
ture.
Operating condition
IO
● Swing pressure sensor: signal output avail-
able
● Arm pressure sensor: signal output avail-

able

4.9.6 Duo travel speed control
Travel motor
Regulator Regulator
L. Travel pressure sensor
R. Travel pressure sensor
Main valve Travel Speed

solenoid valve
Engine
Injection
pump
Throttle
motor
M
P
PD F
Servo
Main pump
R
Servo
Fuel control dial

IO (Motor drive signal)
(Control signal)
(Control signal)
Hi
Lo
Monitor
A B C
Controller
F1 F2 F3 F4 F5
(CAN bus) ESC Enter
ZX215-1002203

Function
● Control travel mode.

Operating condition
● When Hi speed travel mode on the monitor

is enabled.
Operation
● When the travel mode is set at LO speed,

the swash plate angle of the travel motor is
the largest, and travel speed is low.
● When the controller receives the signal

from the travel pressure sensor under the
PD
conditions below, it activates the solenoid
valve. Then, the solenoid valve conducts
pilot pressure oil to the swash plate angle
control valve of the travel motor, and re-
duces the swash plate angle to increase
travel speed.
Remark:
When one side of the tracks is lifted off the

IO
ground by the work equipment and rotating,
pressure at one side of the pump increases,
which makes the lifted track rotate very fast.
When the machine is traveling under Hi speed
mode, even if work equipment is being op-
erated (work equipment pressure sensor is
switched ON), travel mode remains in Hi travel
mode.

4.9.7 Engine preheating/overheating alarm
Start switch
Heat
Preheat s/w Preheat relay Main valve
Engine Main
Throttle motor pump
Coolant
tempe
F R
sensor
M
P Servo Servo
PD
Fuel control dial
(Control signal)
(Control signal)
Hi
Lo
Monitor
A B C
IO
F1 F2 F3 F4 F5
(CAN bus) Controller
ESC Enter
ZX215-1002204

4.9.7.1 Engine preheating
Function
● Preheating control
Operation
● This function shall be used in combination

with the preheating switch located on the
right armrest. Turn the engine start key
counterclockwise to the HEAT position and
hold on, the engine will start preheating.
When released, the key will return to the
OFF position automatically and preheating
stops.
Operating condition
PD
● Power ON. Start key set at the HEAT posi-
tion.
● Preheating switch: ON
IO

4.9.7.2 Engine overheating alarm
Function
● When engine coolant temperature be-

comes excessively high (above 110°C)
during operation, overheating alarm will be
displayed on the monitor screen.
Operation
● The controller collects signal from the cool-

ant temperature sensor. When coolant
temperature rises too high, alarming infor-
mation will be generated and transmitted
to the machine monitor.
Operating condition
● Power ON.
● Coolant temperature above 110°C.

PD
4.9.8 Engine oil under–pressure alarm
Function
IO
● The engine controller collects signal from
the engine oil pressure sensor. When en-
gine speed exceeds 600 rpm, if oil pres-
sure is too low, alarming information will be
generated and transmitted to the machine
monitor. The alarm indicator lights up when
the monitor receives the signal.

4.9.9 Auto deceleration/acceleration control
Right joystick
Boom Bucket
DOWN
OUT
UP
IN
Engine
Swing Left joystick Arm

Engine
throttle
CURL
DUMP
controller
R
L
(Potentiometer signal)
Fuel control dial L.Travel R.Travel

Travel lever
Forward
Reverse
Forward
Reverse
Monitor
A B C
(Throttle signal)
(CAN bus)
PD Controller
F1 F2 F3 F4 F5
Control lever signal
ESC Enter
IO
ZX215-1002205

Function
● If all the control levers are neutralized, en-

gine speed will drop to the medium level
automatically to reduce fuel consumption
and noise.
● If any of the levers is operated, the engine

speed rises to the set level instantly.
Operation
● About 3 second after all control levers are

neutralized, engine speed will drop to the Speed (rpm)
first deceleration level about 100 rpm lower

Set rpm Drop 100rpm
than the set speed. After another 3 sec-
onds engine speed enters low speed (1400 Deceleration
PD
rpm) to reduce the loss of the hydraulic
system and engine wear, and reduce fuel
consumption and noise. When the control
lever is operated again, the engine speed
rises instantly to the previous level.
Operated
Control lever
3s
(1350rpm)
less than 2 S
Unoperated
Less than 1 S
Operated
Time (s)
ZX215-1002206
● If any control lever is operated while the

engine speed is kept at decelerated level,
engine speed will rise instantly to the level
set by the fuel control dial.
IO

4.9.10 Engine speed calibration function
Swing pripority Bucket confluence
Main valve
Engine Pressure sensor Pressure sensor

Main pump
Injection Throttle
pump motor F R
M
P Speed
sensor Servo Servo
PD
(Throttle position feedback signaL)
Fuel control dial

(Engine speed signaL)
(Control signaL)
(Control signaL)
(Motor drive signaL)
Hi
Lo
IO
Monitor
A B C
Controller
(CAN bus)
F1 F2 F3 F4 F5
Bucket DUMP signal
ESC Enter
Boom DOWN signal
Calibtator
Bucket DIG signal
SW LED
Boom UP signal
Arm OUT signal
R. Travel signal
MEMORYON
L. Travel signal
Arm IN signal
Swing signal
H S L A/I
LED
DOWN UP
7 RPW
LED
SW
H S L A/I
ZX215-1002207

Function
● Set the maximum engine speed under

each working mode. This set speed is the
standard to control engine speed.
Operation
● Calibrating procedure for positive flow exca-

vators.
1) Selection of fixing point of throttle motor

soft shaft
2) H, S, L maximum speed calibration, and A/

I speed calibration. PD
3) Turn the dial on the calibrator counter-
clockwise to the end
4) Power OFF
5) Set the calibrator to "Monitor mode", power

on and check the result.
IO
Remark:
Memory SW up: Calibration mode;
Memory SW down: Monitor mode

4.9.11 Electrical Components
4.9.11.1 Pump pressure sensor
Pressure connector Body Connector
Connection diagram
No. Signal name

Z
A PWR +5V
B GND
C Output
Terminal A Terminal B
Operation
Z direction
PD
Terminal C
ZX215-1002208
● The relationship between the pressure ap- (V)

5
plied on the sensor (P) and output voltage
Sensor output voltage (E)
4. 5
(E) is shown in the right diagram.
4
IO
3
1
0. 5
(MPa)
0 10 20 30 40 50
Oil pressure (P)
ZX215-1002209

4.9.11.2 Pilot pressure sensor
Pressure connector Body Connector
Connection diagram
No. Signal name

Z
A PWR +5V
B GND
C Output
Terminal C
Z direction ZX215-1002208
Operation
● The relationship between the pressure ap-

PD (V)
5
plied on the sensor (P) and output voltage
4. 5
(E) is shown in the right diagram.
Sensor output voltage (E)
3
IO
2
1
0. 5
(MPa)
0 1 2 3 4 5
Oil pressure (P)
ZX215-1002210

4.9.11.3 Engine speed sensor
2 1
ZX215-1002211
Function
PD
● The engine revolution sensor is installed to
the ring gear of the engine flywheel. It elec-
trically calculates the number of the gear
teeth which pass in front of it and transmits
the result to the engine controller.
Operation
● Measure the resistance between terminal

1 and terminal 2 when it is in service.
IO
Standard value (@25°C) 2.3±0.2 kΩ
● If the measured value exceeds the stan-

dard value, replace the sensor.
CAUTION
● If the engine speed sensor is not tight-
ened to the specified torque, the sen-
sor may send out no signals. Tighten
the engine speed sensor to the speci-
fied torque.

4.9.11.4 Coolant temperature sensor
2
1
ZX215-1002212
1) Sensor
2) Connector
Function
PD
● The output resistance of the engine cool-
ant temperature sensor changes with the
coolant temperature. The controller collects
and processes coolant temperature signals
and works out the coolant temperature.
IO
Specifications
50°C 80Ω (Ref.)

60°C 56.3Ω
Standard 80°C 29.5±10Ω
value 100°C 16.5Ω
106°C 14.3±0.5Ω
120°C 10Ω(Ref.)

4.9.11.5 Fuel level sensor
1 2 3 4
ZX215-1002246
1) Float PD 3) Casing
2) Lever 4) Coupler
IO

4.9.11.6 Oil pressure switch
1 2 3
Load
Pressure
Electrical
diagram
ZX215-1002214
1)
2)
3)
O-ring
Sensor
Connector
PD
Function
● The oil pressure switch is installed on the

outlet circuit of the oil filter. It detects oil
IO
pressure and transmits warning signals to
the controller.
Specifications
● Type of contact: Normally closed type
● Operating pressure: 1.9kg

4.10 Monitoring System
Machine monitor
A B C
Sany Hydraulic Excavator
S 10
CAN signal
Engine
controller
00/00/00
0000h 00m 12 00:00:00
S Lo
F1 F2 F3 F4 F5
ESC Enter
Power source
PD Sensor
IO
Battery
ZX215-1002215
● The state of the machine is monitored 1. Alert information when a machine fault is
by the sensors mounted on the machine detected.
components. The controller processes the
signals and transmits the signals to the 2. Operating condition (coolant temperature,
monitor display, informing the operator of fuel level, etc. )
the machine condition.
● The machine control system can be oper-
● Information on the monitor display includes ated using the switches and keys on the
primarily: monitor panel.

4.10.1 Machine monitor
A B C
F1
ESC
F2 F3
Enter
PD
F4 F5
7
6
12
ZX215-1002216
Outline
● The monitor displays various kinds of items ● When the monitor is turned on, blinking
and is used by the operator to select a strips may appear on the LCD screen.
IO
working mode. This is normal.
● The monitor has a CPU which processes,

displays, and outputs information. Input and output signals
● The monitor has an LCD (Liquid Crystal No. Signal name Input/output
Display) screen. 1 Digital input A Input
3 CAN high
NOTE:
4 CAN low
7 Digital input B
● The LCD may have black spots (which do
not light up) or bright spots (which stay on). 8 Trigger power source (24V)
Products having 10 or less black or bright 9 Power source (24V)
spots conform to the product specification; 10 Grounding
such condition is quite normal. 11 Digital input C
12 Grounding
● Continuous operation of the monitor may
cause the LCD to display bright blue spots
on a black background; it is quite normal.

4.10.2 Monitor functions
When the engine start switch is turned to ON

position, the monitor is energized and system
initialization begins. Normal operation display
is shown below.
Warning indicator
Indicators
A B C Signal indicator

Page heading
S 5
C H
Screen display Page items
PDS
E
36 h 25 m 12
Lo
F
2010/07/27
15:32:48
Function icon
F1 F2 F3 F4 F5 Function keys
Operation keys ESC Enter

Navigation keys
XP2151106001
IO
Outline
1. The monitor monitors and displays various 6) Service hour calibration

kinds of items and is used by the operator
to select a working mode and switch on or 7) Key machine parameters calibration
off electrical components.
2. Function keys
1) Running parameter indication
1) For functions of keys F1 to F5, ENTER,
2) Machine configuration ESC, refer to operation instructions of
the monitor.
3) Machine fault
2) Navigation keys [↑], [↓], [←] and [→]
4) Throttle installation assistance are used to scroll up or down, select an
option, adjust a value, etc.
5) System clock calibration

Warning and signal indicators
1
1. Warning indicator
2
● When a machine fault occurs , the warning

indicator lights up, reminding the user to A B C
check and address the fault.
2. Signal indicator
XP2151106002
● The signal indicators include: power indica-
tor, CAN indicator and standby indicators
which may light up under certain circum-
stances.
Screen display
PD
The LCD display is the screen display of the
monitor. Depending on the selected entry of
the user, the screen displays different page
headings, items, parameters, times and func-
tion icons. The user can use the navigation
1
3
S
5 2
keys to select an option and adjust a value. C H
Main items on the normal operation display in-

clude: 4
E F
5
1. Working mode (S, H, L and B) 7
IO
2010/07/27
6 36 h 25 m 12 15:32:48
8
S Lo
2. Coolant temperature
XP2151106003
3. Fuel level
4. Engine speed level (1~11)
5. Failure code (refreshed every 2 seconds)
6. Machine service hours (XX Hr XX Min)
7. Date (Y/M/D)
8. Clock (H:M:S)

Operation keys
S Lo
1. Function keys
1 F1 F2 F3 F4 F5
● Functions of the five keys (F1, F2, F3, F4
and F5) are indicated by the function icons ESC Enter
2
above them on the screen display.
● When the icon above a function key chang-

es, the function of this key also becomes XP2151106004
different.
● When no icon is displayed above a func-

tion key, this key is disabled.
Function key Icon Function Display range
F1
F2
F3
S
Lo
PD
Working mode selection
Auto idle/Full speed selection
High/Low travel speed

Auto idle/Full
F4 Enter/Confirm Same as ENTER key
Information menu ——
F5
Return to previous page Same as ESC key
IO
Every time the system is energized, the de- Auto-idle switch
fault working state is:
● Auto-idle function is active under default
● Working mode: S condition. When neither of the joysticks are
operated for 5 seconds, the engine enters
● Full/Auto idle speed: Auto-idle the idling state automatically in order to
save fuel and reduce noise.
● High/Low travel speed: Lo
● When the controller detects movement of
the joysticks or adjustment of speed level
while the engine is idling, engine speed re-
sumes its previous or newly set speed.
NOTE: Auto-idle is disabled under L mode.

13. Navigation keys
Navigation keys Function
Enter Enter/Confirm
ESC Return to previous page
Select item on upper side (Selects bottom item after top item)
Select item on lower side (Selects top item after bottom item)
Select item on left side (Selects right end item after left end item)
Select item on right side (Selects left end item after right end item)
4.10.3 Monitor operation
[1] Home page
Function
PD Sany Hydraulic Excavator
1 S 5 12
This is the normal operation display. Items on
this page include: working mode, speed level, 2
C
coolant temperature, fuel level, service hours, H
IO
clock, fault code, etc.. You can set the working
condition of the machine on the home page.
3
E F
11
Display
4 36 h 25 m 12 15:32:48 10
S Lo
1. Working mode (S, H, L and B)
5 6 7 8 9
2. Coolant temperature (°C) XP2151106003
3. Fuel level (%)
4. Service hours (XX h XX m)
5. When F1 is pressed successively, working

mode changes in the order of H → L → B
→S→H

6. When F2 if pressed successively, auto-idle

function changes in the order of OFF →
ON → OFF.
7. When F3 is pressure successively, travel

speed changes in the order of HI→LO→HI.
8. When F4 is pressed, the screen changes

to “Fault Information”.
9. When F5 is pressed, the screen changes

to the password entry page of “Information
Menu”.
10. Date and clock (Y/M/D, H:M:S)
11. If a machine fault occurs, fault code is re-

PD
freshed every 2 seconds).
12. Engine speed level (1-11).
Operation
● F1: Working mode selection

IO
● F2: Auto-idle/Full speed selection
● F3: High/Low travel speed selection
● F4: Go to “Fault Information” when fault is

available
● F5: Go to password entry of “Information

Menu”

[2] Information Menu password entry
Function
Password entry page before accessing the

“Information Menu”
Display Information Menu
1. A 5-digit password displayed in (*). The as-

terisks becomes a number when the cursor
moves on it, while the rest is still displayed Please enter the password
in asterisks. 1
2. When F1 is pressed, the number on the

*****
cursor changes in an ascending order.
3. When F2 is pressed, the cursor moves

from the left to the right. PD
4. When F3 is pressed, the system checks
the validity of the password. If the pass-
2 3 4 5
word is correct, you access the “Information XP2151106004
Menu”. Otherwise, you are required to en-
ter the correct password.
5. When F5 is pressed, the screen returns to

the “Home Page”.
IO
Operation
● F1: Change the number on the cursor in an

ascending order.
● F2: Move the cursor from the left to the

right. It returns to the left after the right end
item.
● F3, ENTER: Confirm the validity of the

password.
● F5, ESC: Return to the “Home Page”.
● [↑] or [↓]: Change the number on the cursor

in an ascending or descending order.
● [→] or [←]: Move the cursor to the left or to

the right.
Note: Password can be obtained from your

Sany dealer.

[3] Information Menu
Function
Information menu is a list of system functions.

You can select and access any of the items on
this page.
Information Menu
Display
1. System function list.

Running parameter
2. When F1 is pressed, the highlighter move Fault information

1
downward. Throttle installation
System language
3. When F2 is pressed, you access the se- System time setup
lected item.
4. When F4 is pressed, the screen changes 6

Engine, main pump and main valve parameters
to the password entry page of “System PD
Setup”.
5. When F5 is pressed, the screen returns to 2 3 4 5

XP2151106005
the “Home Page”.
6. Function of the items on the “Information

Menu”:
● Running parameters of the engine,

main pup and main valve
IO
● Fault code and description
● Throttle installation assistance
● System language selection
● System time setup
Operation
● F1: Select the item on the system function

list. The highlighter moves from the top to
the bottom and returns to the top when af-
ter the bottom end.
● F2, ENTER: Enter the selected item.
● F4: Go to “System Setup”.
● F5, ESC: Return to the “Home Page”.
● [↑] and [↓]: Select the upper or lower item

on the system function list.

[4] Engine Signal
Function
This page displays the running parameter of

Engine Signal
the engine.
Display
Coolant temp °C： 0
1. Real-time display of engine signals col-
lected by the controller. 1 Fuel level %： 0
2. When F1 is pressed, the screen moves to Oil press kPa： 0

the next page “Throttle Signal”.
Hydro oil temp ℃:0
the “Information Menu”.
Operation
● F1: Go to “Throttle Signal” page.

PD
● F5, ESC: Return to the “Information Menu”.
● [↑]: Go to “Main Valve Signal”

2 3
XP2151106006
● [↓]: Go to “Throttle Signal”
[5] Throttle Signal
Function
IO
This page displays the throttle signal of the
Throttle Signal
engine.
Display
Throttle gear N:12
1. Real-time display of throttle signals col-
lected by the controller. 1 Eng speed r p m : 1 2 3 4
2. When F1 is pressed, the screen moves to Gear position V:1.23

“Pilot Pressure Signal -1”.
Throt positionV:1.23
Operation
● F1: Go to “Pilot Pressure Signal -1” page.
● F5, ESC: Return to the “Information Menu”. 2 3

XP2151106007
● [↑]: Go to “Engine Signal”
● [↓]: Go to “Pilot Pressure Signal -1”

[6] Pilot Pressure Signal -1
Function
This page displays the pilot pressure signal of Pilot Pressure Signal 1
the hydraulic system.
Display
Boom UP kg： 123.4
1. Real-time display of pilot pressure signals
1 Boom DN kg： 123.4
collected by the controller.
Arm IN kg： 123.4
2. When F1 is pressed, the screen moves to
the next page “Pilot Pressure Signal -2”. Arm OUT kg： 123.4

Operation
PD
● F1: Go to “Pilot Pressure Signal -2” page.
● [↑]: Go to “Throttle Signal”

2 3
XP2151106008
● [↓]: Go to “Pilot Pressure Signal -2”
[7] Pilot Pressure Signal -2
Function
IO
This page displays the pilot pressure signal of
Pilot Pressure Signal 2
Display
1. Real-time display of pilot pressure signals Bucket DIG kg:123.4

collected by the controller. 1 Bucket DMP kg:123.4
2. When F1 is pressed, the screen moves to Swing kg:123.4

the next page “Main Pump Signal”.
Travel L kg:123.4
3. When F5 is pressed, the screen returns to Travel R kg:123.4
Operation
● F1: Go to “Main Pump Signal” page.
● F5, ESC: Return to the “Information Menu”. 2 3

XP2151106009
● [↑]: Go to “Pilot Pressure Signal -1”
● [↓]: Go to “Main Pump Signal”

[8] Main Pump Signal
Function Main Pump Signal
This page displays the main pump signal of

Pump1 press kg： 123.4
Display
Pump2 press kg： 123.4
1
1. Real-time display of main pump signals Prop valve1 current mA:123.4
collected by the controller.
Prop valve2 current mA:123.4
the next page “Main Valve Signal”.

Operation
PD 2 3
● F1: Go to “Main Valve Signal” page. XP2151106010
● [↑]: Go to “Pilot Pressure Signal -2”
● [↓]: Go to “Main Valve Signal”
[9] Main Valve Signal
Function
IO
Main Valve Signal
This page displays the main valve signal.
Display
1. Display of main valve signals. When output Bucket confluence val ●

switches are turned on, the matching sym- Swing priority val ●
bol turns green. 1
Boom priority val ●
Hi/Lo speed switch ●
the next page “Engine Signal”.

Operation
● F1: Go to “Engine Signal” page.

2 3
● F5, ESC: Return to the “Information Menu”. XP2151106011
● [↑]: Go to “Main Pump Signal”
● [↓]: Go to “Engine Signal”

[10] Fault Information
Function
This page displays machine fault information. Fault Information
Display
Current fault code：13 1

1. Fault code.

Operation
[12] Throttle Installation Assistance

PD 2
XP2151106012
Function
This page displays throttle installation assis- Throttle Installation

tance function.
IO
Display
1 Current gear N:11
1. Real-time display of detected value.
Eng speed rpm:1200
2. Working mode selection.
Gear position V:1.23
3. Auto-idle function selection.
Throttle position V:1.23
4. High/low travel speed selection

H Lo
Operation
2 3 4 5
● F1: Select working mode (S, H. L and B).
XP2151106013
● F2: Select auto-idle or full speed.
● F3: Select high or low travel speed.

[13] System Language
Function System Language
Select system language on this page.
Display 中文系统
1. List of system languages. 1 English Systems
2. When F2 is pressed, Chinese is selected.
3. When F3 is pressed, English is selected.

Operation
中文 Eng
● F2: Select Chinese.

PD 2 3 4
● F3: Select English. XP2151106014
[14] System Time Setup
Function
Set system time on this page. System Time Setup
Display
IO
1. Current time. C ur r ent ti m e：
1 1234 ·12 · 12 12： 12：12
2. Setup time.
3. Save setup time. Setup time ：迁移

2 1234 · 12 ·12 12 ：12： 12
Operation
Use [ ↑] [↓] [←] [→] t o adj ust syst em t i m e!
● F1, ENTER: Confirm.

3 4
Remark: XP2151106015
● When F1 or ENTER is pressed, the screen

displays “Setup Finished” on the bottom.
● If system time has been adjusted, it cannot

be adjusted again until the system is re-
energized.

[15] System Setup password entry
Function
Password entry page before accessing the System Setup

“System setup” page.
Display
1. A 5-digit password displayed in (*). The as- Please enter the password:
moves on it, while the rest is still displayed
in asterisks.
1
* * * * *

from the left to the right.

PD
word is correct, you access the “System
Setup” page. Otherwise, you are required
to enter the correct password.
2 3 4 5
XP2151106016

Operation
IO
ascending order.

item.

password.


the right.
Remark:
● Password to access “System Setup” page

is only given to authorized personnel.

[16] System Setup list
Function
Set up machine configuration on this page. System Setup
Display
Machine configuration
1. System setup list. 1 Service hour setup
Machine configuration setup
2. When F1 is pressed, the highlighter move
downward.
3. When F2 is pressed, you access the se-

lected item.

Operation
PD
● F1: Select the item on the system setup
2 3 4
XP2151106017
list. The highlighter moves from the top to

the bottom and returns to the top when af-
ter the bottom end.
● F2, ENTER: Enter the selected item.

IO
● [↑] or [↓]: Select the upper or lower item on

the system setup list.

[17] Machine Configuration password entry
Function
Password entry page before accessing the System Setup
“Machine Configuration” page.
Display
Please enter the password:
1
* * * * *
in asterisks.



PD
word is correct, you access the “Machine
configuration” page. Otherwise, you are
2 3 4 5
XP2151106018
required to enter the correct password.

the “System Setup”.
IO
Operation

ascending order.

item.

password.
● F5, ESC: Return to the “System Setup”.


the right.

[18] Machine Configuration

System Setup
Function
View machine configuration information on this Machine model 215

page.
Machine No. 11SY0216 00008
Display 1
Engine model MITSUBISHI_II
1. Machine configuration information.
Hydraulic system model KPM P
the “System Setup”. Controller model KC-MB-001
Operation
● F5, ESC: Return to the “System Setup”. 2

PD XP2151106019
IO

[19] Service Hour Setup password entry
Function

System Setup
“Service Hour Setup” page.
Display
1. A 5-digit password displayed in (*). The as- Please enter the password:
in asterisks.
1
* * * * *


PD
word is correct, you access the “Service
Hour Setup” page. Otherwise, you are re-
2 3 4 5
XP2151106020
quired to enter the correct password.

IO
Operation

ascending order.

item.

password.


the right.

[20] Service Hour Setup
Function
Set up machine service hours Service Hour Setup
Display
Current service hour
1 100 h 50 m
1. Current total service hour in the controller.
Setup service hour

2. Setup service hour.
2 100 h 50 m
3. When F1 is pressed, the current total ser-
vice hour is upgraded into the setup ser-
vice hour.
Use [ ↑ ] [↓] [← ] [→ ] t o a d j u s t s e rv i c e h o u r!

the “System Setup” page.
Operation
PD
● F1, ENTER: Confirm the completion of ser-
3 4
XP2151106021
vice hour adjustment. The screen displays

“Setup finished, please re-energize the
system.”

IO

[21] Machine Configuration Setup pass-

word entry
System Setup
Function

“Machine Configuration Setup” page. Please enter the password:
Display

1
* * * * *
in asterisks.



PD
word is correct, you access the “Machine
2 3 4 5
XP2151106022
Configuration Setup” page. Otherwise, you

are required to enter the correct password.

IO
Operation

ascending order.

item.

password.


the right.

[22] Machine Configuration
Function Machine Config Setup
Set up machine configuration.

M a c h i n e m o d e l : 215
Display
Engine model: MITSUBISHI_II
1. Machine configuration information.
2. When F1 is pressed, machine model 1 H y d r a u l i c m o d e l : KPM_P
changes.
C o n t r o l m o d e l : KC-MB-001
3. When F2 is pressed, engine model chang-
es Ma chi ne N o.: 11SY0216 00008
4. When F3 is pressed, hydraulic system Use[ ↑] [↓] [←] [→ ] to set up machine number!
model changes.
机型引擎液压控制
5. When F4 is pressed, control system model
changes
PD
6. When F5 is pressed, machine configura-
tion setup is saved.
Operation
2 3 4 5 6
XP2151106024
● F1: Change machine model.

● F2: Change engine model.
● F3: Change hydraulic system model.
IO
● F4: Change controller model.
● F5: Confirm the machine configuration. The
screen displays “Setup finished. Please re-
energize the system.”
● [↑] or [↓]: Increase or decrease the selected
machine number by 100 each time.
● [→] or [←]: Increase or decrease the se-
lected machine number. One quick press-
ing increase or decrease the number by
1. Long pressing increase or decrease the
number in a quicker pace.
● ESC: The screen returns to “System Set-
up” page.
● ENTER: Move the cursor in the machine
number. When the cursor blinks, use [↑], [↓],
[→] and [←] to adjust the number.

Remark:
Machine number adjustment:
The machine serial number is made up of 4

parts: 1) Production year, 2) Product code, 3)
Tonnage code, 4) Alteration code, 5) Serial
number, and 6) Tail number “8”.
1) Press ENTER to move the cursor to dif-

ferent part (Production year, Product code
and Serial number) in the machine num-
ber.
2) When the cursor moves to Production year

and Alteration code, press [←] or [→] to
increase or decrease Production year and
PD
Alteration code by 1 each time.
3) When the cursor moves to Tonnage code,

press [←] or [→] to increase or decrease
tonnage code by 1 each time; or press
[↑] or [↓] to increase or decrease tonnage
code by 100 each time.
4) When the cursor moves to Serial number,

press [←] or [→] to increase or decrease
IO
this number by 1 each time. Long press-
ing to change the number in a quick pace.
Press [↑] or [↓] to increase or decrease this
number by 100 each time.
5) The machine number has 4 adjustable

digits. Use [←] and [→] to switch between
the four digits, and use [↑] or [↓] to change
the value on a digit. The value of the first
digit from the left could be any numbers
from 0 to 9 and any letters from A to Z; the
value of the rest three digits could only be
any number from 0 to 9. When the number
exceed 9999, capital letter from A to Z will
have to be used. A, B, C, D, E ... means
respectively 10000, 11000, 12000, 13000,
14000, 15000 .... For example: 10000 will
be written as A000; 11020 as B020, 12999
as C999.

[23] Lockout Information (Level 1)
Function Lockout Information
This display indicates that the machine has

entered lockout state (level 1), and all keys are Macine model :215
disabled. Machine No. :11SY0216 00008
Machine state :Lockout (2)
Display 1
Current time:12：12：11
● Machine configuration information, lockout
level 1 and current time.
System locked
NOTE:
Contact manufacturer to unlock system
● The screen displays any of the following All keys are disabled!
machine states after 5 seconds. “Lockout
PD
(Level 1)” or “Lockout (Level 2)” or “Un-
locked”. (Five seconds is the filtering time)
XP2151106025
[24] Lockout Information (Level 2)

Lockout Information
Function
Macine model :215
This display indicates that the machine has
IO
entered lockout state (level 2), and all keys are Machine No. :11SY0216 00008
disabled. Machine state :Lockout (2)
1
Current time:12：12：11
Display
● Machine configuration information, lockout

level 2 and current time. System locked
Contact manufacturer to unlock system
NOTE:
All keys are disabled!
● The screen displays any of the following
machine states after 5 seconds. “Lockout XP2151106026
(Level 1)” or “Lockout (Level 2)” or “Un-
locked”. (Five seconds is the filtering time)

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SY195-205-215C9 Crawler Hydraulic Excavator Standard Values
Standard Values
5 Standard Values
5.1 Standard Values of Engine - related Parts............................................................... 5-3
5.2 Standard Values of Chassis-related Parts ............................................................... 5-4
PD
IO

Standard Values SY195-205-215C9 Crawler Hydraulic Excavator
PD
IO
WARNING
jury or death.

5 STANDARD VALUES
5.1 Standard Values of Engine - related Parts
Std. value for

Item Measurement condition Unit Permissible value
new machine
High Idling rpm 2,060 ± 70 2,060 ± 70
Engine Speed Low Idling rpm 1,050 ± 50 1,050 ± 50
Rated Speed rpm 2,000 2,000
Intake Pres-
sure ● Air Cleaner Outlet Location kPa Min. 133 Min. 133
(Negative ● Arm-In Overflow+Max. rpm {mmH2O} {Min. 1,000} {Min. 1,000}
Pressure)
At Sudden Acceleration Bosch Max.25 35
Exhaust Color PD
At High Idling Index — —
Valve Clear- Intake Valve mm 0.25 0.152 ~ 0.381

ance Exhaust Valve mm 0.51 0.381 ~0.762
Compression ● Oil Temp: 40~60°C Mpa Min. 2.41 1.69
Pressure ● Engine Speed 250 rpm {kg/cm²} {Min. 24.6} {17.2}
Blow-by Pres- ● Coolant Temp: Working Range kPa Max. 0.98 1.96
sure ● Arm-In Overflow: Max. rpm {mmH2O} {Max. 100} {200}
MPa Min. 0.29 0.25
High Idling
IO
{kg/cm²} {Min. 3.0} {2.5}
Oil Pressure
MPa Min. 0.10 0.07
Low Idling
{kg/cm²} {Min. 1.0} {0.7}
Oil Temp. ● Full Speed Range (In Oil Pan) °C 80 ~ 110 120
● Between fan belt pulley and
Fan Belt Ten- alternator belt pulley
mm 8.0 Min. 6, Max. 10
sion ● Deflection when pressed with
finger force of 58.8 N {6 kg}
● Between fan belt pulley and
A/C Compres-
compressor belt pulley
sor Belt Ten- mm 5~8 5 ~8
● Deflection when pressed with
sion
finger force of 58.8 N {6 kg}

5.2 Standard Values of Chassis-related Parts
Std. value for Permis-

Categ. Item Measurement condition Unit
new machine sible value
● Engine coolant temperature: Within
operational range
● Hydraulic oil temperature: Within
Engine Speed
2 pumps at relief operational range rpm 2,050 ± 50 2,050 ± 50

● Engine running at high idle
● Heavy-load operating mode (H)
● Arm-in relief condition
Speed when auto ● Engine running at high idle
deceleration is oper- ● Auto idling switch on rpm 1,350 ± 50 1,400 ± 100
ated ● All control levers neutral
UP mm 11.5 ± 0.5 11.5 ± 0.5
Boom control valve PD DOWN mm 9.5 ± 0.5 9.5 ± 0.5
Spool Stroke
IN mm 11.5 ± 0.5 11.5 ± 0.5

Arm control valve
● Engine stopped OUT mm 9.5 ± 0.5 9.5 ± 0.5
Bucket control valve ● See Control valve. DIG/DUMP mm 9.5 ± 0.5 9.5 ± 0.5
Swing control valve Travel (L&R) mm 9.5 ± 0.5 9.5 ± 0.5
Forward &
Travel control valve mm 9.5 ± 0.5 9.5 ± 0.5
Reverse
Boom control lever mm 85 ± 10 85 ± 10
● Engine stopped
Arm control lever mm 85 ± 10 85 ± 10
IO
● Control lever grip at center
Bucket control lever mm 85 ± 10 85 ± 10
● Max. reading at stroke end (except
Control Lever stroke
Swing control lever mm 85 ± 10 85 ± 10

lever play in NEUTRAL position)
Travel control lever mm 115 ± 12 115 ± 12
● Engine stopped Work Equip-
mm Max. 15 Max. 20
● Slightly push the ment
control lever. Stop
Play of control lever pushing when re-
sistance is felt. Stroke mm Max. 20 Max. 25
● Max. reading at
stroke end.


Boom control Max. 19.6 Max. 24.5
Operating Force of Control Lever/
lever {Max. 2.0} {Max. 2.5}

Arm control Max. 19.6 Max. 24.5
lever ● Hydraulic oil temp: Within operational {Max. 2.0} {Max. 2.5}
Bucket con- range Max. 15.6 Max. 21.6
trol lever ● Engine running at high idle N {Max. 1.6} {Max. 2.2}
Pedal
Swing control ● Control lever grip at center {kgf} Max. 15.6 Max. 21.6
lever ● Pedal at tip {Max. 1.6} {Max. 2.2}
Travel control Max. 30.4 Max. 39.2
● Max. reading at stroke end
lever {Max. 3.1} {Max. 4.0}
Travel control Max. 93.1 Max. 107.8
pedal {Max. 9.5} {Max. 11}
● Hydraulic oil temp: Within operational
range
Unloaded
pressure
Boom relief
PD
● Working mode: H
● All control levers in neutral position
● Hydraulic pump output pressure
0~1.0
{0~10}
34.3 ± 1.0
0~2.0
{0~20}
33.3 ~ 35.3
range {350 ± 10} {340 ~ 360}
● Operate corresponding control lever 34.3 ± 1.0 33.3 ~ 36.8
Arm relief
after engine runs at high idling speed. {350 ± 10} {340 ~ 375}
● Working mode: H
Hydraulic Pressure
34.3 ± 1.0 33.3 ~ 36.8

IO
Bucket relief ● Hydraulic pump output pressure with {350 ± 10} {340 ~ 375}
all measurement circuits relieved MPa
● Hydraulic oil temp: Within operational 25.5 ± 1.0 24.5 ~ 27.5
Swing relief {kg/cm²}
range {261 ± 10} {250 ~280}
● Operate corresponding control lever
after the engine runs at high idling
speed. 33.4 ± 1.0 32.4 ~ 34.4
Travel relief
● Working mode: H {342 ± 10} {330 ~ 351}
● Hydraulic pump output pressure with
all measurement circuits relieved
range
Control circuit
● Engine running at high idle 3.9 ± 0.2 3.7 ~ 4.1
source pres-
● Self pressure reducing valve output {40 ± 2} {37 ~ 41}
sure
pressure with all control levers in
NEUTRAL position


● Hydraulic oil temp: Within operational range
Swing
● Working mode: H Deg. Max. 100 Max. 130
brake
● Swing circle misalignment amount when stopping mm (—) (—)
angle
after one turn
● For measuring posture see Swing 1.
● Hydraulic oil temp: Within operational range 90° sec. 3.1 ± 0.3 Max. 3.7
Time ● Engine running at high idle
taken ● Working mode: H
to start ● Time required for passing points 90°and 180° sec. 4.4 ± 0.4 Max. 5.5
swing 180° from starting point
PD
Swing
Time
● Working mode: H
taken to sec. 24 ± 3.5 Max. 30
● Time required for 5 turns after making initial 1
swing
turn
● Engine stopped
● Keeping the upper structure transverse on a
Hydraulic
IO
grade of 15°. For more information see Swing 2. mm 0 0
drift
● Notching a mating mark on inner and outer races
of the swing circle
● Mating mark misalignment amount during 5 min.
Motor ● Engine running at high idle ml/
Max. 5 Max. 10
leakage ● Swing lockout switch: ON min
● Leakage amount for 1 minute during swing relief
● Hydraulic oil temp: Within operational range Lo 51.3 ± 5.1 46.2 - 60.4
Travel
● Working mode: H
Travel
speed
● Time required for track shoes to make 5 sec.
(unload- Hi 28.0 ± 1.4 26.6 - 31.4
turns after making one initial idle turn
ed)
● For more information on measuring posture
see Travel 1.


Cat. Item Measurement Condition Unit

Travel speed
● Engine running at high idle Lo 20 ± 2.5 17.5~22.5

(Actual run)
● Working mode: H
sec.
● Level ground
● Time required for traveling 10m after 10m trial run
Hi 13 ± 2.5 11.5~15.5

● Working mode: H
Deviation
● Travel Speed: Low

mm Max. 800 Max. 900
● Hard level ground
● Amount of deviation (χ) while traveling 20m after initial
Travel
10m trial run PD

● For measuring posture see Travel 2/3.
Hydraulic drift
● Engine stopped
● Park the machine on a grade of 12°, with the sprocket
mm 0 0
in the downhill direction
● Measure the sliding distance for 5 minutes
● For measuring posture see Travel 4.
travel motor
Leakage of

IO
● Traveling with the sprocket locked mm 13.6 27.2
● Oil leakage amount for one minute with traveling in re-
lief condition
Bucket

tips
mm Max. 600 Max. 900

● Flat and level ground
● Bucket full of earth or with rated load (0.8m³: 1,440 kg)
cylinder
● Boom horizontal, arm fully retracted and bucket cylin-

Arm cylin- Boom
der fully extended mm Max. 20 Max. 27

Work Equipment
● Engine stopped
Hydraulic drift
● Work equipment control lever in neutral position

● Measure total amount of falling for 15 min. by measur-
der
mm Max. 20 Max. 20
ing the falling every 5 min. immediately after initial set-
ting
● Bucket tip lower distance
Bucket cylinder
● Boom cylinder: Cylinder retracting distance

● Arm cylinder: Cylinder extending distance mm Max. 35 Max. 40
● Bucket cylinder: Cylinder retracting distance
● For measuring posture see Work Equipment 1.


● Hydraulic oil temp: Within operation-
al range
Boom
● Working mode: H
UP sec. 3.4 ± 0.4 Max. 4.8
● Time required for the bucket to raise
from the ground to its stroke end
● For measuring posture see Work
Equipment 2.
● Hydraulic oil temp: Within operation- IN sec. 3.6 ± 0.4 Max. 4.5
al range
Work Equipment Speed

Work Equipment
● Working mode: H
Arm
● Time required from dumping stroke OUT sec. 2.9± 0.3 Max. 3.5
PD
end to digging stroke end
Equipment 3.
● Hydraulic oil temp: Within operation- DIG sec. 2.9 ± 0.5 Max. 3.4
al range
Bucket
● Working mode: H
● Time required from dumping stroke
DUMP sec. 1.9 ± 0.3 Max. 2.3
IO
end to digging stroke end
Equipment 4.

Std. value for Judgement

Cat. Item Measurement condition Unit
new machine criteria

● Engine running at low idle
● Working mode: H
● Time required from maneuvering the joystick
Boom
to the moment that the bucket reaches the sec. Max. 1.0 Max. 1.2
ground and begins to push the machine up-
ward, within 50mm off the ground
● For measuring posture see Work Equipment
5.

Time Delay
● Working mode: H
● Average time required for operating the con-
Arm
PD sec. Max. 2.0 Max. 2.8

trol lever back and forth till the arm starts to
Work Equipment
move
6.

● Working mode: H
Bucket
● Average time required for operating the con-

sec. Max. 1.0 Max. 3.6
trol lever back and forth till the arm starts to
IO
move
7.
Cylinders
5 20
Internal Leakage

● Engine running at high idle ml/
Central Swivel
● Leakage amount for one minute with cylinder min

Joint
or travel measured at relief condition 10 50

work equipment and travel
Performance in Combined
simultaneous operation of
Amount of deviation in

Operations
● Working mode: H
● Travel Speed: Low mm Max. 200 Max. 220
● Amount of deviation measured for 20 m after
traveling about 10 m on a hard level ground
● For measuring posture see Travel 2.

Machine postures for measuring (For all models)
Control value: Spool stroke Travel 1: Travel speed (without load)
ZX215-1003002 ZX215-1003005
start swing, time taken to swing

PD
Swing 1: Swing brake angle, time taken to Travel 2: Travel speed (actual run), Travel de-
viation
45°
IO
ZX215-1003003 ZX215-1003006
Swing 2: Hydraulic drift of swing Travel 3: Travel deviation
15° x
10m
ZX215-1003007
Sprocket
ZX215-1003004

Travel 4: Hydraulic drift of Travel Work equipment 3: Arm speed
12°
ZX215-1003008 ZX215-1003011
Work equipment 1: Hydraulic drift of work Work equipment 4: Bucket speed

equipment
PD
IO
ZX215-1003009 ZX215-1003012
Work equipment 2: Boom speed Work equipment 5: Boom delay
ZX215-1003010 ZX215-1003013

Work equipment 6: Arm delay Work equipment 7: Bucket delay
ZX215-1003014 ZX215-1003015
PD
IO

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SY195-205-215C9 Crawler Hydraulic Excavator Testing and Adjusting
Testing and Adjusting

6 Testing and Adjusting
6.1 Engine Speed - Test and Calibrate .......................................................................... 6-3
6.2 Exhaust Gas Color - Test ......................................................................................... 6-5
PD
6.3 Valve Clearance - Adjust.......................................................................................... 6-7
6.4 Compression Pressure - Measure ......................................................................... 6-10
6.5 Fuel Injection Timing - Test and Adjust .................................................................. 6-12
6.6 Engine Oil Pressure - Measure.............................................................................. 6-16
6.7 Engine Speed Sensor - Adjust ............................................................................... 6-18
6.8 A/C Compressor Belt Tension - Test and Adjust ................................................... 6-19
6.9 Swing Bearing Clearance - Measure ..................................................................... 6-21
6.10 Track Tension - Test and Adjust ........................................................................... 6-23
IO
6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust .................................. 6-25
6.12 Control Circuit Oil Pressure - Test and Adjust...................................................... 6-29
6.13 Solenoid Valve Output Pressure - Measure......................................................... 6-31
6.14 Pilot Valve Output Pressure - Measure................................................................ 6-33
6.15 Pilot Valves (Work Equipment and Swing) - Adjust ............................................. 6-35
6.16 Work Equipment Hydraulic Drift - Test ................................................................. 6-36
6.17 Residual Pressure in Hydraulic Circuit - Release ................................................ 6-39
6.18 Oil Leakage - Measure ........................................................................................ 6-40
6.19 Air in Each Component - Bleed............................................................................ 6-45

Testing and Adjusting SY195-205-215C9 Crawler Hydraulic Excavator
PD
IO
WARNING
jury or death.

6 TESTING AND ADJUSTING
6.1 Engine Speed - Test and Calibrate
Engine speed calibrator
ID Part Number Part Name

1 B249900001206 Engine Speed Calibrator
6.1.1 Testing
Start the engine and keep the engine running

until engine coolant temperature rises within
the operational range. Key in the code on the
monitor and check if the engine speed is nor-
PD
mal in each throttle position.
Testing Items:
1. Engine speed at low idle
2. Engine speed at fuel control dial position

11 (H and S modes)
IO
3. Engine speed at relief, with fuel control dial
placed at position 11 (H and S modes)
4. Engine speed at auto idle
6.1.2 Adjusting
Speed calibration steps:
1. Plug the calibrator and chassis harness;
2. Set the calibrator to "Calibrate" mode and

turn the calibrator dial counterclockwise to
its end;
3. Start the engine;
4. Adjust the calibrator dial to the max. speed

under H mode;

Note: Memory SW UP: Calibrating mode

MEM SW State LED Dial
MEMORYON
Memory SW DOWN: monitoring mode

H S L A/I
Pwr Mode LED
DOWN UP
5. Press the button under H. The correspond-
7 Slice Displays RPW
ing power mode LED flashes, indicating LED
the controller is storing data. No operation Pwr Mode SW
should be performed during the moment. H S L A/I
The storing process will finish in about 5

Analog Output
seconds. Current data is regard as the Calibrator Appearance
max. engine speed under this mode. ZX215-1004001
6. Increase the engine speed to the max.

speed under S mode. Press the button
under S. The corresponding power mode
LED flashes, indicating the controller is
storing data. No operation should be per-
PD
formed during the moment. The storing
process will finish in about 5 seconds.
Current data is regard as the max. engine
speed under this mode.
7. Calibrate the engine speed for the L mode

and for auto idle following the description
in step 5 and step 6.
8. Lower the engine speed to the minimum.

IO
9. Turn off the engine.
Set the calibrator to "Monitoring" mode.

Power on and start the engine. Make sure
that the max. engine speed calibration is
correct under each mode.
10. If engine speed calibration fails, repeat

step 1 through step 9.
NOTE:
When the control levers are neutralized, en-

gine speed will drop automatically to about
1400 rpm after 3 seconds. This not only re-
duces loss of the hydraulic system and engine
wear, but also cuts fuel consumption and re-
duces noise. When any of the control lever is
moved, the engine resumes its original speed.

6.2 Exhaust Gas Color - Test
Testing tools
ID Model Part Name

1 YDJ-2006 Smoke meter
2 SV-2TY Opacimeter
CAUTION
● Do not touch any hot parts when mount-
ing or dismounting the testing tools.
1. Measure with a smoke meter
1) Put the filter paper into the smoke me-

PD
ter.
2) Insert the waste gas intake pipe into

the exhaust pipe.
3) Start the engine and keep the engine

running until engine coolant tempera-
ture is within the operational range. ZX215-1004002
4) When engine speed increases sudden-

IO
ly or is kept at high idle, direct exhaust
gas through smoke meter to the filter
paper.
5) Remove the filter paper from the smoke

meter. Read the smoke value through
the apparatus provided.
6) Remove the testing tools after measur-

ing. Make sure the machine goes back
to its normal state.

2. Measure with an opacimeter
1) Mount the opacimeter onto the exhaust

pipe by clamping it to the pipe outlet.
ZX215-1004003
2) Open the opacimeter and preheat it for

about 15 minutes.
PD
running until engine coolant tempera-
ture is within the operational range.
ZX215-1004004
IO
4) When engine speed increases sud-
denly or is kept at high idle, use the
opacimeter to read the smoke value of
exhaust gas.
5) Remove the testing tools after measur-

ing. Make sure the machine goes back
to its normal state.

6.3 Valve Clearance - Adjust
Service Standard (Unit: mm)
Location Service Item Standard Value Limits Remedy

— Valve clearance (engine cold) 0.4 — Adjust
Special Tools
Symbol Tool Name and Shape Part Number Application
Flat head screwdriver
Valve clearance adjustment

MH060008
(Carried on vehicle)
as per the following procedure:

PD
Check and adjust valve clearance in cold state
Sight Glass
6.3.1 Testing
1. Remove the rocker arm cover.

IO
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 flywheel aligns with the pointer on
sight glass of the flywheel shell.
Sight Glass
● Turn the No.1 piston or the No.6 piston

to the top dead center of compression
stroke.
16
Pointer
ZX215-1004009

NOTE:
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-
ton has reached the top dead center of com-
pression stroke. Turning the engine by one
more turn, the top dead center of compression
stroke of No.1 piston and No.6 piston inter-
changes.
3. When the No.1 piston is at the top dead

center, adjust the valve clearance in a se-
quence marked by the black dot.
Cylinder 1 2 3 4 5 PD 6
INT ● ○ ● ○ ● ○
EXH ● ● ○ ● ○ ○
1) When a feeler gauge is used for such

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

felt.
IO
2) If the feeler gauge moves easily in the
clearance, it is impossible to obtain ac-
curate result.
4. If the measured value is out of specifica-

ZX215-1004007
tion, readjustment shall be performed ac-
cording to the following method.

6.3.2 Adjusting
1. To adjust valve clearance, loosen the lock- Adjustment Screw

nut before adjusting the adjustment screw.
Standard clearance is achieved when re-
sistance to the feeler gauge is felt when Locknut
pulling it out from the clearance.
2. After adjustment, stop the turning motion

of the adjustment screw with a screwdriver,
and tighten the locknut.
Locknut: 16-24 N·m {1.7±2.5 kgf·m}

Valve Clearance ZX215-1004006
3. Go on with the next step until all valve

clearances marked with a black dot have
been adjusted. PD
4. Check the clearances again with the feeler
gauge. Readjustment should be made if
the value is out of specification. Adjustment
Screw
5. When the engine is carried in vehicle, us-

ing to turn the adjustment screw will
make your work easy.
IO
ZX215-1004008

6.4 Compression Pressure - Measure
Service Standard

Each cylinder (at 200
2550kPa {26kgf/cm²} 1960 kPa {20kgf/cm²} Test
Compression rpm)
—
pressure Differential pressure
— Below 390 kPa {4kgf/cm²} Test
between cylinders
Special Tool
Symbol Tool Name and Shape Part Number Application

Compression
pressure gauge
connector Measuring compression
PD MH061460
A pressure
M14×1.5
A
1. Reduction of compression pressure can be

an indication for engine overhaul.
2. Check the compression pressure regularly

and pay attention to its variation from time
IO
to time. In addition, in a new vehicle or
when new parts are installed for replace-
ment, the pressure may be higher due to
running-in of the piston ring, valve seat,
etc. The pressure will become normal as
the parts wear.
3. Before testing, make sure engine oil, start

motor and battery are in normal condition.
4. Set the machine as per the following:
1) Preheat the engine until engine coolant

temperature reaches 75~85°C.
2) Switch off all lamps and auxiliary de-

vices.
3) Place the gear lever in a neutral posi-

tion.

5. Remove the entire fuel injector.
6. Cover the fuel injector mounting opening Rags

with cloth. Injector MTG Hole
7. Activate the start motor in order to run the

engine. Check if the cloth is stained by for-
eign substances.
8. Determine the problem with the engine ac-

cording to the substances (engine oil and/
or coolant) on the cloth.
ZX215-1004005
1) When engine oil is found, it might be

improper sealing caused by piston ring.
Check the piston ring.
the crankcase.
9. Mount the gasket and

PD
2) When engine oil and coolant are found,
it might be cracking of cylinder. Replace
to the fuel in-

CAUTION
When coolant and/or engine oil is found
attached to the cloth, running the engine
may cause the hot coolant and engine oil
jector mounting hole and fix them with the to squirt out through the mounting hole of
injector cap. Install the compression pres- the fuel injector. This is very dangerous.
sure gauge. Never touch or look into the fuel injector
mounting hole when the engine is running.
10. Start the engine and measure the com-
IO
pression pressure of each cylinder. Calcu-
late the differential pressure between the
cylinders.
11. When the compression pressure and the

differential pressure between cylinders de-
viate from their limits, inject a small amount
of engine oil through the fuel injector
mounting hole, and measure the compres-
sion pressure again.
● If the compression pressure is higher,

it is probably due to worn or damaged
piston ring or cylinder inner surface.
● If the compression pressure is still low,

it is probably due to stuck valve or im-
proper seating, or improperly mounted
gasket of cylinder head.

6.5 Fuel Injection Timing - Test and Adjust
Service Standard

— Fuel injection timing (BTDC) 14° — Adjust
Tightening Torque (Unit: N·m)
Symbol Parts Tightened Tightening Torque Remark

— Union nut 24 —
— Lock plate 3.4~4.9 —
— Lock seat - delivery valve 39~44 —
— Nut (used for mounting fuel injection pump) 29~39 —
Special Tool
Symbol Tool Name and Shape
Universal Exten-
sion Rod
PD Part Number Application
Testing and adjusting the

A MH061099
fuel injection timing
14
A
IO
6.5.1 Testing
Injection pipe
1. Remove the injection pipe, lock plate, lock

Lock Seat
seat, retainer ring and delivery valve from
the No.1 cylinder of the fuel injection pump. Retainer Ring
2. After removal of all the parts, install the Spring
lock seat. Delivery Valve Lockplate
NOTE: The removed parts should be put

into light oil in order to keep them free from
dust.
ZX215-1004011

3. Install the prepared injection pipe onto

Injection pipe
No.1 cylinder. Keep the other end of the in-
jection pipe downward so that fuel flowing
out can be observed.
4. Turn the crankshaft manually over 180° in

the forward direction to locate No.1 cylin-
der in a position that is about 30° from the
top dead center of compression stroke.
ZX215-1004012
5. The main pump is used to transfer fuel. As

the fuel flows out of the injection pipe, turn Injection pipe
tion.
PD
the engine manually in the forward direc-
NOTE: The engine positioning lever on the

governor must be placed in the starting
position.
6. When the fuel coming out of the injection

pipe is about to stop, continue to turn the Engine Positioning
Priming pump
engine slowly until the fuel stops coming
IO
Lever ZX215-1004013
out.
7. Make sure that the flywheel mark and

pointer are one degree before the fuel in-
jection timing.
Pointer
ZX215-1004014

NOTE: When the fuel injection timing deviates

from its standard value, the following steps
must be followed for adjustment.
6.5.2 Adjusting
1. Loosen the mounting nuts of fuel injection

pump.
A: 4 nuts (on the flange)
B: 1 nut
A
PD ZX215-1004015
2. Targeted at the pointer, activate the injec-

Injection Pump
tion pump in order to adjust injection tim-
ing.
IO
3. Tighten the nuts to specific torque. Mea-
sure the injection timing again.
Pointer ZX215-1004016

4. When the injection timing is slow, move the

injection pump toward the crankcase (di-
rection C). C
D
5. When the injection timing is fast, move the
injection pump away from the crankcase Injection Pump
(direction D).
ZX215-1004017
6. When injection timing meets the standard Lock Seat

value, install the delivery valve, spring, re-
Injection pipe
tainer ring, lock seat, lock plate and injec-
PD
tion pipe.
7. Tighten all the parts to specific torques.

Lockplate
ZX215-1004018
IO

6.6 Engine Oil Pressure - Measure
Service Standard
Location Service Item Standard Value Limits

— Engine oil pressure at Min. speed, unloaded 145 KPa 49 KPa
— 70~90°C Max. speed, unloaded 295 KPa~490 KPa 195 KPa
Tightening Torque (Unit: N·m)
Symbol Part Tightened Tightening Torque Remark

— Engine oil pressure switch 7.8~12 Engine cold
Lubricant/Sealant
Symbol Location Part Number Amount

— Threads of pressure switch
PD A420300000032 As necessary
1. Remove the engine oil pressure switch.
Engine Oil
IO
Pressure Switch
ZX215-1004019
2. Mount the adaptor to where the engine oil Pressure Gauge

pressure switch has been removed. Mount
the engine oil pressure gauge to the adap-
tor.
Adaptor
ZX215-1004020

3. Preheat the engine until engine oil temper-

ature reaches 70-90°C.
4. Measure respectively the unloaded engine

oil pressure at minimum speed and maxi-
mum speed.
5. If the measured value is lower than the

specified standard value, check the entire
lubrication system.
6. After measuring, apply sealant to the

threads of pressure switch. Tighten the
pressure switch to specific torque.
NOTICE PD
Then engine oil pressure switch must be
installed when the engine is cold.
IO

6.7 Engine Speed Sensor - Adjust
NOTE: Remove the engine speed sensor (1)

before adjusting. Check for presence of metal
chips and for damaged sensor top. Restore
the sensor.
ZXT215-1004001
1. Screw on the sensor (1) until its end con-

PD
tacts with ring gear tip (2) of the flywheel.
1 2
2. Unscrew the sensor some degrees.
Degrees: 1.2~1.4 turns
Adjust the clearance (a) between the

sensor end and the flywheel edge to 2±0.2
mm.
IO
3
a
3. Tighten the sensor (1) with the nut (3).
ZX215-1004021
Nut: 49.0~68.6 N·m {5~7kg·m}
4. Make sure that the engine speed is dis-

played properly on the control panel after
adjustment.

6.8 A/C Compressor Belt Tension - Test and Adjust
6.8.1 Testing Compressor Belt

Pulley
Press the intermediate point of the belt be- A

tween the drive pulley and the compressor pul-
ley 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).
Drive Pulley
ZX215-1004022
6.8.2 Adjusting
NOTE: If the belt deflection is abnormal, adjust
1. Loosen the bolts (1) and (2).

PD
it according to the following procedure.
2. Move the compressor (3) and the bracket

(4) together to adjust belt tension.
1
4
2
3. After positioning the compressor (3), tight-
en the bolts (1) and (2). 3
IO
4. Check belt tension again after adjustment. ZXT215-1004002

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}
NOTE:
● Check each belt for damage. Check the

V-groove and the V-belt for wear. In addi-
tion, it is especially important to keep the
V-belt free from friction with bottom of the
V-groove.
PD
● Contact local Sany dealer and replace the
belt in case of the following conditions.
● The fan belt has been stretched and

little margin is left for adjustment.
● Cuts or cracks are found in the belt.
● Abnormal sliding or noise.

IO
● When a new belt is mounted, readjust the
belt tension after one hour operation.

6.9 Swing Bearing Clearance - Measure
Measuring tool
Symbol Part Number Part Name

H 60033930 Dial gauge
● The following steps are to be followed

when measuring the clearance of swing
bearing.
CAUTION
● Park your machine on a level ground.
Lower your work equipment to the
ground.
undercarriage during measurement.

PD
● Do not put your hands or feet under the
1. Fix the dial gauge (H) to the track frame

and apply the probe to the lower end of the
outer race.
2. Place the work equipment to the maxi-

mum reach position. Raise the bucket to
IO
a height that the bucket tips and the swivel
table bottom are on the same level. H
At the moment, the front of upper structure ZX215-1004023

lowers while the rear rises.
3. Set the dial gauge (H) to zero.
4. Set the arm almost perpendicular to the

ground and lower the boom until the front
track shoe floats.
At the moment, the front of upper structure

rises while the rear lowers.
ZX215-1004024

5. Read the dial gauge (H).
The value indicated by the dial gauge (H)
150～200mm
is the clearance of the bearing.
For more information, see “Swing bearing”

on page 4-12.
ZX215-1004025
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.
PD
IO

6.10 Track Tension - Test and Adjust
6.10.1 Testing
1. Move your machine forward for a distance

3 2
that is equal to the length of track on the
ground. Keep running the engine at low a
idle. Park your machine slowly.
2. Place a straight bar on the track over idler

(1) and carrier roller (2).
1
NOTE: A straight angle steel bar is recom- ZX215-1004026
mended for this purpose as it has good
resistance to bending strain.
3. Measure the maximum clearance (a) be-

PD
tween the upper surface of track and the
lower edge of the straight bar.
● Max. clearance (a): 10~30 mm (0.4~1.2

in)
IO

6.10.2 Adjusting
● If track tension is incorrect, make adjust-

ment as per the following instruction.
CAUTION
● Do not loosen the valve over one turn.
If the valve is loosened too much, the
grease under high pressure may cause
the valve to eject.
1. Reduce track tension
1) Loosen the valve (1) to discharge

grease. Tighten the valve after dis-
charging.
PD
2) Check the track tension again as per
the above method after adjustment.
2. Increase track tension 2

1
1) Add grease through the grease fitting ZXT215-1004003
(2) with a grease gun.
2) Check the track tension again as per

IO
the above method after adjustment.
NOTE: Add grease until the gap (b) be-

tween the idler guide and the track frame
end becomes zero. If the tension is till low,
it indicates that the pins and bushings are
seriously worn. Replace the pins and bush-
ings, or remove a piece of track shoe.
b
ZX215-1004027

6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust
Testing and adjusting tools

60038932 Hydraulic Tester
—
B210770000084 Adaptor
NOTE: The hydraulic pressure in work equip-

ment, swing and travel (hydraulic pump out-
put) circuits can be viewed on the monitor.
6.11.1 Measuring
CAUTION
● Lower the work equipment to the PD
ground and stop the engine. Operate
the control levers for several times to
release the residual pressure in hydrau-
lic circuits.
● Open the butterfly nut on the breather

valve and press the relief button to re-
lease pressure in the hydraulic tank.
IO
1. Preparatory work before measuring
1) Remove the plug (1) and plug (2) for

measuring the hydraulic pressure.
2
● Plug (1): For oil circuit of rear pump
1
● Plug (2): For oil circuit of front pump
2) Install the priming adaptor and connect

it to the hydraulic tester.
ZX215-1004028
● Use an oil pressure gauge with a ca-
pacity of 40 MPa {408 kgf/cm²}.
3) Start the engine and keep it running

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

2. Measurement of unloading pressure
1) Start the engine.
2) Measure the hydraulic pressure when

the engine is running at high idle and
all control levers are in a neutral posi-
tion.
NOTE: The hydraulic pressure indicat-

ed is the pressure when the unloading
valve unloads.
3. Measurement of work equipment pres-

sure at relief
1) Start the engine and move the cylinder

PD
to be measured to its stroke end.

the cylinder is in relief condition.
NOTE: The hydraulic pressure indi-

cated is the pressure when the main
relief valve is in relief condition.
IO
4. Measurement of swing pressure at relief
1) Start the engine. Reach out the work

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

the swing circuit is in relief condition.
NOTE: The hydraulic pressure indi-

cated is the pressure when the swing
motor relief valve is in relief condition.
NOTE: The relief pressure of swing

motor is lower than the main relief pres-
sure.

5. Measurement of travel pressure at relief
1) Start the engine and lock the travel

mechanism.
NOTE: Place the pin (1) between the

sprocket and the track frame to lock the
travel mechanism.

1
the travel circuit is in relief condition.
NOTE: The hydraulic pressure indi- ZXT215-1004004
cated is the pressure when the main

relief valve is in relief condition. When
the travel circuit is in relief condition,
PD
the pressure indicated is always the
pressure at high relief.
6.11.2 Adjusting
NOTE: The boom relief valve cannot be ad-

justed.
1. Adjustment of main relief pressure

IO
NOTE: If the high relief pressure is abnor- 3
mal, adjust the high pressure setting of the
main relief valve (3) as per the following.
1) Disconnect the pilot hose.

ZXT225-1104002
2) Loosen the locknut (4). Turn the adjust-

ment screw (5) to adjust the pressure.
Pressure rises as the screw turns right.

4
Pressure drops as the screw turns left.
Each turn of the screw equals about:

12.5 MPa {128 kgf/cm²}
5
Locknut: ZX215-1004029
53.5±4.9 N·m {5.5±0.5 kgf·m}

3) Check the pressure again after adjust-

ment. Measure the pressure according
to the procedure described above.
● Connect the pilot hose before measur-

ing 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.
2. Adjustment of swing relief pressure
NOTE: If the swing relief pressure is ab-

normal, adjust the swing motor relief valve
(6) as per the following.
PD
1) Loosen the locknut (7). Turn the adjust-
ment screw (8) to adjust the pressure.
Pressure rises as the screw turns right.

Pressure drops as the screw turns left.
Each turn of the screw equals about:

IO
6.71 MPa { 68.4 kgf/cm²}
8
Locknut: 6 7
ZXT225-1104003
78-103 N·m{8.0-10.5 kgf·m}
2) Check the pressure again after adjust-

ment. Measure the pressure according 7
to the procedure described above.
8
ZX215-1004030

6.12 Control Circuit Oil Pressure - Test and Adjust
Testing and adjusting tools

—
B210770000084 Adaptor
6.12.1 Testing
CAUTION
● Lower the work equipment to the
the control levers for several times to
lic circuits.
PD

1. Remove the plug (1) for measuring the hy-

draulic pressure.
IO
2. Install the priming adaptor and connect it
to the hydraulic tester.
Use an oil pressure gauge with a capacity

of 6 MPa{61 kgf/cm²}
1
3. Start the engine and keep it running until
the hydraulic pressure rises to a point with-
in the operational range.
2
4. Measure oil pressure when the engine is ZXT215-1004007
running at high idle and all control levers
are in a neutral position.

6.12.2 Adjusting
1. If the measurement is less than 3.5 kgf/

cm², loosen the retaining nut (2) and screw 3 2
in adjusting stud (3). Watch the change
of readings on the pressure gauge at the
same time. Tighten the retaining nut (2)
when proper pressure value is achieved.
2. Remove all the tools after measurement

and make sure the machine returns to its
ZX215-1004031
normal condition.
PD
IO

6.13 Solenoid Valve Output Pressure - Measure
Measuring tools

—
B210770000084 Adaptor
NOTE: Make sure that the initial pressure of

control oil circuit is normal before measuring
the output pressure of solenoid valve.
CAUTION
the control levers for several times to PD
lic circuits.

1. Disconnect the hose of solenoid valve to

measure the pressure at the outlet.
IO
No. Solenoid Valves to be Measured
1 Solenoid valve - high/low travel speed
2 Solenoid valve - swing priority
Solenoid valve - bucket confluence/difflu- A
3
ence
4 Solenoid valve - boom priority
5 Solenoid valve - pilot lockout
2. Install a tee to location (A) on each sole-

noid valve and connect the hose.
1 2 3 4 5
ZXT225-1104004
3. Mount the adaptor onto the tee and con-
nect it to the hydraulic tester.
Use a hydraulic tester with a capacity of 6

MPa{61 kgf/cm²} .

4. Start the engine and keep it running un-

til the hydraulic oil temperature rises to a
5. Run the engine at full speed. Operate the

control levers to open or close each sole-
noid 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

following values, the solenoid valve is
normal.
High speed travel
Solenoid Valve
OFF (de-energize)
ON (energize)
Output Pressure
0 {0}
PD
3.9~4.1 MPa{39~41 kgf/cm²}
Swing priority
Solenoid Valve Output Pressure

OFF (de-energize) 0 {0}
IO
ON (energize) 3.0~3.9 MPa{30~39 kgf/cm²}
6. Remove all measuring tools after measure-

ment. Make sure that the machine returns
to its normal condition.
Table of functioning state - pilot lock solenoid

valve
Functioning State Function

Lock OFF
Lockout control
Free ON

6.14 Pilot Valve Output Pressure - Measure
Measuring tools

—
B210770000084 Adaptor
NOTE: Make sure that the initial pressure of

control oil circuit is normal before measuring
the output pressure of pilot valve.
1. Remove the pilot pressure switch.
Oil Circuit Oil Circuit

No. No. PD
Measured Measured
1 Travel left 7 Bucket DUMP
2 Travel right 8 Arm IN
3 Arm OUT 9 Swing
4 Bucket DIG
5 Boom DOWN
1
6 Boom UP
4 3 2
6 5
2. Install the adaptor and connect it to the hy- 8 7
9
IO
draulic tester. ZXT225-1104005
Use a hydraulic tester with a capacity of 6

MPa {61kgf/cm²}
3. Start the engine and keep it running un-

til the hydraulic oil temperature rises to a
4. Measure the output pressure when the en-

gine is running at high idle and all control
levers of the tested circuit are in neutral
position or at full stroke.

NOTE: When the measured output pres-

sure reads the following values, the pilot
valve is normal.
Control Lever Hydraulic Pressure

Neutral 0{0}
Close to the average initial pres-
Full stroke sure of oil control circuit
(See Table of Standard Values)
5. Remove all measuring tools after measure-

ment. Make sure that the machine returns
to its normal condition.
PD
IO

6.15 Pilot Valves (Work Equipment and Swing) - Adjust
● If the play of work equipment or swing con- 2

trol lever is excessive, make adjustment as
per the following procedure.
3
1. Remove the work equipment and swing pi-
lot valve assembly.
1
2. Remove the rubber sleeve (1).
3. Loosen the locknut (2). Screw on the disc

(3) until it contacts with the four heads of 4
plunger (4).
NOTE: Do not move the plunger.
nut (2) to specified torque.
Locknut:
PD
4. When the disc (3) is fixed, tighten the lock-
ZX215-1004032
98~127 N·m {10~13 kgf·m}
5. Install the rubber sleeve (1).

IO
6. Install the work equipment and swing pilot
valve assembly.

6.16 Work Equipment Hydraulic Drift - Test
NOTE: If hydraulic drift exists in the work

equipment cylinder, check it according to the
following procedure and determine whether
the failure lies in the cylinder seal or in the
control valve.
1. Boom and bucket cylinders
1) Park your machine in an attitude as

shown and stop the engine.
NOTE: Load the bucket fully with earth

or impose rated load on the bucket.
PD
2) Operate the control levers so that the
boom is in the raising position and the
bucket in the digging position.
ZX215-1004033
● If the lowering speed rises, the prob-

lem lies in the cylinder seal. If nothing
changes, the problem lies in the control
IO
valve.
● Operate the control levers with engine

start switch in the ON position.
● If the pressure in accumulator drops,

charge the accumulator again by run-
ning the engine for about 10 seconds.

2. Arm cylinder
1) Park your machine in an attitude as

shown. The distance between the arm
cylinder and the digging stroke end is
100 mm. Stop the engine.
2) Operate the control levers in order to

place the arm in the digging position.
ZX215-1004034
● If the lowering speed rises, it is failure
of the cylinder seal. If nothing changes,
it is failure of the control valve.

PD
[Reference]
If hydraulic drift is caused by failure of the

cylinder seal, the reason for lowering speed
increase during the above operation is de-
scribed below:
IO
1) If the machine is set in the above position
(where the holding pressure is applied to
the bottom side), the oil leaks from the bot-
tom side to the head side. The pressure in
the head side is increased.
2) As the pressure in the head side de-

creases, the pressure in the bottom side
increases in order to keep it balanced.
This process is repeated until balance is
reached at a certain level depending on
the amount of leakage.

3) When the pressure is balanced, the lower-

ing speed decreases. If the control levers
are operated according to the above proce-
dure, the oil circuit in the head side opens
to the drain circuit (while the bottom side is
closed by a check valve), and the oil flows
to the drain circuit from the head side. As a
result, the lowering speed increases.
3. Checking the pilot valve
While the pressure in the accumulator is

high, set the hydraulic lockout control in
the LOCKED/FREE position and measure
the hydraulic drift respectively.

PD

● If there is a difference in hydraulic drift

between the LOCKED position and the
FREE position, it the failure (internal
fault) of the pilot valve.
IO

6.17 Residual Pressure in Hydraulic Circuit - Release
CAUTION
● Release the residual pressure in the hy-
draulic circuit before disconnecting the
lines between the hydraulic cylinders
or between the hydraulic motor and the
control valve.
NOTE: Even if the swing motor circuit and

the travel motor circuit are free from re-
sidual pressure, they will be influenced by
the internal pressure of hydraulic tank. The
breather valve must therefore be opened
to release pressure prior to such operation.
PD
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.
IO
● The pilot lock valve must be energized.
Operate the control levers with the en-
gine start switch in the ON position.
● The pressure in accumulator will be

released after the control levers have
been operated 2 or 3 times.
3. Start the engine and keep the engine run-

ning at low idle for about 10 seconds in
order to increase the pressure in accumu-
lator. Stop the engine.
4. Repeat the above step 2 through step 3

several times.

6.18 Oil Leakage - Measure
1. Measure oil leakage from boom cylinder
1) Start the engine and keep it running un-

1
til the hydraulic oil temperature is within
the operational range. Fully extend the
boom cylinder.
NOTE: Release the residual pressure

in the circuits.
See “Residual Pressure in Hydraulic

Circuit - Release” on page 6-39.
ZXT215-1004010
2) Disconnect the hose (1) on the cylinder

head side and plug the hose end with a
PD
cap.
NOTE: Be careful not to disconnect the

hose on the cylinder bottom side.
3) Start the engine and apply relief pres-

sure to the bottom side of the cylinder
while the engine is running at high idle.
IO
4) Hold this condition for 30 seconds.
Measure oil leakage for one minute.
5) Make sure that the machine returns to

its normal condition after measurement.

2. Measure oil leakage from arm cylinder

2
arm cylinder.

in the circuits.

ZXT225-1104007
2) Disconnect the hose (2) on the cylinder

cap.
PD


IO

3. Measure oil leakage from bucket cylin-

der

bucket cylinder.

in the circuits.

2) Disconnect the hose (3) on the cylinder 3

cap. PD
ZXT225-1104008


IO

4. Measure oil leakage from swing motor
1) Fully extend the work equipment. Lower

the bucket on the ground and raise the
machine slightly. Secure machine from
rotating clockwise or counter clockwise
while testing. Stop the engine.
2) Disconnect the hose (4) and the hose

(5). Plug the hose ends with caps.
3) Start the engine and apply relief pres- 5

sure to the bottom side of the swing 4
motor while the engine is running at
high idle. Measure oil leakage under
this condition.
PD
● Hold the condition described in step 3)
for 30 seconds. Measure oil leakage for
one minute.
● After the first measurement, turn the

ZXT225-1104006
upper structure 180°and measure the

leakage again in the same way.

IO

5. Measure oil leakage from travel motor
1) Remove the cover of the travel motor.
2) Start the engine and lock the travel

mechanism.
NOTE: Insert pin (1) between the

sprocket and the track frame to lock the
travel mechanism.
1
ZXT215-1004004
3) Disconnect the drain hose (6) of the

PD
travel motor. Plug the hose end with a
cap.

sure to the bottom side of the travel
motor while the engine is running at
high idle. Measure oil leakage under
this condition.
6
WARNIN G
IO
ZXT215-1004014
● During measurement, mis-operation of
the control levers can cause serious ac-
cidents. Make sure that all signals are
given correctly.
● Hold the condition described in step 4)

for 30 seconds. Measure oil leakage for
one minute.
● Rotate the motor slightly. Change the

positions of the valve plate and the
travel motor and of the cylinder and pis-
ton. Repeat the measurement several
times.


6.19 Air in Each Component - Bleed
Air bleeding procedures

Air bleeding item
1 2 3 4 5 6
Bleed air Bleed Bleed air Bleed air
Contents of work Starting Starting
from hydrau- air from from swing form travel
engine operation
lic pump cylinder motor motor
● Replacing hydraulic oil

○ ○ ○ ○ ○ ○
● Cleaning filter element
(Note) (Note)
● Replacing return filter element ○ ○
● Repairing/replacing hydraulic pump
○ ○ ○ ○
● Removing suction piping
● Repairing/replacing control valve ○ ○ ○
● Replacing cylinder
○ ○ ○
● Removing cylinder piping PD
● Replacing swing motor
○ ○ ○
● Removing swing motor piping
● Replacing travel motor
○ ○ ○
● Removing travel motor piping
NOTE: Bleed air from the swing motor and

travel motor only when the oil in the motor
cases is drained.
IO
1. Bleed air from hydraulic pump
1) Loosen the air bleeder (1) and check

that oil oozes out through the air bleed-
er.
1
2) Tighten the air bleeder (1) if oil is seen.
Bleeder:
7.8~9.8 N·m{0.8~1.0 kgf·m}
NOTE: Run the engine at low idle for

10 minutes after bleeding the air ac- ZXT215-1004015
cording to the above procedure.

2. Bleed air from hydraulic cylinder

running at low idle for 5 minutes.
2) Raise or lower the boom 4 or 5 times

with the engine running at low idle.
NOTE: Be careful not to apply relief

pressure. Stop the piston when the rod
is about 100 mm before stroke end.
3) Repeat step 2) with the engine running

at high idle.
4) While running the engine at low idle,

move the piston rod to the stroke end
PD
and apply relief pressure.
5) Bleed air from arm cylinder and bucket

cylinder by performing step 2) through
step 4).
NOTE: When a new cylinder is installed

for replacement, bleed the air from the
new cylinder before mounting it to the
work equipment. Especially the boom
IO
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
bled from the boom cylinder before it is
mounted to the work equipment.
3. Bleed air from swing motor
1) Start the engine and run the engine at

low idle.
2) Bleed air from the swing motor by turn-

ing the upper structure slowly.

4. Bleed air from travel motor
1) Start the engine and run the engine at

low idle.
2) Loosen the bleeder (2) and check that

oil oozes out through the air bleeder.
3) Tighten the air bleeder (2) if oil is seen.
Bleeder:
2
27.5~35.3 N·m{2.8~3.6 kgf·m}
ZXT215-1004016
PD
IO

Table of monitored items
Monitored Item Unit Remark
Controller Mode Selection Graph

High/Low Travel Speed Selection Graph
Auto Idle Selection Graph
Engine Speed r / min
Pressure - Front pump Kg
Pressure - Rear pump Kg
Current - Proportional Valve (Solenoid, Front pump) mA
Current - Proportional Valve (Solenoid, Rear pump) mA
Pilot Pressure - Boom Raise Kg
Pilot Pressure - Boom Lower PD Kg
Pilot Pressure - Arm In Kg
Pilot Pressure - Arm Out Kg
Pilot Pressure - Bucket Curl Kg
Pilot Pressure - Bucket Dump Kg
Pilot Pressure - Swing Kg
Pilot Pressure - Travel Left Kg
Pilot Pressure - Travel Right
IO
Kg
Bucket Confluence ON / OFF
Solenoid
Swing Priority ON / OFF
Valve 1
Hi/Lo Speed Switching ON / OFF
Voltage - Fuel Control Dial V
Voltage - Motor Position V
Temperature - Engine Coolant °C Gauge reading
Temperature - Hydraulic oil °C Gauge reading
Pressure - Engine Oil KPa

E
G
PPDA
A IONK
BL

E
PPDAG
IOK
AN
BL

SY195-205-215C9 Crawler Hydraulic Excavator Troubleshooting
Troubleshooting
7 Troubleshooting
7.1 Points to Remember When Troubleshooting ........................................................... 7-3
7.2 Troubleshooting Procedures .................................................................................... 7-5
PD
7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-8
7.4 Failure Symptoms and Troubleshooting Codes ..................................................... 7-26
7.5 Troubleshooting with an Event Code ..................................................................... 7-28
7.6 Troubleshooting of Electrical System (E - Mode)................................................... 7-63
7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode) ...................... 7-93
IO

Troubleshooting SY195-205-215C9 Crawler Hydraulic Excavator
PD
IO
WARNING
jury or death.

7 TROUBLESHOOTING
7.1 Points to Remember When Troubleshooting
● Stop the machine in a level ground, and check that lock pins, blocks, and parking brake are
securely fitted.
● 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.
PD
● 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 first. When installing measuring equipment, be sure to
connect it properly.
The aim of troubleshooting is to pinpoint the ● It will become impossible to find the
basic cause of the failure, to carry out repairs cause of the failure.
swiftly, and to prevent reoccurrence of the fail-
ure. It will also cause a waste of man-hours,
IO
parts, or oil or grease, and at the same
When carrying out troubleshooting, important time, will also lose the confidence of the
point is to understand the structure and func- user or operator.
tion.
For this reason, when carrying out
However, a short cut to effective troubleshoot- troubleshooting, it is necessary to carry out
ing is to ask the operator various questions thorough prior investigation and to carry
to form some idea of possible causes of the out troubleshooting in accordance with the
failure that would produce the reported symp- fixed procedure.
toms.
2. Points to ask user or operator:
1. When carrying out troubleshooting, do not
hurry to disassemble the components. 1) Have any other problems occurred apart
from the problem that has been reported?
If components are disassembled immedi-
ately any failure occurs: 2) Was there anything strange about the
machine before the failure occurred?
● Parts that have no connection with the
failure or other unnecessary parts will 3) Did the failure occur suddenly, or were
be disassembled. there problems with the machine condition

before this? NOTE: When operating the machine to

reenact the troubleshooting symptoms, do
4) Under what conditions did the failure oc- not carry out any investigation or measure-
cur? ment that may make the problem worse.
5) Had any repairs been carried out before 5. Troubleshooting

the failure? When were these repairs car-
ried out? ● Use the results of the investigation and
inspection in Items 2 – 4 to narrow down
6) Has the same kind of failure occurred be- the causes of failure, then use the trouble-
fore? shooting flowchart to locate the position of
the failure exactly.
3. Check before troubleshooting
● The basic procedure for troubleshooting is
1) Check the oil level. as follows.
2) Check for any external leakage of oil from

PD 1) Start from the simple points.
the piping or hydraulic equipment.
2) Start from the most likely points.
3) Check the travel of the control levers.
3) Investigate other related parts or informa-
4) Check the stroke of the control valve spool. tion.
5) Other maintenance items can be checked 6. Measures to remove root cause of failure
externally, so check any item that is con-
sidered to be necessary. ● Even if the failure is repaired, if the root
cause of the failure is not repaired, the
IO
4. Confirming failure same failure will occur again. To prevent
this, always investigate why the problem
● Confirm the extent of the failure yourself, occurred. Then, remove the root cause.
and judge whether to handle it as a real
failure or as a problem with the method of
operation, etc.

7.2 Troubleshooting Procedures
If some phenomenon occurs on a machine that looks like a failure, identify the corresponding
troubleshooting 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.
1. Read related technical manuals in detail. d. What kind of trouble did machine have
Have a knowledge of related system, before?
principle of operation, and structure,
function and technical specification of For example: Which parts have been
parts. repaired or replaced?
2. Ask operator e. What has been done after troubles take

place and how about the reaction?
failure.
PD
Before checking, ask related person, i.e.
the operator for all information about the
a. Current working condition of machine

f. Will the trouble reoccur? Does the trou-
ble occur regularly?
3. Check before starting

(Whether machine is operated prop-
erly). Before starting troubleshooting, check
the operator's records on operation,
b. When troubles are found and what kind maintenance and service of the machine.
of operation does machine perform at Understand whether related personnel has
IO
that time? done wrong in operation, maintenance and
service. Check for wrong operation and
c. Development of troubles (Whether maintenance at the same time.
troubles are becoming severer or occur
for the first time.)

Item Criterion Remedy
1. Check fuel level and type of fuel — Add fuel

2. Check for impurities in fuel — Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level — Add oil

4. Check hydraulic oil strainer — Clean, drain
5. Check swing drive oil level — Add oil
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
—
mechanical Electrical equipment
1. Check for looseness, corrosion of battery terminal and

— Tighten or replace
wiring
2. Check for looseness, corrosion of alternator terminal
PD —
Tighten or replace
and wiring
3. Check for looseness, corrosion of start motor terminal
Tighten or replace
and wiring
equipment
Hydraulic,
1. Check for abnormal noise and smell — Repair

2. Check for oil leakage — Repair
3. Bleeding air — Bleed air
1. Check battery voltage (with engine stopped) 20-30V Replace

Electrics, electrical equipment
2. Check electrolyte level — Add or replace

IO
3. Check for discolored, burnt, exposed wiring — Replace
4. Check for missing wiring clips and hanging wiring — Repair
5. Check for wet wires (esp. wet connectors or terminals) — Disconnect con-
6. Check for blown or corroded fuses nector and dry
7. Check alternator voltage (with engine speed at middle —
or higher) After running for Replace
8. Check operating sound of battery relay (when start several minutes: Replace
switch is turned ON or OFF) 27.5~ 29.5V Replace
—

4. Operate machine by yourself (trial run) ● Failure codes may not indicate machine
trouble. Temporary electrical failure can oc-
Confirming that the third item above is cur in controller memory, such as low bat-
normal, run startup check on the machine tery output voltage, or open circuit in switch
to determine the cause of failure. If the or sensor. Therefore, make repeated trials
failure cannot be determined, turn off the to erase the accumulated failure codes
engine and get more information from the from the controller memory and confirm
operator. whether the failure codes are displayed af-
ter repeated trials. That is to say, "reoccur-
5. Perform troubleshooting rence" of this trouble is possible.
Conduct deep analysis and determine the 6. Find out possible causes
cause of trouble according to the symp-
toms of the machine and the information Before making a conclusion, check the
displayed on the monitor. most possible causes again and try to de-
termine the root causes of troubles. Make
Remark: PD a feasible repair scheme according to your
conclusion.
● Never disconnect harness and hydraulic
lines when the engine is running. Oil and
water under high pressure and high tem-
perature may squirt and cause personal
injuries. Shut off then engine when discon-
necting the harness and hydraulic lines.
IO

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
T-107 Terminal 1 Alternator (B terminal) K-6 L-5
T-108 Terminal 1 Preheating fuse (21#) M-2 G-9
T-109 Terminal 1 Preheating fuse (17#) M-2 G-9
T-110
T-111
T-112
T-115
Terminal
Terminal
Terminal
Terminal
1
1
1
PD
Body grounding
Body grounding
Preheating resistance wire
terminal
Starting motor grounding
M-1
K-6
J-7
J-6
B-1
H-9
L-3
Body grounding (at the sides
T-119 Terminal 1 M-1 B-9
of battery)
T-201 Terminal 1 Body grounding X-6
T-202 Terminal 1 Body grounding X-6
IO
K5 R 5 Horn relay X-6 H-9
K6 R 5 Lamp relay X-6 I-9
K8 R 5 Top lamp relay X-6 J-9
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

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
CN-112M A 2 Washing motor K-5 K-4
CN-102M A 2 Platform lamp E-5 K-2
CN-104M
CN-105M
CN-113M
CN-101M
A
A
S
2
2
1
PD
Boom lamp (left)
Boom lamp (right)
Hydraulic oil temperature
sensor
Fuel level sensor
E-7
E-7
I-7
F-6
K-1
K-2
F-9
F-9
CN-152M A 2 Intermediate connector W-6 F-8
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
IO
CN-115M DF 3 Main pressure sensor (front) I-7 F-4
CN-116M DF 3 Main pressure sensor (rear) I-7 F-4
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-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

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
Bucket Confluence solenoid
CN-134F AMP 2 J-6 F-3
valve
Boom priority solenoid valve
CN-132F AMP 2 J-6 F-3
1 PD
CN-136F AMP 2 Pilot solenoid valve J-6 L-2
Hi/Lo speed travel solenoid
CN-131F AMP 2 J-6 F-1
valve
CN-133F AMP 2 Swing priority solenoid valve J-6 F-4
F-108 W 1 Coolant temperature sensor J-7 F-8
F-104 W 1 Horn (right) I-5 K-2
F-103 W 1 Horn (left) I-5 K-2
CN-616F AMP 81 Controller W-6 A-4
IO
CN-615F AMP 40 Controller W-6 A-9
CN-800M S 2 Alternator terminal L/R K-6
CN-7-707 AMP 2 Cigarette lighter P-4
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
PD
IO

7.3.1 Connector location layout
CN-105M CN-104M CN-101M
5
PD
CN-102M
Z
IO
4
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
CN-112M
CN-124M
F-104
F-103
PD CN-125M
CN-126M
CN-128M
IO
CN-127M
CN-123M
CN-122M
CN-121M
T-108 T-109
CN-120M T-101
CN-131F T-102
CN-132F
KB
CN-133F
CN-134F T-104
CN-135F T-103
CN-136F
T-110
T-119
Z ZX215-1005034
G H I J K L M

CN-307M CN-306M CN-132F
9 CN-305M
CN-304M
CN-303M
CN-104M
8 CN-302
CN-131M
CN-301M
6
PD
5
CN-7-705
IO
4
3 CN-7-707
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
CN-615F
CN-616F
PD CN-412F
KH
IO
CN-204F
PF021
CN-207F
CN-107M
CN-106F
ZX215-1005036
T U V W X Y Z

PD
IO

CN-1-002M
8
CN-1-005
CN-1-001M
7
CN-1-103M
6
PD
5
CN-1-004M
IO
4
CN-1-110
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 120Ω 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
32
33
Fuel control knob voltage 34
7 35
36
37
38
39
40
41
s GND
s GND
s PWR
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
00
00
50
CAN-
PD 28
70
X-1
X-2
59 CAN+
60
61
62
CN-132F
63
5
(D-12)
64 1
65 2
1
33 X-3
2
66 3 3 24 X-4
67 4 4 25 X-5
68 5 5
69
37 X-6
70 12 12
IO
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
4 CAN- 78
79
23 X-11
80
81
X-12
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
24V power supply 119
1 35 H 1 2 3 4 5
42
24V power 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
M
CN-161F 3
X-2 (S-16)
35H 4 4
1 1 7
3 3
4 4
5 5 35 L
6 6 5 5
X-3
X-4
X-5
X-6
X-7
X-8
X-9
7
8
7
8
PD CN-112M
(A-2)
1
2
Washer motor
1
2
0
37 M
6
X-10
Right top lamp
X-11
1 1
0
71
5
X-12 2 2
X-13 Left top lamp

1 0
1
X-14 71
IO
2 2
CN-150M
(S-8) F-104
R+
1 1
R+
(W-1)
R- R- Horn
L+
2
3
2
3 L+ 1 1 4
CN-661F
L- 4 4 L-
(S-12)
0
5 5 0 32 F-103
3 3
71
6 6
71
34 (W-1)
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
31 21
32
33
34
35 13 X-4
36
37
7 38
39
40 X-5
41 18
42
43
44
45 X-6
5V power supply
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
00
00
50
PD 22
12
606
X-7
X-8
X-9
62 X-10
63 50
64
65
5 66 507 X-11
67
68 X-12
69 MT+
70
71 X-13
72 00 00
73 50
5V power supply74 X-14
MT-
IO
50
5V power supply75
76
77 F16 CN-221M
78
79 1 1
4 80
81
CN-615F
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
24V power 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 64
10 10
18
X-5
7
X-6 22
X-7 12
X-8
X-9
X-10
X-11
X-12
0
606
50
507
MT-
PD 12 a
14
10
47
0
1
2
3
4
6
CN-613F
1
2
3
4
6
12a
14
10
47
S
L Safety relay
R
P
0
6
X-13 00
5
X-14 MT+ 10
14 R
21 L
47 B
P
E
0
IO
Generator
Body ground
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 B B Left travel pilot
32 200 C C
pressure sensor
33 CN-123M
34 (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)
41
50 A A
42 PD 0 B B
Bucket curl pilot
43 205 C C
pressure sensor
44
45 CN-127M
(DF-3)
46 50 A
47 0
A
Oil pressure switch 48 B B Bucket dump pilot
6 Travel sensor (left) 49

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

Swing sensor 68 (DF-3)
Bucket curl sensor 69 50 A A
Boom raise sensor 70 0 B B
Arm out
Arm in sensor 71 202 pressure sensor
IO
C C
Front pump main pressure sensor 72
CN-115M
5V power supply GND 73 (DF-3)
5V power supply GND 74
5V power supply GND 75
50 A A
76 0 B B
Front pump
77 501 C C
pressure sensor
4 78
79
CN-116M
(DF-3)
80 50 A A
81 0 B B
Rear pump
CN-615F 502 C C
pressure sensor
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
24V power supply 119 CN-131F
1 24V power supply 120

121 24V power 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 )
7222-1424-40
PD 7123-1424-40 (No. of pin: 2)
IO
7222-7464-40 7123-7464-40 (No. of pin: 6)
7222-7484-40 7123-7484-40 (No. of pin: 8)
7222-7564-40 7123-7564-40 (No. of pin: 16)

7.3.6 A/AMP type connector
Male (Plug) Female (socket)
Part No.: 282104-1 Part No.: 282080-1 (No. of pin: 2)
282105-1
PD 282087-1 (No. of pin: 3)
IO
174354-2 174352-2 (No. of pin: 2)
1473252-1 1473255-1 (No. of pin: 40)
1473244-1 1473247-1 (No. of pin: 81)

7.3.7 DT type connector
Housing (Plug) Housing (socket)
A
A B B
C C
DT06-3S DT04-3P (No. of pin: 3)
1 6 PD 6 1
2 5 5 2
3 4 4 3
8 5 8
5
IO
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
time to start up the engine)
5 Engine misfires. E-1 S-2
6 Color of exhaust gas is too dark.(Incomplete combustion) S-3
7
8
9
Engine pickup is poor.
Engine runs rough or is unstable.
PD
Engine is short of output, or lacks power
10 Auto Idle fails.
E-2
E-4
H-2
H-5
S-4
S-5
S-6
Excessive engine oil consumption, or color of exhaust gas

11 S-7
is blue
12 Premature engine oil contamination S-8
13 Excessive fuel consumption S-9
IO
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
16 Abnormal noises are heard S-12
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
35 Travel speed cannot be shifted H-17
36 Track shoe does not move (only on one side) H-18
37 Machine does not swing
39
PD Swing-related failure
38 Swing acceleration is poor, or swing speed is slow

Upper structure overruns remarkably when stopping
swinging
H-19
H-20
H-21
40 Large shock is made when stopping swinging H-22

41 Large sound is made when stopping swinging H-23
42 Hydraulic drift of swing is large H-24
Monitor panel-related failure
IO
43 Monitor display is blank. E-11
44 Monitor displays nothing. E-12
45 Engine coolant temperature reading is incorrect. E-14
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
E322 (abnormality in arm-in pilot pressure)............................................................................... 7-40
E323 (abnormality in arm-out pilot pressure) ............................................................................ 7-41
E324 (abnormality in boom-raise pilot pressure) ...................................................................... 7-42
PD
E325 (abnormality in boom-lower pilot pressure) ...................................................................... 7-43
E326 (abnormality in bucket-curl pilot pressure) ....................................................................... 7-44
E327 (abnormality in bucket-dump pilot pressure) .................................................................... 7-45
E328 (abnormality in swing pilot pressure ................................................................................. 7-46
E329 (abnormality in left travel pilot pressure) ......................................................................... 7-47
E330 (abnormality in right travel pilot pressure) ........................................................................ 7-48
E231 (abnormality in fuel control dial set voltage) ..................................................................... 7-49
E237 (abnormality in hydraulic oil temperature) ........................................................................ 7-50
E541 (abnormality in engine speed) .......................................................................................... 7-51
IO
E450 (abnormality (a) in front pump proportional solenoid coil current) .................................... 7-52
E450 (abnormality (b) in front pump proportional solenoid coil current) .................................... 7-53
E451 (abnormality (a) in rear pump proportional solenoid coil current)..................................... 7-54
E451 (abnormality (B) in rear pump proportional solenoid coil current) .................................... 7-55
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

Information in troubleshooting table
User Code Service Code

Trouble Title of failure shown in failure history
Display on monitor —
Failure description
Failure is described on the monitor display.
When failure is detected, the controller has taken action to protect the affected
Response from controller
system or equipment.
Symptom of machine Symptom that is shown on the machine due to action of controller.
Cause Standard value in normal state and remarks on troubleshooting

Possible causes and standard value in normal state
2 <Inclusion>
● Standard value under normal condition can be used to judge pos-
3 PD sible causes
Possible causes ● Reference for passing the above "Good" or "No Good" judgement
4
of trouble (Given
<Symptom of Wiring Harness Failure>
numbers are ref-
● Open circuit
erence numbers,
Faulty contact with connector or open circuit in wiring harness
which do not indi-
cate priority)
5 ● Faulty grounding
An ungrounded wiring is grounded.
IO
● Short circuit
A wiring has mistaken contact with a 24 V electric circuit.
Related circuit diagram
This is part of the circuit diagram which shows the portion where the failure occurred.
● Connector No.: A connector number Indicates a connector.
● Arrow: An arrow roughly indicates the installing location.

E111 (controller memory failure (FROM))

Trouble Controller memory fails and the system slows down.
E111 11
When the power is on, abnormality is detected by checking through FROM sum-
Failure description
mation and RAM verification.
Response from controller Stop the operation of motor and solenoid coil.
Symptom of machine Engine acceleration fails and the machine acts slowly. .
Cause Standard value in normal state/Remarks on troubleshooting

Possible causes and standard value in
1 Internal failure No troubleshooting can be done for failure occurs in the inner of controller. (If
of controller this failure occurs, replace the controller.)
2
normal state
5
PD
IO

E212 (throttle motor current & motor connection abnormal)
User Code Service Code Throttle motor loading circuit is abnormal and the
Trouble
E212 12 engine acceleration fails.
When the power is on, magnitude of throttle motor coil current is out of the
Failure description
range of 0.1A~1.8A and lasts for 2 seconds.
Response from controller The controller stops the motor driving system when this failure is detected.
Symptom of machine Engine acceleration fails and the machine acts slowly.

● Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of throt-
1 form troubleshooting.
tle motor coil
Between CN-445M ③ and ⑥ Resistance 12.2 Ω
2 Open circuit of form troubleshooting.
3
harness
Short circuit
of harness
PD
Unplug the controller and measure the resistance
between pin 113 and pin 105.
form troubleshooting.
Unplug the connector CN-445M and measure the
resistance between motor ③ ( ⑥ ) and the hous-
Resistance 12.2 Ω
Resistance ≥2M Ω
(grounded)
ing.
No troubleshooting can be done for failure occurs in the inner of controller.
Internal failure
4 (Except for the above reasons, the controller must be replaced in case of
of controller
failure.)
IO
5
CONTROLLER
CN-445M THROTTLE MOTOR
50# GREEN
SENSOR 5V 75 1 1
507# WHITE
THRTL FEEDBACK VOLT. 55 2 2
MT- 3 RED
MT- 113 3 M
4 4
GND WIRE 55
0#
5 5 YELLOW
MT+ 105
MT+ BLUE
6 6
CAB CHASSIS HARNESS
ZX215-1005071

E213 (throttle motor operation suspends)
User Code Service Code Operation of throttle motor suspends and engine
Trouble
E213 13 acceleration fails.
The controller monitoring accuracy deviates by over 5%, which is normally
Failure description
between 0.8 - 4.2 Voltage, after the system is powered on for 30 seconds.
Response from controller The controller stops the motor driving system when this failure is detected.

Failure of throttle
motor coil Between CN-445M ③ and ⑥ Resistance 12.2 Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
Failure of 5V
2 perform troubleshooting.
power supply Between CN-445M ① and ⑤ Voltage About 5V
3
Open circuit of
harness
Failure of throttle
PD
Resistance 12.2 Ω
position sensor Between CN-445M ② and ground Voltage 0.8V~3.5V
Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to per-
5 of harness Unplug the connector CN-445M and measure the
Resistance ≥2M Ω
IO
(grounded) resistance between motor ③ ( ⑥ ) and the housing.
Internal failure of
controller
failure.)
CONTROLLER
50# GREEN
SENSOR 5V 75 1 1
507# WHITE
MT- 3 RED
MT- 113 3 M
4 4
GND WIRE 55
0#
5 5 YELLOW
MT+ 105
MT+ BLUE
6 6

E214 (throttle motor working range abnormal)
User Code Service Code Throttle motor working range is abnormal and the
Trouble
E214 14 engine returns to auto idle.
The voltage is below 0.8V at the minimal stroke or above 4.2V at the maximal
Failure description
stroke, and it lasts for 100msec when the power is on.
Response from controller Turn the throttle to idle speed.
Symptom of machine Engine returns to auto idle.

Failure of throt-
tle motor coil Between CN-445M ③ and ⑥ Resistance 12.2 Ω

Failure of 5V
power supply Between CN-445M ① and ⑤ Voltage About 5V
3
Open circuit of
harness
Failure of
PD
Resistance 12.2 Ω
4 throttle position perform troubleshooting.
sensor Between CN-445M ② and ground Voltage 0.8V—3.5V
Short circuit form troubleshooting.
5 of harness Unplug the connector CN-445M and measure the
IO
(grounded) resistance between motor ③ ( ⑥ ) and the hous- Resistance ≥2M Ω
ing.
Internal failure
of controller
failure.)
CONTROLLER
50# GREEN
SENSOR 5V 75 1 1
507# WHITE
MT- 3 RED
MT- 113 3 M
4 4
GND WIRE 55
0#
5 5 YELLOW
MT+ 105
MT+ BLUE
6 6
CAB CHASSIS HARNESS
ZX215-1005071

E015 (power supply voltage abnormal)

Trouble Power supply voltage is abnormal.
15 E015
Failure description Voltage of power supply is above 36V when the machine is running.
Response from controller The system stops the motor and solenoid valve automatically.

Failure of ● Turn engine start switch to OFF position. Keep it at OFF position to perform
1 power sup- troubleshooting.
ply Measure battery voltage Voltage ≤25V
● Turn engine start switch to OFF position. And Then, keep the engine running
normal state
Alternator to perform troubleshooting.

2 Measure the voltage between the alternator terminal
abnormal Voltage About 28V
B and ground. PD
3
CN-613 SAFETY RELAY

START SWITCH 1
L S
TERMINAL B BR ACC R1 R2 C 2
3 R
IO
HEAT 4
E P
OFF 5
ON 6
START
1 2 F-107
CN-800M
G
R
L P
B E
0
ALTERNATOR
- + - +
BATTERY RELAY
0
CAB CHASSIS HARNESS
ZX215-1005072

E116 (controller internal temperature abnormal)
User Code Service Code Internal temperature of controller is abnormal. Engine

Trouble
E116 16 acceleration fails and the machine acts slowly.
Internal temperature of controller keeps above 80°C or below -30°C for 10 sec-
Failure description
onds when the power is on.
Response from controller The controller stops the motor and the solenoid coil.

Possible causes and standard value in nor-
Internal
No troubleshooting can be done for failure occurs in the inner of controller. (If this
1 failure of
failure occurs, replace the controller.)
controller
2
mal state
4
PD
5
IO

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

Trouble Abnormal output of power supply in sensor
E017 17
The controller detects out over current or short circuit of sensor power source
Failure description
output when the power is on.
Response from controller Only output alarm is enabled.
Symptom of machine —

Possible causes and standard value in normal
Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to perform
troubleshooting.
1 in harness Measure the resistance between pin 56, pin 75, pin 74 of
(grounded) controller KC-MB and the ground. Resistance ≥2M Ω
Internal
No troubleshooting can be done for failure occurs in the inner of controller. (Except
2 failure of
for the above reasons, the controller must be replaced in case of failure.)
PD
state
controller
5
IO

E118 (abnormal communication between controller and monitor)
User Code Service Code Abnormal communication between controller and

Trouble
E118 18 monitor
Communication of monitor is interrupted for 5 consecutive times when the
Failure description
power is on.

Failure of CAN
resistance Between CN-7-709 ① and ② Resistance 60 Ω
Open circuit of Unplug the controller and measure the resistance
2 PD ≤1 Ω
state
harness between pin 60 and CN-7-705 ③

Resistance
≤1 Ω
between pin 78 and CN-7-705 ④
Internal failure
of controller
failure.)
CN-7-709
IO
CANH
1 1
120Ω RESISTANCE
2 2
CANL
CONTROLLER CN-7-705
CANH 3 3 3
MONITOR
CANL 4 4 4
29 8 8 8
22
CANH 60 CN-1-111 9 9 9
0 10 10 10
1 1
CN-441 2 2 12 12 12
CANL 78 3 3 3 3
1 1 F1 20A
22
F10 5A
29
20
21
PWR PWR
CAB CHASSIS HARNESS
ZX215-1005073

E320 (abnormality in front pump output pressure)
User Code Service Code Front pump output pressure is abnormal. Only output
Trouble
E320 20 alarm is enabled. .
A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec
Failure description
when the power is on.

Failure of 5V form troubleshooting.
1
power supply Between CN-115M A and B Voltage About 5V
Open circuit of form troubleshooting.
2
3
Short circuit
of signal wire
(grounded)
● Turn engine
PD
signal wire Between CN-115M C and pin 72 of controller
Between CN-115M B and ground
start switch
to OFF position.
Between CN-115M C and ground

Keep
Resistance
it at OFF
Resistance
≤1 Ω
≤1 Ω
position to per-
≥2M Ω
Failure of sen-
sor Between CN-115M C and ground Voltage 0.5±0.2V
5
IO
CONTROLLER CN-115 FRONT PUMP
PRESS. SENSOR
501#
FRONT PUMP PRESSUSRE 72 C SIGNAL
SIGNAL COLLECTING PORT
00#
54 B GND WIRE
GND WIRE
50#
5V PWR SUPPLY 56 A 5V
CAB CHASSIS HARNESS
ZX215-1005074

E321 (abnormality in rear pump output pressure)
User Code Service Code Reading of rear pump output pressure is abnormal.
Trouble
E321 21 Only output alarm is enabled. .
Failure description


Failure of 5V
2 Between CN-116M C and pin 53 of controller ≤1 Ω
signal wire PD Resistance
Between CN-116M B and ground ≤1 Ω
3 of signal wire form troubleshooting.
(grounded) Between CN-116M C and ground Resistance ≥2M Ω
● Turn engine start switch to OFF position. Then, keep it at OFF position to
Failure of sen-
5
IO
CONTROLLER CN-116 REAR PUMP
PRESS. SENSOR
REAR PUMP PRESSURE
502#
53 C SIGNAL
SIGNAL COLLECT PORT
00#
GND WIRE 54 B GND WIRE
50#
CAB CHASSIS HARNESS
ZX215-1005075

E322 (abnormality in arm-in pilot pressure)
User Code Service Code Arm-in pilot pressure is abnormal. Only output alarm
Trouble
E322 22 is enabled. .
Failure description
Symptom of machine The arm in motion is slow.


Failure of 5V
Open circuit form troubleshooting.
of signal wire PD Resistance
Failure of
sensor Between CN-128M C and ground Voltage 0.5±0.2V
5
IO
CONTROLLER CN-128M ARM-IN PILOT
PRESS. SENSOR
203#
ARM-IN PILOT PRESSURE 71 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005076

E323 (abnormality in arm-out pilot pressure)
User Code Service Code Reading of arm-out pilot pressure is abnormal. Only
Trouble
E323 23 output alarm is enabled.
A pressure feedback voltage other than 0.25 – 4.75V keeps more than
Failure description
200msec when the power is on.
Symptom of machine Arm-out motion is slow.


Failure of 5V
● Turn engine start switch to OFF position. Keep it at OFF position to perform
Open circuit troubleshooting.
3 of signal wire troubleshooting.
Failure of sen-
5
IO
CONTROLLER CN-122M ARM-OUT PILOT
PRESS. SENSOR
ARM-OUT PILOT PRESSURE
202#
52 C SIGNAL
00#
54 B GND WIRE
GND WIRE
50#
CAB CHASSIS HARNESS
ZX215-1005077

E324 (abnormality in boom-raise pilot pressure)
User Code Service Code Reading of boom-raise pilot pressure is abnormal.

Trouble
Failure description
Symptom of machine Boom-raise motion is slow.


Failure of 5V
2 Between CN-126M C and 70 pin of controller ≤1 Ω
Failure of
5
IO
CONTROLLER CN-126M BOOM-RAISE PILOT
PRESS. SENSOR
BOOM-RAISE PILOT PRESS. 206#
70 C SIGNAL
00#
54 B GND WIRE
GND WIRE
50#
56 A 5V
5V PWR SUPPLY
CAB CHASSIS HARNESS
ZX215-1005078

E325 (abnormality in boom-lower pilot pressure)
User Code Service Code Reading of boom-lower pilot pressure is abnormal.

Trouble
Failure description
Symptom of machine Boom-lower motion is slow.


Failure of 5V
Failure of
5
IO
CONTROLLER CN-125M BOOM-LOWER PILOT
PRESSURE SENSOR
207#
BOOM-LOWER PILOT PRESS 51 C SIGNAL
00#
50# 5V
5V PWR SUPPLY 56 A
CAB CHASSIS HARNESS
ZX215-1005079

E326 (abnormality in bucket-curl pilot pressure)
User Code Service Code Reading of bucket-curl pilot pressure is abnormal.

Trouble
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200msec
Failure description
Symptom of machine Bucket-curl motion is low.


Failure of 5V
Open circuit of troubleshooting.
2 Between CN-124M C and 69 pin of controller ≤1 Ω
Failure of sen-
5
IO
CONTROLLER CN-124M BUCKET-DIG PILOT
PRESSURE SENSOR
205#
BUCKET-DIG PILOT PRESS.
69 C SIGNAL
00#
54 B GND WIRE
GND WIRE
50#
CAB CHASSIS HARNESS
ZX215-1005080

E327 (abnormality in bucket-dump pilot pressure)
User Code Service Code Reading of Bucket-dump pilot pressure is abnormal.

Trouble
A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200msec
Failure description
Symptom of machine Bucket-dump motion is low


Failure of 5V
Failure of sen-
5
IO
CONTROLLER BUCKET-DUMP PILOT
CN-128M
PRESSURE SENSOR
204#
BUCKET-DUMP PILOT PRESS.
50 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005081

E328 (abnormality in swing pilot pressure
User Code Service Code Reading of swing pilot pressure is abnormal. Only
Trouble
E328 28 output alarm is enabled. .
Failure description
Symptom of machine Swinging motion is slow.


Failure of 5V
Failure of sen-
5
IO
CONTROLLER CN-123M SWING PILOT
PRESS. SENSOR
208#
SWING PILOT PRESSURE
68 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005082

E329 (abnormality in left travel pilot pressure)
User Code Service Code Reading of left travel pilot pressure is abnormal.
Trouble
Failure description
Symptom of machine Left travel speed is low. Travel deviates.


Failure of 5V
2 Between CN-120M C and pin 49 of controller
PD ≤1 Ω
signal wire Resistance
Failure of sen-
sor
Between CN-120M C and ground Voltage 0.5±0.2V
5
IO
CONTROLLER CN-120M L. TRAVEL PILOT
PRESS. SENSOR
L. TRAVEL PILOT PRESSURE
200#
49 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005083

E330 (abnormality in right travel pilot pressure)
User Code Service Code Reading of right travel pilot pressure is abnormal.
Trouble
Failure description
Symptom of machine Right travel speed is low. Travel deviates.


Failure of 5V
Failure of sen-
5
IO
CONTROLLER CN-121M R. TRAVEL PILOT
PRESS. SENSOR
201#
R. TRAVEL PILOT PRESSURE 67 C SIGNAL
00#
50#
CAB CHASSIS HARNESS
ZX215-1005084

E231 (abnormality in fuel control dial set voltage)
User Code Service Code Voltage setting of fuel control dial is abnormal. En-
Trouble
E231 31 gine returns to auto idle.
The voltage of fuel control dial other than 0.25 – 4.75V keeps more than
Failure description
Response from controller The throttle is switched to idle position.
Symptom of machine Engine returns to auto idle speed.


Failure of 5V
power supply Between CN-302F ① and ③ Voltage About 5V
2 Open circuit
of signal wire Between CN-302F ② and pin 34 of controller Resistance ≤1 Ω
4
Short circuit
of signal wire
(grounded)
Short circuit
of signal wire
PD
Between CN-302F ② and ground Resistance ≥2M Ω
perform troubleshooting.
(contact with Between CN-302F ② and ground Voltage ≤5V
power supply)
5 Defective form troubleshooting.
Unplug the connector CN-302F, and measure the
IO
knob Resistance 5K±15% Ω
resistance between dial ① and ③
CN-142M CN-131M CN-302F

50# YELLOW
1 1 1 1
SENSOR 5V 75
506# BLUE FUEL CTRL
2 2 2 2
DIAL
55 RED
GND WIRE 3 3 0# 3 3
FUEL CONTROL DIAL

SET VOLTAGE
34
CAB
ZX215-1005085

E237 (abnormality in hydraulic oil temperature)
User Code Service Code Hydraulic oil temperature is abnormal. Only output
Trouble
E237 37 alarm is enabled.
A voltage other than 0.2 – 4.75V, transformed from hydraulic oil temperature
Failure description
that is detected by controller, keeps more than 200msec.
Only output alarm is enabled. The alarm resets automatically when conditions
become normal.

Failure of sen-
sor Between CN-113M ① and ground Voltage 0.2~4.75V
Open circuit of
PD
wire harness Between CN-113M ① and pin 31 of controller Resistance ≤1 Ω
state
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
3 wire harness form troubleshooting.
(grounded) Between CN-113M ① and ground Resistance ≥1M Ω
● Turn engine start switch to OFF position. Keep it at ON position to perform
Failure of 24V
4 troubleshooting.
power supply Between CN-113M ② and ground Voltage About 24V
5
IO
CN-152M
0#
1 1
CONTROLLER 240Ω
2 2
HYDRAULIC OIL
CN-113M TEMP SENSOR
HYDRAULIC OIL SIGNAL
TEMP SENSOR 31 1 1
2 2 24V PWR
SUPPLY
24V PWR SUPPLY
CAB CHASSIS HARNESS
ZX215-1005086

E541 (abnormality in engine speed)
User Code Service Code Engine speed is abnormal. Only output alarm is en-
Trouble
41 E541 abled.
Failure description CPU detects out that engine speed is too low (below 100 rpm).
Only output alarm is enabled. The alarm resets automatically when conditions
become normal.

● Code 41 will be displayed on the monitor when engine start switch is

Normal condi-
1 turned from the OFF position to the ON position. This is normal as the en-
tion
gine is not started.
2 Between CN-448M ① and pin 38 of controller ≤1 Ω
wire harness PD Resistance
Between CN-448M ② and pin 19 of controller ≤1 Ω
(grounded) Between CN-448M ① and ground Resistance ≥1M Ω
Failure of sen- form troubleshooting.
4 Unplug the connector CN-448M, and measure the
sor Resistance 2.3±0.2k Ω
resistance between the speed sensors's ① and ② .
5
IO
CONTROLLER
CN-448M ENGINE SPEED SENSOR
108A
ENGINE SPEED
1 SIGNAL
38
PROBING
108B
GND WIRE 19 2 GND WIRE
CAB CHASSIS HARNESS
ZX215-1005087

E450 (abnormality (a) in front pump proportional solenoid coil current)
User Code Service Code Front pump proportional solenoid coil current is ab-
Trouble
E450 50 normal. The system operates slowly.
Abnormality occurs in loaded circuit of proportional solenoid coil. Current above
Failure description
1.8A lasts for 1 second. Differential current occurs in drive protection loop.
Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.
Symptom of machine System operates slowly.

1 Between CN-113F ① and pin 88 of controller ≤1 Ω
wire harness Resistance
Between CN-113F ② and ground ≤1 Ω
PD
(grounded) Between CN-113F ① and wire 0# Resistance ≥1M Ω
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
3 portional valve Unplug the connector CN-113F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ②
Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
5
IO
CONTROLLER
SOLENOID VALVE
CN-113F (FRONT PUMP)
FRONT PUMP 702#
SOLENOID VALVE 88 1 SIGNAL
SIGNAL OUTPUT PORT
0#
CAB CHASSIS HARNESS
ZX215-1005088

E450 (abnormality (b) in front pump proportional solenoid coil current)
User Code Service Code Front pump proportional solenoid coil current is ab-
Trouble
Failure description
0.1 A lasts for 1 second. Differential current occurs in drive protection loop.

2
3
wire harness
(grounded)
PD
Between CN-113F ① and wire 0# Resistance ≥1M Ω
portional valve Unplug the connector CN-113F, and measure the
resistance between solenoid valve's ① and ② .
Failure of con-
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-113F (FRONT PUMP)
FRONT PUMP 702#
SIGNAL OUTPUT PORT
0#
CAB CHASSIS HARNESS
ZX215-1005088

E451 (abnormality (a) in rear pump proportional solenoid coil current)
User Code Service Code Rear pump proportional solenoid coil current is ab-
Trouble
Failure description

PD
resistance between solenoid valve's ① and ② .
Failure of con-
troller
failure.)
5
IO
CONTROLLER
SOLENOID VALVE
CN-114F (REAR PUMP)
REAR PUMP
702#
SIGNAL OUTPUT PORT
0#
CAB CHASSIS HARNESS
ZX215-1005089

E451 (abnormality (B) in rear pump proportional solenoid coil current)
User Code Service Code Rear pump proportional solenoid coil current is abnor-
Trouble
E451 51 mal. The system operates slowly.
Failure description

PD
Failure of con-
troller
failure.)
5
IO
CONTROLLER
SOLENOID VALVE
CN-114F (REAR PUMP)
REAR PUMP
702#
SIGNAL OUTPUT PORT
0#
CAB CHASSIS HARNESS
ZX215-1005089

E452 (abnormality (A) in swing priority proportional solenoid coil current)
User Code Service Code Current through the proportional solenoid coil for
Trouble
E452 52 swing priority is abnormal.
Failure description
Operation of solenoid coil is stopped when failure is detected. Power supply
must be restored.

PD
Failure of con-
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-133F (SWING PRIORITY)
SWING PRIORITY 608#
88 1 SIGNAL
SOLENOID VALVE
SIGNAL OUTPUT PORT
0#
CAB CHASSIS HARNESS
ZX215-1005090

E452 (abnormality (B) in swing priority proportional solenoid coil current)
Trouble
E452 52 swing priority is abnormal.
Failure description
must be restored.

PD
Failure of con-
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-133F (SWING PRIORITY)
SWING PRIORITY 608#
88 1 SIGNAL
SOLENOID VALVE
SIGNAL OUTPUT PORT
0#
CAB CHASSIS HARNESS
ZX215-1005090

E453 (abnormality (A) in bucket confluence proportional solenoid coil current)
User Code Service Code Current through the proportional solenoid coil for bucket
Trouble
E453 53 confluence is abnormal. Motion of bucket is slow.
Failure description
must be restored.
Symptom of machine Motion of bucket is slow.

1 Between CN-134F ① and 99 pin of controller ≤1 Ω
PD
Failure of con-
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-134F (BUCKET CONFLUENCE)
BUCKET CONFLUENCE 604#
SIGNAL OUTPUT PORT
0#
CAB CHASSIS HARNESS
ZX215-1005091

E453 (abnormality (B) in bucket confluence proportional solenoid coil current)
User Code Service Code Current through the proportional solenoid coil for bucket
Trouble
E453 53 confluence is abnormal. Motion of bucket is slow.
Failure description
must be restored.
Symptom of machine Motion of bucket is slow.

PD
Failure of con-
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-134F (BUCKET CONFLUENCE)
BUCKET CONFLUENCE 604#
SIGNAL OUTPUT PORT
0#
CAB CHASSIS HARNESS
ZX215-1005091

E455 (abnormality (A) in boom priority 2 proportional solenoid coil current)
Trouble
E455 55 boom priority is abnormal.
Failure description
must be restored.

PD
Failure of con-
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-135F (BOOM PRIORITY 2 )
BOOM PRIORITY 2 603#
SIGNAL OUTPUT PORT
GND WIRE 0#
55 2 GND WIRE
CAB CHASSIS HARNESS
ZX215-1005093

E455 (abnormality (B) in boom priority 2 proportional solenoid coil current)
Trouble
E455 55 boom priority is abnormal.
Failure description
must be restored.

PD
Failure of con-
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-135F (BOOM PRIORITY 2 )
BOOM PRIORITY 2 603#
SIGNAL OUTPUT PORT
GND WIRE 0#
55 2 GND WIRE
CAB CHASSIS HARNESS
ZX215-1005093

E460 (abnormality in dual speed travel solenoid valve)
User Code Service Code Connection of the solenoid coil for dual speed travel is
Trouble
60 E460 abnormal. High speed travel is not functioning.
Failure description Abnormality, open circuit or short circuit occurs in the proportional solenoid coil.
Symptom of machine High speed travel is not functioning.

(grounded)
PD
Between CN-132F ① and wire 0# Resistance ≥1M Ω
Failure of con-
troller
failure.)
5
IO
CONTROLLER
SOLENOID VALVE
CN-132F (DUAL-SPEED TRAVEL)
DUAL SPEED TRAVEL 602#
SIGNAL OUTPUT PORT
0#
CAB CHASSIS HARNESS

7.6 Troubleshooting of Electrical System (E - Mode)
Information in troubleshooting table .......................................................................................... 7-64

E-1 Engine does not start ......................................................................................................... 7-65
E-2 Engine runs rough or is unstable ....................................................................................... 7-67
E-3 Power supply of machine cannot be cut off ....................................................................... 7-68
E-4 Auto idle not functioning ..................................................................................................... 7-70
E-5 Preheating function fails..................................................................................................... 7-71
E-6 Work equipment does not work ......................................................................................... 7-72
E-7 Boom-raise speed or power is low ...................................................................................... 7-73
E-8 Arm speed or power is low ................................................................................................. 7-74
E-9 Bucket speed or power is low ............................................................................................ 7-75
E-10 Travel speed or power is low ........................................................................................... 7-77
E-11 Blank monitor display ....................................................................................................... 7-78
E-12 Monitor displays nothing .................................................................................................. 7-79
E-13 Dual speed travel not functioning..................................................................................... 7-80
PD
E-14 Incorrect engine coolant reading...................................................................................... 7-81
E-15 Incorrect fuel level reading ................................................................................................ 7-82
E-16 Wiper does not work ........................................................................................................ 7-83
E-17 Incorrect arm-in pilot pressure reading ............................................................................ 7-84
E-18 Incorrect arm-out pilot pressure reading .......................................................................... 7-85
E-19 Incorrect boom-raise pilot pressure reading .................................................................... 7-86
E-20 Incorrect boom-lower pilot pressure reading.................................................................... 7-87
E-21 Incorrect bucket-curl pilot pressure reading ..................................................................... 7-88
E-22 Incorrect bucket-dump pilot pressure reading.................................................................. 7-89
IO
E-23 Incorrect swing pilot pressure reading ............................................................................. 7-90
E-24 Incorrect left travel pilot pressure reading ........................................................................ 7-91
E-25 Incorrect right travel pilot pressure reading...................................................................... 7-92

Information in troubleshooting table
● The following information is contained in the troubleshooting table and related electric circuit
diagrams. Fully understand these information before carrying out troubleshooting.
Trouble Trouble which occurs on the machine

Related information Information related to detected trouble or troubleshooting
Cause Standard value in normal state and remarks on troubleshooting

4 PD
Possible causes of
< Description >
trouble (Given num-
bers are reference
● Standard value in normal state, which is used to judge possible
numbers, which do
causes that might be OK or N/G.
not indicate priority)
● A reference value is used to determine OK or N/G.
5
IO
Related circuit diagram
This is part of the circuit diagram which shows the portion where the failure occurred.
● Connector No.: A connector number Indicates a connector.
● Arrow: An arrow roughly indicates the installing location.

E-1 Engine does not start
Trouble Engine cannot be started.

Related information

● Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
Low battery
1 bleshooting.
capacity Battery voltage Voltage ≥24V
Internal fail- ● Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
2 ure of start bleshooting.
switch OFF position: between wire 22# and wire 11# Resistance ≥1M Ω
● Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
Failure of bleshooting.
3
pilot switch Lockout lever FREE position: between 105 # and 27# wire ≤1 Ω
Resistance
Lockout lever LOCKED position: between wire 105# and 27# ≥1 M Ω
PD
● Turn engine start switch to OFF position. Keep the engine running during trouble-
shooting. (When all power supplies, grounding, signal and engine inputs are nor-
mal except engine output, it is the failure of start motor)
4 Failure of Engine start motor Start switch Voltage
start motor Power supply: Terminal B and ground 20~30V
Start
Between engine input terminal S and ground 20~30V
● Turn engine start switch to OFF position. Then, keep it at OFF position to perform
5 of wire har- Wire 21# and start motor terminal B ≤1 Ω
IO
ness Wire 12# and start relay terminal SW Resistance ≤1 Ω
Start relay terminal L and safety relay terminal S ≤1 Ω
Failure of
6 Battery terminal "+" (wire 20#) and control dial wire 22# Resistance ≤1 Ω
fuse F1
Short cir- ● Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
cuit of wire bleshooting.
7
harness Start relay terminal SW and ground ≥1 M Ω
Resistance
(grounded) Engine input terminal S and ground ≥1 M Ω
Internal ● Turn engine start switch to OFF position. Then, keep it at ON position to perform
8 failure of troubleshooting.
alternator Alternator terminal P and ground Voltage ≤1V
● Turn engine start switch to OFF position. Move it to START position when per-
forming troubleshooting.
9 Start relay Terminal SW and ground App. 24V
Voltage
Terminal S and ground App. 24V
● Turn engine start switch to OFF position. Then, keep it at ON position to perform
Failure of troubleshooting.
10 ≤1 Ω
parking unit Between CN-801F 2 and 3
Resistance
Unplug connector CN-801F; measure resistance of motor coil. App 63 Ω

START SWITCH
TERMINAL B BR ACC R1 R2 C
F1 20A 22 HEAT
20 OFF
CN-241F 21
F2 5A 10 ON
BATTERY (D-12)
START
20 22 22 13 11
1 1
10
2 2
9 9
12 12
BATTERY RELAY
21
PILOT SWITCH
1 2 3 4 5
1 2 3 4 5
F16 10A 105
0
LOCK RELAY
PD 0
1
1
2
2
3 4 5
3 4 5
22 PARK RELAY
CN-661F PARK MOTOR
(S-16)
64
CN-801F 64 A
10 10
9 9
63 (H-6) 22
65
B
P1
6 6 65 63
CN-161F 1 2 3 4 5
1 1
P2
E
(S-16)
2 2
IO
0
10 10 1 2 3 4 5 0
15 15
13 3 3
6 6
12a
12
14
HLR CHARGE 47
CN-613F
4
3
2
1
INDICATOR
(L-6)
4 47
3 10
2 14
1
21
12a
10
10
12a
47
14
10
SW
R
P
S
L
R
P
B
L
B
0
S
E
E
0
START RELAY SAFETY RELAY ZX215-1005095

START MOTOR ALTERNATOR

E-2 Engine runs rough or is unstable
Trouble Engine Runs Rough or Is Unstable

Related information Engine speed can be read on the monitor.

1 Unplug the connector controller, and measure
wire harness Resistance 2.3±0.2 K Ω
the resistance between pin 19 and pin 38.
Internal failure
in sensor Between CN-448M A and B Resistance 2.3±0.2 K Ω
(grounded) Between CN-448M B and ground Resistance ≥1M Ω
Internal failure No troubleshooting can be done due to internal failure. (Failure lies in the con-
PD
4
of controller troller if the reasons above are ruled out)
CONTROLLER
CN-448M
IO
（S-2） SPEED SENSOR
SPEED SENSOR 38 A SIGNAL
INPUT SIGNAL
GND 19 B GND
CAB CHASSIS HARNESS
ZX215-1005096

E-3 Power supply of machine cannot be cut off
Trouble Engine cannot be stopped.

Engine stalls when start switch it turned to OFF position. There is no time
Related information
delay for power cutout.

When engine start switch is operated, if the operation of battery
Failure of bat-
1 relay contact is heard, the battery is normal. Turn the start switch
tery relay
OFF→ON→OFF.
Breakdown of form troubleshooting.
2
surge diode Between battery relay wire 20# and wire 21# Resistance ≥1M Ω
4
PD
5
IO

START SWITCH
F1 20A 22 HEAT
20 OFF
CN-241F 21
F2 5A 10 ON
BATTERY (D-12)
START
20 22 22 13 11
1 1
10
2 2
9 9
12 12
BATTERY RELAY
21
PILOT SWITCH
1 2 3 4 5
1 2 3 4 5
F16 10A 105
0
LOCK RELAY
PD 0
1
1
2
2
3 4 5
3 4 5
22 PARK RELAY
CN-661F PARK MOTOR
(S-16)
64
CN-801F 64 A
10 10
9 9
63 (H-6) 22
65
B
P1
6 6 65 63
CN-161F 1 2 3 4 5
1 1
P2
E
(S-16)
IO
0 2 2
10 10 1 2 3 4 5 0
15 15
13 3 3
6 6
12a
12
14
HLR CHARGE 47
CN-613F
4
3
2
1
INDICATOR
(L-6)
4 47
3 10
2 14
1
21
12a
10
10
12a
47
14
10
SW
R
P
S
L
R
P
B
L
B
0
S
E
E
0
START RELAY SAFETY RELAY ZX215-1005095

START MOTOR ALTERNATOR

E-4 Auto idle not functioning
Trouble Auto idle speed do not work

Engine speed do not decrease wen the mode is auto idle speed and grip keeps
Related information
still in "NEUTRAL" position

● Turn engine start switch to OFF position. Start the engine and keep it
Error of boom- running to perform troubleshooting.
1 Levers in NEUTRAL, pressure signal transmitted 0 KG
raise signal Pressure
Lever in operation, pressure signal transmitted 0~39 KG
Error of boom- running to perform troubleshooting.
lower signal
Pressure
Error of arm-in running to perform troubleshooting.
PD
signal
Pressure

Error of arm-out running to perform troubleshooting.
signal
Pressure
Error of bucket- running to perform troubleshooting.
curl signal
Pressure
IO
Error of Bucket- running to perform troubleshooting.
6
dump signal Levers in NEUTRAL, pressure signal transmitted 0 KG
Pressure
Error of swing running to perform troubleshooting.
signal
Pressure
running to perform troubleshooting.
8 Error of travel Levers in NEUTRAL, pressure signal transmitted 0 KG
signal Pressure
Error of attach- running to perform troubleshooting.
ment signal
Pressure
Failure of con- No troubleshooting can be done for it is internal failure. (If it is not caused by
10
troller one of the factors listed above, it should be the failure of controller.)

E-5 Preheating function fails
Trouble Engine does not preheat.

Related information

Failure of pre-
1 troubleshooting.
heat fuse Between wire 21# and preheat relay pin 3# (contact) Resistance ≤1 Ω
When the preheating function is activated, if operation of the preheat relay
Failure of pre-
2 contact is heard, the relay is normal. The preheat switch is to be switched
heat relay
OFF→ON→OFF.
troubleshooting.
Failure of pre- Turn off the preheat switch and measure the resistance
3 ≥1M Ω
heat switch between wire 16# and wire 18#. Resistance
Turn on the preheat switch and measure the resistance
PD ≤1 Ω
between wire 16# and wire 18#
of wire har- troubleshooting.
4
ness (ground- Between preheat relay pin 3# (contact) and ground Resistance ≥1M Ω
ed)
5
START SWITCH
IO
HEAT
OFF
ON
BATTERY 20 CN-241F START

22 13 16
_ _ (D-12)
+ + 22
1 1
20 F1 20A 22
9 9 16
BATTERY RELAY
1 2 3 45
PREHEAT PREHEAT RELAY
1 2 3 45
21 21
F13 160A
SWITCH CN-131M CN-142M
0
1 2 345
(D-12) (D-12) 1 2 345
18 GR-1 GLOW PLUG
7 7 6 6 17
PREHEATER
CHASSIS HARNESS CAB CHASSIS HARNESS
ZX215-1005097

E-6 Work equipment does not work
Trouble The machine is motionless while operated after starting.

Related information

running to perform troubleshooting.
Failure of lockout Item Lockout control lever Resistance
1
switch LOCK ≤1 Ω
Between wire 105# and wire 27#
FREE ≥1M Ω
state

(grounded) Between 105# and ground Resistance ≥1M Ω
Failure of coil ● Turn engine start switch to OFF position. Keep it at OFF position to per-
3 inside lockout form troubleshooting.
solenoid valve Between CN-136F 1 and 2
PD Resistance About 34 Ω
CN-106F PILOT SWITCH

（AMP-2）
F16 10A
21 27 27 105
B- 2 2
1 1
CN-161F
IO
(S-16)
2 2
10 10
12 12
0 105 27 606 CN-661F CN-136F
1 2 3 45 （S-16）（AMP-2）
1 2 3 45
1 1 1 1
8 8 2 2
PILOT SOLENOID VALVE
CAB CHASSIS HARNESS
ZX215-1005098

E-7 Boom-raise speed or power is low
Trouble Boom-raise speed or power is low.

Pilot pressure of the boom in operation can be
Related information
checked on the monitor.

● Turn engine start switch to OFF position. Start the engine and keep it run-
Failure of sen- ning to perform troubleshooting.
1 Levers in NEUTRAL, boom-raise pressure signal 0 KG
sor Pressure
Lever in operation, boom-raise pressure signal 0~39 KG
mal state
Short circuit
troubleshooting.
2 of harness Between harness ( from controller pin 70 to CN-126M
(grounded) Resistance ≥1M Ω
A) and ground
Open circuit of PD
3 troubleshooting.
harness Between controller pin 54 and CN-126M B Resistance ≤1 Ω
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the con-
4
troller troller if the reasons above are ruled out)
CONTROLLER
CN-126M BOOM UP
（DF-3） PRESS. SENSOR
BOOM UP 70 A
PRESSURE SENSOR SIGNAL
IO
54 B GND WIRE
SENSOR GND WIRE
SENSOR 5V 56 C 5V
CAB CHASSIS HARNESS
ZX215-1005099

E-8 Arm speed or power is low
Trouble Arm speed or power is low during operation.

Related information Pilot pressure of the arm in operation can be checked on the monitor.

ning to perform troubleshooting.

Failure of sen- Levers in NEUTRAL, arm-in and arm-out pressure
1 0 KG
sor signals
Pressure
Levers in operation, arm-in and dump pressure
0~39 KG
signal
Short circuit
Between harness (from controller pin 71 to CN-
2 of harness
128M A) and ground
(grounded) Resistance ≥1M Ω
Between harness (from controller pin 52 to CN-
PD
122M A) and ground
3 Between controller pin 54 and CN-128M B
harness Resistance ≤1 Ω
Between controller pin 54 and CN-122M B
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the
4
troller controller if the reasons above are ruled out)
ARM-OUT
IO
CN-122M
A SIGNAL
B GND WIRE
C 5V
CONTROLLER
ARM-OUT ARM-IN
CN-128M
PRESS SENSOR 52 （DF-3） PRESS. SENSOR
ARM-IN
PRESS SENSOR 71 A SIGNAL
SENSOR GND WIRE 54 B GND WIRE
SENOSR 5V 56 C 5V
CAB CHASSIS HARNESS
ZX215-1005119

E-9 Bucket speed or power is low
Trouble Bucket speed or power is low during operation.

Related information Pilot pressure of the bucket can be checked on the monitor.

● Turn engine start switch to OFF position. Start the engine and keep it running
Failure of to perform troubleshooting.
1 Levers in NEUTRAL, bucket-curl/dump pressure signals 0 KG

sensor Pressure
Levers in operation, bucket-curl/dump pressure signals 0~39 KG
troubleshooting.
Short circuit Between harness (from controller pin 69 to CN-124M A)
2 of harness and ground
(grounded) Between harness (from controller pin 50 to CN-127M A) Resistance ≥1M Ω
and ground PD
3 Between controller pin 54 and CN-124M B
of harness Resistance ≤1 Ω
Between controller pin 54 and CN-127M B
Defective ● Turn engine start switch to OFF position. Keep it at OFF position to perform
bucket troubleshooting.
4 confluence About
solenoid Between CN-134F 1 and 2 Resistance
17.5 Ω
valve
Failure of No troubleshooting can be done due to internal failure. (Failure lies in the control-
5
IO
controller ler if the reasons above are ruled out)

CN-127M BUCKET-DUMP
PRESS. SENSOR
（DF-3）
A SIGNAL
B GND WIRE
C 5V
CONTROLLER
BUCKET-CURL CN-124M BUCKET-CURL

PRESS. SENSOR 50 （DF-3） PRESS. SENSOR
BUCKET-DUMP A SIGNAL
69
PRESS. SENSOR
SENSOR GND WIRE 54 B GND WIRE
5V
SENOSR 5V 56 C
BUCKET PD
CONFLUENCE SIGNAL 99
CN-134F BUCKET CONFLUENCE

（AMP-2） PROPORTIONAL VALVE
1 SIGNAL
2 GND WIRE
IO
CAB CHASSIS HARNESS
ZX215-1005100

E-10 Travel speed or power is low
Trouble Travel speed or power is low during operation.

Related information Pilot pressure of travel operation can be checked on the monitor.

ning to perform troubleshooting.
Failure of sen- Levers in NEUTRAL, left and right travel pressure
1 0 KG
sor signals
Pressure
Levers in operation, left and right travel pressure
0~39 KG
signals
troubleshooting.
Short circuit Between harness (from controller pin 49 to CN-
2 of harness 120M A) and ground
(grounded) Between harness (from controller pin 67 to CN- Resistance ≥1M Ω
3
Open circuit of
harness
PD
121M A) and ground
troubleshooting.
Between controller pin 54 and CN-120M B Be-
tween controller pin 54 and CN-121M B
Resistance ≤1 Ω
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the con-
4
troller troller if the reasons above are ruled out)
CN-121M RIGHT TRAVEL

IO
A SIGNAL
B GND WIRE
C 5V
CONTROLLER
RIGHT TRAVEL CN-120M LEFT TRAVEL

PRESS SENSOR 67 （DF-3） PRESS. SENSOR
LEFT TRAVEL SIGNAL
49 A
PRESS SENSOR
54 GND WIRE
SENSOR GND WIRE B
56 5V
SENOSR 5V C
ZX215-1005101

E-11 Blank monitor display
Trouble Monitor display is blank after the machine is powered on.

Related information


1 Failure of fuse Between wire 22# and ground About 24V
Voltage
Between wire 29# and ground About 24V
troubleshooting.
2
Open circuit of Between CN-7-705 pin 8 and CN-241F pin 3 ≤1 Ω
wire harness Between CN-7-705 pin 9 and CN-241 pin 1 Resistance ≤1 Ω
Between CN-7-705 pin 10# and ground ≤1 Ω
Short circuit of
3 wire harness
PD
troubleshooting.
Between harness (from CN-7-705 pin 8 to CN-241
pin 3) and ground
(grounded) Between harness (from CN-7-705 pin 9 to CN-241
pin 1) and ground
Resistance
≥1M Ω
≥1M Ω
Failure of No troubleshooting can be done for it is internal failure. (If it is not caused by
4
monitor one of the factors listed above, it should be the failure of monitor.)
CN-1-112
(D-3)
CANH
1 1
IO
120Ω RESISTANCE
2 2
CANL CN-7-705
CONTROLLER (D-12)
CANH 3
3 3
CANL
MONITOR
4 4 4
CN-1-111 29 8 8 8
CANH 60 (D-6) 22 9 9 9
0 10 10 10
1 1
2 2 12 12 12
CANL 78 3 3 3 3
1 1 CN-241F F1 20A
(D-12) 22
F10 5A
29
20
21
PWR PWR
CAB CHASSIS HARNESS
ZX215-1005102

E-12 Monitor displays nothing
Display of monitor is illuminated but no information is

Trouble
shown on the screen after machine is powered on.
Related information

● Turn engine start switch to OFF position. Keep it at OFF position to
Failure of resis- perform troubleshooting.
1
tance Between CN-1-112 1 and 2 Resistance 120 Ω
Open circuit of perform troubleshooting.
2
wire harness Between CN-7-705 pin 3 and controller pin 60 ≤1 Ω
Resistance
Between CN-7-705 pin 4 and controller pin 78 ≤1 Ω
Short circuit of perform troubleshooting.
PD
Between harness (from CN-7-705 pin 3 to con-
3 wire harness ≥1M Ω
troller pin 60) and ground
(grounded) Resistance
Between harness (from CN-7-705 pin 4 to control-
≥1M Ω
ler pin 78) and ground
Failure of monitor No troubleshooting can be done for it is internal failure. (If it is not one of
4
or controller the failures stated above, it should be the failure of monitor or controller.)
CN-1-112
(D-3)
CANH
1 1
IO
120Ω RESISTANCE
2 2
CANL CN-7-705
CONTROLLER (D-12)
CANH 3
3 3
CANL
MONITOR
4 4 4
CN-1-111 29 8 8 8
CANH 60 (D-6) 22 9 9 9
0 10 10 10
1 1
2 2 12 12 12
CANL 78 3 3 3 3
1 1 CN-241F F1 20A
(D-12) 22
F10 5A
29
20
21
PWR PWR
CAB CHASSIS HARNESS
ZX215-1005103

E-13 Dual speed travel not functioning
Trouble Only low speed travel is functioning during operation.

Related information Press the Hi/Lo button on the monitor to change travel speed.

Failure of dual ● Turn engine start switch to OFF position. Keep it at OFF position to perform
1 speed travel troubleshooting.
solenoid valve Between CN-131F A and B Resistance About 17.5 Ω
normal state

2
wire harness Between CN-132F pin A and controller pin 100 Resistance ≤1 Ω
Between CN-132F pin B and controller pin 55 ≤1 Ω
Short circuit of
troubleshooting.
3 wire harness
Between harness (from CN-131F pin A to con-
(grounded) PD Resistance ≥1M Ω
troller pin (100) and ground
4
CONTROLLER
CN-132F HIGH SPEED TRAVEL
（AMP-2） SOLENOID VALVE
HIGH SPEED TRAVEL 100 A SIGNAL

SOLENOID VALVE
IO
GROUND 55 B GND WIRE
CAB CHASSIS HARNESS
ZX215-1005104

E-14 Incorrect engine coolant reading
Engine coolant temperature sensor cannot correctly reflect cur-

Trouble
rent coolant temperature.
Related information Coolant temperature can be checked on the monitor.

Standard values for engine coolant temperature sensor

50°C 80 Ω
Failure of coolant 60°C 56.3 Ω
1 temperature sen- 80°C 29.5 Ω
sor 100°C 16.5 Ω
106°C 14.3 Ω
120°C 10 Ω
PD
Open circuit of
lead
Between wire 510# and controller pin 30 Resistance ≤1 Ω
Short circuit of
lead (grounded) Between wire 510# and ground Resistance ≥1M Ω
Lead short to 24V
circuit Wire 510# to ground Voltage ≤1V
IO
CONTROLLER
COOLANT TEMP
510
30
SENSOR
CAB CHASSIS HARNESS
ZX215-1005105

E-15 Incorrect fuel level reading
Trouble Engine fuel level sensor cannot correctly reflect current fuel level.
Related information Fuel level can be checked on the monitor.

troubleshooting.
Fuel level sen- Pin Fuel level Resistance
1
sor error Between wire 509# and ground FULL (Upper limit) Approx. 10 Ω
EMPTY (Lower limit) 85-95 Ω
state
Open circuit of
2 troubleshooting.
lead Between wire 509# and controller pin 11 Resistance ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform
3 lead (ground- troubleshooting.
PD
ed) Between wire 509# and ground Resistance ≥1M Ω
Lead short to
4 troubleshooting.
24V Wire 509# grounded Voltage ≤1V
CONTROLLER
IO
FUEL LEVEL 509
SENSOR 11
CAB CHASSIS HARNESS
ZX215-1005106

E-16 Wiper does not work
Trouble Wiper does not work

Related information

Internal Fail- ● Turn engine start switch to OFF position. Keep it at OFF position to perform
1 ure of wiper troubleshooting.
motor Between wiper wire 25# and ground Resistance >10 Ω
troubleshooting.
2
Open circuit of Between CN-241F 1 and CN-1-110 (2) ≤1 Ω
lead
state
Between wiper switch wire 35L# and CN-1-110 (5) Resistance ≤1 Ω

Between wiper switch wire 35L# and CN-1-110 (4) ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform
troubleshooting.
PD
3 lead (ground- Harness from CN-241F 1 to CN-1-110 2 short to
ed) Resistance ≥1M Ω
ground
WIPER SWITCH
CN-121F CN-132F CN-1-110 25
（D-12）（D-12） CN-131M （D-6）
1 1 （D-12）
F5 5A 36 2 2 36
IO
11 3 3 35L 35L M
25 25 4 3 3
35H 35H
4 4 4 4
CN-241F
（D-12） 5 5
1
21
PWR
CAB
ZX215-1005107

E-17 Incorrect arm-in pilot pressure reading
Trouble Reading of arm-in pilot pressure is incorrect.

Related information

Failure of 5V
power supply Between CN-128M ① and ③ Voltage Approx. 5V
Open circuit of
signal wire Between CN-128M ② and controller pin 71 Resistance ≤1 Ω
Short circuit of form troubleshooting.
3
signal wire Between CN-128M ② and ground Resistance ≥2M Ω
5
Failure of sen-
sor
PD
Between CN-128M ② and ground Voltage 0.5V~ 4.5V
CONTROLLER
CN-128M ARM IN
（DF-3） PRESS SENSOR
IO
ARM IN 71 2 SIGNAL
PRESS SENSOR
SENSOR GND WIRE 55 3 GND WIRE
SENSOR 5V 75 1 5V
CAB CHASSIS HARNESS
ZX215-1005108

E-18 Incorrect arm-out pilot pressure reading
Trouble Reading of arm-out pilot pressure is incorrect.

Related information


Failure of 5V
power supply Between CN-122M ① and ③ Voltage About 5V
Open circuit of
state
Short circuit of
4
5
Failure of sen-
sor
PD
CONTROLLER
CN-122M ARM OUT
ARM OUT
IO
52 2 SIGNAL
PRESS SENSOR
SENSOR 5V 75 1 5V
CAB CHASSIS HARNESS
ZX215-1005109

E-19 Incorrect boom-raise pilot pressure reading
Trouble Incorrect Boom-Raise Pilot Pressure Reading

Related information


Failure of 5V
Open circuit of
state
Short circuit of
4
5
Failure of sen-
sor
PD
CONTROLLER
CN-126M BOOM UP
BOOM UP
IO
70 2 SIGNAL
PRESS SENSOR
SENSOR 5V 75 1 5V
CAB CHASSIS HARNESS
ZX215-1005110

E-20 Incorrect boom-lower pilot pressure reading
Trouble Boom-Lower pilot pressure reading is incorrect.

Related information


Failure of 5V
Open circuit of
state
Short circuit of
4
5
Failure of sen-
sor
PD
CONTROLLER
CN-125M
BOOM DOWN
（DF-3）
PRESS SENSOR
BOOM DOWN 51 2 SIGNAL
IO
PRESS SENSOR
55 3 GND WIRE
SENSOR GND WIRE
SENSOR 5V 75 1 5V
CAB CHASSIS HARNESS
ZX215-1005111

E-21 Incorrect bucket-curl pilot pressure reading
Trouble Bucket-curl pilot pressure reading is incorrect.

Related information


Failure of 5V
Open circuit of
state
Short circuit of
4
5
Failure of sen-
sor
PD
CONTROLLER
CN-124M BUCKET CURL
BUCKET CURL SIGNAL
69 2
IO
PRESS SENSOR
SENSOR 5V 75 1 5V
CAB CHASSIS HARNESS
ZX215-1005112

E-22 Incorrect bucket-dump pilot pressure reading
Trouble Bucket-dump pilot pressure reading is incorrect.

Related information


Failure of 5V
Open circuit of
state
Short circuit of
4
5
Failure of sensor
PD
CONTROLLER
CN-127M BUCKET DUMP
BUCKET DUMP SIGNAL

50 2
IO
PRESS SENSOR
SENSOR 5V 75 1 5V
CAB CHASSIS HARNESS
ZX215-1005113

E-23 Incorrect swing pilot pressure reading
Trouble Swing pilot pressure reading is incorrect.

Related information

● Turn engine start switch to OFF position. Then, keep it at ON position

Failure of 5V
1 to perform troubleshooting.
Open circuit of
state
Short circuit of
● Turn engine start switch to OFF position. Then, keep it at ON position
4
5
Failure of sensor
PD
to perform troubleshooting.
CONTROLLER
CN-123M SWING PILOT
SWING PILOT
IO
68 2 SIGNAL
PRESS SENSOR
SENSOR 5V 75 1 5V
CAB CHASSIS HARNESS
ZX215-1005114

E-24 Incorrect left travel pilot pressure reading
Trouble Left Travel Pilot Pressure Reading is incorrect.

Related information


Failure of 5V
Open circuit of
state
Short circuit of
4
5
Failure of sensor
PD
CONTROLLER
CN-120M LEFT TRAVEL PILOT
（DF-3） PRESSURE SENSOR
LEFT TRAVEL PILOT SIGNAL

IO
49 2
PRESSURE SENSOR
SENSOR 5V 75 1 5V
CAB CHASSIS HARNESS
ZX215-1005115

E-25 Incorrect right travel pilot pressure reading
Trouble Right travel pilot pressure reading is incorrect.

Related information


Failure of 5V
Open circuit of
state
Short circuit of
4
5
Failure of sen-
sor
PD
CONTROLLER
CN-121M RIGHT TRAVEL PILOT
（DF-3） PRESSURE SENSOR
IO
RIGHT TRAVEL PILOT 67 2
PRESSURE SENSOR SIGNAL
SENSOR GND WIRE 55 3

GND WIRE
SENSOR 5V 75 1 5V
CAB CHASSIS HARNESS
ZX215-1005116

7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode)
A Schematic of hydraulic system and mechanical system ........................................................ 7-94

Information contained in troubleshooting table .......................................................................... 7-96
H-1 Work equipment speed slow, or swing and travel speeds slow ......................................... 7-97
H-2 Engine speed drops sharply or engine stalls ..................................................................... 7-98
H-3 Work equipment, swing, and travel systems do not work .................................................. 7-99
H-4 Abnormal noise in hydraulic pump ................................................................................... 7-100
H-5 Auto deceleration not functioning..................................................................................... 7-101
H-6 Boom speed slow ............................................................................................................ 7-102
H-7 Arm speed slow ............................................................................................................... 7-103
H-8 Bucket speed slow ........................................................................................................... 7-104
H-9 Work equipment cylinders no response in separate operation ....................................... 7-105
H-10 Work equipment drifts excessively ................................................................................ 7-106
H-11 Work equipment moves sluggishly ............................................................................... 7-108
H-12 Other work equipment moves while single oil circuit is relieved .................................... 7-108
PD
H-13 Travel speed drops considerably while swinging and travelling .................................... 7-109
H-14 Machine deviates during travel ...................................................................................... 7-110
H-15 Travel speed is low .........................................................................................................7-111
H-16 Machine is not steered well or steering power is low..................................................... 7-112
H-17 Travel speed cannot be changed................................................................................... 7-113
H-18 Travel system fails (only at one side)............................................................................. 7-114
H-19 Swing operation fails...................................................................................................... 7-115
H-20 Swing acceleration poor or swing speed low ................................................................. 7-117
H-21 Upper structure overruns remarkably when it stops swinging ....................................... 7-119
IO
H-22 Large shock is produced when upper structure stops swinging .................................... 7-120
H-23 High noise is produced when upper structure stops swinging ....................................... 7-120
H-24 Swing drift excessive ..................................................................................................... 7-121

A Schematic of hydraulic system and mechanical system
PILOT VALVE - L PILOT VALVE - TRAVEL PILOT VALVE - R
ARM SWING TRAVEL TRAVEL

BOOM BUCKET
(LEFT) (RIGHT)
LOWER
RAISE
RIGHT
BWD
OUT
DUMP
BWD
FWD
LEFT
CURL
FWD
IN
LOCK
(PILOT VALVE )
16
BOOM PRIORITY
1 2 3 4 15
5 6 7 8 9 10 11 12 BUCKET CONFLUENCE
14
SWING PRIORITY
13
VARIABLE SPEED
(TRAVEL)
ACCUMULATOR
PD 1
2
19 20
IO
17 18
REGULATOR REGULATOR
SERVO SERVO
MECHANISM MECHANISM
P1 P2
M
FRONT REAR
ZX225-1105039

● The system schematic is a simplified hydraulic circuit schematic, which can be used as a ref-
erence to the hydraulic system and the mechanical system.
Sa: SAFETY VALVE

Su: SUCTION VALVE
S&S: SAFETY&SUCTION
1 BACKUP VALVE
CONFLUENCE
BUCKET
CONFLUENCE 15
ARM HOLD
1 S&S ARM VALVE

S&S 2
VALVE
REG. VALVE
1 ARM 2 VALVE
2
14
BUCKET
CYLINDER
BUCKET S&S BUCKET 12 S&S BACKUP

S&S
10 11 VALVE S&S VALVE
BACKUP ACTUATOR
CYLINDER
9
BOOM HOLD
VALVE
ANTISWING ANTISWING
BOOM 9 S&S
BOOM
S&S 10
BOOM 2
9
Su
PD
VALVE
VALVE
CYLINDER SWING
Sa
MOTOR
Su
VALVE
13
5 Su l. TRAVEL
VALVE
Su 6 3 SWING
VALVE 4
13
BALANCE VALVE
Sa
MECHANISM
SERVO
BALANCE VALVE
R. TRAVEL
STRT. TRAVEL 7 Su VALVE Su 8
Sa
VALVE
Sa
MECHANISM
SERVO
Sa
TRAVEL
MOTOR (L)
TRAVEL
IO
MOTOR (R)
1
2
3
ZX225-1105040

Information contained in troubleshooting table
● The following information is contained in the troubleshooting table and related electric circuit diagrams.
Fully understand these information before carrying out troubleshooting.
Trouble Trouble which occurs on the machine

Related information Information related to detected trouble or troubleshooting

4
Possible causes of
trouble (Given numbers
are reference numbers,
which do not indicate
priority)
PD
< Description >
● Standard value in normal state, which is used to judge possible
causes that might be OK or N/G.
● A reference value is used to determine OK or N/G.
5
IO

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

Trouble
are slow.
● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.

● Stop the engine. Perform troubleshooting while the engine is running at

high idle.
Defective
adjustment or Control levers Main relief pressure
1 malfunction
33~34.3 MPa
of main relief Arm in
{337~350 kg/cm²}
valve
If normal pressure cannot be restored after adjustment, it is possible the fail-
2
Malfunction
of pilot relief
valve
PD
ure of main relief valve or internal defect. Check the valve directly.
high idle.
Control levers Pilot control pressure
3.9~4.1 MPa
All levers in "NEUTRAL"
{40~42 kg/cm²}
Malfunction of
3 The regulator possibly fails. Check the servo mechanism of the regulator.
regulator
Malfunction of If the trouble is caused by other factors, it might be the main pump that has
IO
4
main pump performance deterioration, malfunction or internal defect.

H-2 Engine speed drops sharply or engine stalls
Trouble ● Engine speed drops sharply or engine stalls.

Related information ● Information concerned
1 Failure of injection pump Injection pump may be defective. Check it directly.
2 Malfunction of regulator Regulator may have malfunction. Check its servo mechanism.
Clogging of oil filter ele-
3 Oil filter element may be clogged. Check the element directly.
mal state
ment
Carbon buildup at fuel
4 Carbon built up at fuel injection nozzle. Check it directly.
injection nozzle
5 Clogging of air cleaner Air cleaner may be clogged. Check it directly.
7 Failure of oil pump

PD
Abnormal wear of engine Engine may be worn abnormally. Check it directly.
Oil pump may be defective. Check it directly.

IO

H-3 Work equipment, swing, and travel systems do not work
Trouble ● Whole work equipment, swing, and travel systems do not work.
Related information

● Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Malfunction of pilot Pilot lockout control lever Pilot relief pressure

1 LOCKED 0 {0}
relief solenoid valve
3.9~4.1 MPa
FREE
{40~42 kg/cm²}
ning at high idle.
2
Failure of relief valve
(pilot pump)
PD Control lever

Pilot relief pressure
3.9~4.1 MPa
{40~42 kg/cm²}
The main pump may have malfunction or internal defect. Check it by
Failure of hydraulic following method.
3
pump ● Remove the oil pressure measurement plug and start the engine. If
oil flows out of the opening, the piston pump is in good condition.
Internal failure of the coupling can stop rotation of the pump shaft.
Check the coupling.
4 Failure of coupling
IO
● 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
Trouble ● Abnormal noise is produced from the hydraulic pump

Related information ―
Low level of
1 Make a visual check.
hydraulic oil
Inferior hydrau-
2 Hydraulic oil probably contains air. Make a visual check.
lic oil
Clogging of It is probably the clogging of the vent on top of the hydraulic tank that
state
3 vent on top of causes negative pressure in the hydraulic tank. Press the release button of
hydraulic tank the breather valve to eliminate air. Check again if the noise disappears.
Clogging of
It is probably the clogging of hydraulic tank strainer that causes negative
4 hydraulic tank PD
pressure in the oil suction line. Make a visual check.
strainer
Failure of main
5 The main pump may have internal defect. Check the main pump.
pump
IO

H-5 Auto deceleration not functioning
Trouble ● Auto-deceleration is not functioning.

Related information

● Stop the engine. Perform troubleshooting while the engine is running at high
idle.
Malfunction Control levers Pilot valve output pressure
1 "NEUTRAL" 0 {0}
of sensor
3.5~4.1MPa
Operation
{36~42 kg/cm²}
● Stop the engine. Perform troubleshooting while the engine is running at high
idle.
2
Malfunction
of pilot valve
Failure of
PD
Control levers
"NEUTRAL"
Operation
Pilot valve output pressure
0 {0}
3.5~4.1MPa
{36~42 kg/cm²}
3 Controller may be defective. Check it directly.

controller
IO

H-6 Boom speed slow
Trouble ● The boom moves slowly.

Related information

● Stop the engine. Perform troubleshooting while the engine is running
at high idle.
Malfunction of right Boom control lever Pilot valve output pressure
1 pilot valve (boom "NEUTRAL" 0 {0}
circuit)
Boom RAISE ≥3.5MPa
Boom LOWER {36 kg/cm²}

Failure of pressure
2 at high idle.
PD
sensor
Check the pressure sensor by replacing it with a new one.
Malfunction of boom
3 Spool of boom control valve may have malfunction. Check it directly.
control valve (spool)
Malfunction of boom
Retaining valve of boom control valve may have malfunction. Check the
4 control valve (re-
valve directly.
taining valve)
Malfunction or de-
fective seal of boom
The relief valve and makeup valve in boom control valve may have mal-
5 control valve
function or defective seal. Check the valves directly.
IO
(Relief valve and
makeup valve)
at high idle.
Charge the bucket with a load of approximate 1260 kg. Cut off the oil
passage to the high-pressure side of the cylinder. Disconnect the cylin-
Failure of boom
6 der from the main valve. Measure the displacement of piston for 15 min-
cylinder
utes 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 measuring procedure refer to "Testing and Adjusting",
"Hydraulic Drift (Work Equipment) - Test".

H-7 Arm speed slow
Trouble ● The arm moves slowly.

Related information

● Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Arm control lever Pilot valve output pressure
Malfunction of left pilot
1 "NEUTRAL" 0 {0}
valve (arm circuit)
≥3.5MPa
Arm IN or Arm OUT

{36 kg/cm²}
2 Failure of pressure sensor running at high idle.
4
Malfunction of arm control
valve (spool)
PD
Spool of arm control valve may have malfunction. Check it directly.
Malfunction of arm control Regeneration valve of arm control valve may have malfunction.
valve (regeneration valve) Check it directly.
Malfunction or defective
seal of arm control valve The relief valve or makeup valve inside the arm control valve may
5
(Relief valve and makeup have malfunction or defective seal. Check the valves directly.
valve)
IO
Cut off the oil passage to the high-pressure side of the cylinder.
Disconnect the cylinder from the main valve. Measure the displace-
6 Failure of arm cylinder ment of piston for 15 minutes after the cylinder becomes stable. If
the measured value is greater than 10 mm, it is deemed that cyl-
inder has a defective seal. For more information on the measuring
procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work
Equipment) - Test".

H-8 Bucket speed slow
Trouble ● The bucket moves slowly.

Related information

at high idle.
Malfunction of right Bucket control lever Pilot valve output pressure
1 pilot valve (bucket "NEUTRAL" 0 {0}
circuit)
≥3.5MPa
Bucket CURL or Bucket DUMP

{36 kg/cm²}
Failure of pressure
2 at high idle.
3
sensor
Malfunction of
PD
bucket control valve Spool of bucket control valve may have malfunction. Check it directly.
(spool)
Malfunction or
defective seal of
Relief valve and makeup valve in bucket control valve may have mal-
4 bucket control valve
function or defective seal. Check the valves directly.
(relief valve and
makeup valve)
IO
at high idle.
Charge the bucket with a load of approximate 1260 kg. Cut off the oil
passage to the high-pressure side of the cylinder. Disconnect the cylin-
Failure of bucket
5 der from the main valve. Measure the displacement of piston for 15 min-
cylinder
utes 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 measuring procedure refer to "Testing and Adjusting",
"Hydraulic Drift (Work Equipment) - Test".

H-9 Work equipment cylinders no response in separate operation
● Boom cylinder gives no response in separate operation.

Trouble ● Arm cylinder gives no response in separate operation.
● Bucket cylinder gives no response in separate operation.
Related information

Work equipment control lever Pilot valve output pressure
1 Malfunction of pilot valve "NEUTRAL" 0 {0}
≥3.5MPa
state
DIG or DUMP
PD {36 kg/cm²}
Failure of pressure sen-
2 running at high idle.
sor
Malfunction of control
3 Spool of control valve may have malfunction. Check it directly.
valve (spool)
IO

H-10 Work equipment drifts excessively
Trouble (1) ● The boom drifts at excessive speed.

Related information


Charge the bucket with a load of approximate 1260 kg. Cut off the
oil passage to the high-pressure side of the cylinder. Disconnect the
1 Failure of boom cylinder 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 defec-
tive seal. For more information on the measuring procedure refer to
"Testing and Adjusting", "Hydraulic Drift (Work Equipment) - Test".
PD
Failure of boom retain- Boom retaining valve or pilot valve may be worn or sluggish. Check
2
ing valve the valves.
Malfunction or defective
seal of boom control The relief valve and the makeup valve in the boom control valve
3
valve (relief valve and may have a defective seal. Check the seals.
makeup valve)
Failure of boom valve
4 Spool of boom valve may be worn excessively. Check the spool.
spool
IO

Trouble (2) ● The arm drifts excessively.

Related information


high idle.
Cut off the oil passage to the high-pressure side of the cylinder. Disconnect
Failure of arm the cylinder from the main valve. Measure the displacement of piston for 15
1
cylinder 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 infor-
mation on the measuring procedure refer to "Testing and Adjusting", "Hy-
draulic Drift (Work Equipment) - Test".
Malfunction or Relief valve or makeup valve of the arm control valve may be defective.
defective seal of Check the valves directly.
2 arm control valve ● The performance of seal can be judged by replacing it with another re-
PD
(relief valve and lief valve or makeup valve. (Do not replace it with the boom-down relief
makeup valve) valve or makeup valve as their pressures are set differently.)
Failure of arm Arm retaining valve or pilot valve may be worn or sluggish. Check the
3
retaining valve valves.
Failure of arm
4 Arm valve (spool) may be worn excessively. Check it directly.
valve (spool)
Trouble (3) ● The bucket drifts excessively.

IO
Related information

Failure of bucket at high idle.
1 Bucket control lever Leakage from bucket cylinder
cylinder
Bucket-in relief 20 ml/min
mal state
Seal of relief valve or makeup valve of bucket control valve may be defec-
Defective seal
tive. Check it directly.
of bucket control
2 ● The performance of seal can be judged by replacing it with another
valve (relief valve
relief valve or makeup valve. (Do not replace it with the boom-down
and makeup valve)
relief valve or makeup valve as their pressures are set differently.)
Defective seal
3 of bucket control Seal of bucket control valve spool may be defective. Check it directly.
valve (spool)

H-11 Work equipment moves sluggishly
Trouble ● Work equipment moves sluggishly.

Related information

Possible causes and standard value
Malfunction of arm
1 Regeneration valve of arm may have malfunction. Check it directly.
regeneration valve
in normal state
Relief valve or makeup valve of control valve may have malfunction.

Malfunction of Check it directly.
control valve (relief ● For arm and boom, whether a valve has malfunction can be judged
2
valve and makeup by replacing it with another relief valve or makeup valve.
valve) (Do not replace it with the boom-lower relief valve or makeup valve as
PD
their pressures are set differently. )
H-12 Other work equipment moves while single oil circuit is relieved
● Other work equipment moves while single oil circuit of certain work equip-
Trouble
ment is relieved.
Related information ● Set the working mode to (S) in order to perform troubleshooting.
IO

normal state
Defective seal of
1 Seal of control valve may be defective. Check it directly.
control valve

H-13 Travel speed drops considerably while swinging and travelling
Trouble ● Travel speed drops considerably in swinging plus travelling operation.

● If the travel speed is low in only travelling operation, check first ac-
Related information
cording to H-15.

normal state
Failure of straight The straight travel valve gives no response. Check the spool and the
1
travel valve logic oil circuit drain port.
PD
IO

H-14 Machine deviates during travel
Trouble ● Machine deviates during travel.

Related information

Travel control lever Pilot valve output pressure
Malfunction of travel pilot
1 Forward 3.5~3.9 MPa
valve
Reverse { 36~40 kg/cm²}
Difference occurs between
0.4 MPa {4 kg/cm²}
left and right output
PD running at high idle.
Malfunction of pilot relief
2 Control lever Control circuit source pressure
valve
3.5~3.9 MPa
{ 36~40 kg/cm²}
3 Failure of regulator Check the regulator by swapping the front and back regulators.
Sluggishness of proportion- running at high idle.
4 Travel control lever Proportional valve output pressure
al solenoid valve
Operate both control levers ≤0.1 MPa
Sluggishness of travel con-
IO
5 Check the valve spool to see whether it works well.
trol valve (spool)
Internal leakage of central
6 Check it by swapping the lines.
swivel joint
7 Malfunction of travel motor Travel control lever Leakage of travel motor
Travel relief 27.2 ml/min
Final drive may have internal defect. Check it directly.
● Internal defect of the final drive can be determined through
8 Failure of final drive
abnormal noise, abnormal heat, and metal powder or debris
contained in the oil drained.
Failure of travel pilot pres- Forward 3.5~3.9MPa
9
sure sensor Reverse { 36~40 kg/cm²}
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
Trouble ● Machine travel speed is low.

Related information

ning at high idle.
Malfunction of travel
1 Forward 3.5~3.9 MPa
pilot valve
Reverse { 36~40 kg/cm²}
Difference occurs between left and ≤0.4 MPa
right output ≤{4 kg/cm²}
PD
ning at high idle.
Malfunction of pilot Control lever Control circuit source pressure

2
relief valve
3.5~3.9 MPa
{ 36~40 kg/cm²}
ning at high idle.
Travel speed Travel control lever Reading on monitor
3.5~3.9 MPa
3 Failure of sensor Lo Operated
{ 36~40 kg/cm²}
IO
3.5~3.9 MPa
Hi Operated
{ 36~40 kg/cm²}
Check the sensor by replacing it with another one.
4 Spool of travel control valve may have malfunction. Check it directly.
The makeup valve in travel control valve may have malfunction. Check
5 control valve (make-
it directly.
up valve)
Stop the engine. Perform troubleshooting while the engine is running at
Failure of travel mo- high idle.
6
tor Travel control lever Oil leakage of travel motor
Travel relief 27.2 ml/min
● Internal defect of the final drive can be determined through abnor-
mal 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
Trouble ● Machine is not steered well or steering power is low

Related information

Malfunction of travel pilot Travel control lever Pilot valve output pressure
1
valve Both sides in "NEUTRAL" 0 {0}
3.5~3.9 MPa
Either side operated
{ 36~40 kg/cm²}
PD Travel control lever Solenoid valve output pressure
Malfunction of travel pilot
2 3.5~3.9 MPa
pressure sensor Both sides operated
{ 36~40 kg/cm²}
3.5~3.9 MPa
Either side operated
{ 36~40 kg/cm²}
Malfunction of travel Spool of travel control valve may have malfunction. Check it direct-
3
control valve (spool) ly.
The makeup valve in travel control valve may have malfunction.
4 control valve (makeup
IO
Check it directly.
valve)
Seal of relief valve in travel motor may be defective. Check it di-
Failure of travel motor rectly.
5
(relief valve) ● The failure of seal can be determined by swapping the front
and back motors or the left and right motors.
Seal of check valve in travel motor may be defective. Check it di-
Failure of travel motor rectly.
6
(check valve) ● The failure of seal can be determined by swapping the front
and back motors or the left and right motors.

H-17 Travel speed cannot be changed
Trouble ● Travel speed cannot be changed.

Related information


ning at high idle.
Malfunction of travel Solenoid valve output
Travel speed Travel control lever
pressure
normal state
1 speed shifting solenoid

valve Lo Operated 0 {0}
3.5~3.9 MPa
Hi Operated
{ 36~40 kg/cm²}
2
speed change)
PD
Failure of travel motor (in Speed shifting assembly of travel motor may have malfunction.
Check it directly.
IO

H-18 Travel system fails (only at one side)
Trouble ● One side of the tracks cannot make a turn.

Related information

Defective seat of travel
Seat of makeup valve in travel control valve may have malfunction.
1 control valve (makeup
Check it directly.
valve)
Defective seat of travel Seat of relief valve in travel control valve may have malfunction.
2
motor (relief valve) Check it directly.
Defective seat of travel
Seat of check valve in travel motor valve may have malfunction.
3 motor valve (makeup
Check it directly.
valve)
4
Speed of travel motor
drops.
PD
ning at high idle.
Travel control lever
Travel relief
Leakage from travel motor
27.2 ml/min
● Internal defect of final drive can be determined with abnormal
noise, overheat, and metal powder or debris contained in the oil
drained.
ning at high idle.
IO
Defective pilot pressure Forward 3.5~3.9MPa
6
sensor Reverse { 36~40 kg/cm²}
Difference occurs between left and
0.4 MPa {4 kg/cm²}
right output
Check it with swapping method.

H-19 Swing operation fails
Trouble (1) ● Upper structure fails to swing in either direction.

Related information
Malfunction of swing
1 Parking brake of swing motor may have malfunction. Check it directly.

motor (parking brake)
ning at high idle.
Improper adjustment Swing control lever Swing relief pressure
or malfunction of 25.5~28.5 MPa
2 Swing relief
swing motor (relief {260~291 kg/cm²}
valve) If oil pressure does not become normal after adjustment, swing motor
3 Failure of swing motor

PD
relief valve may have malfunction or internal defect. Check the relief
valve directly.
ning at high idle.
Swing control lever Leakage from swing motor
Swing relief ≥10 ml/min
Swing mechanism may have internal defect. Check it directly.
Failure of swing ● Internal defect of swing mechanism can be determined with ab-
4
mechanism normal noise, overheat, and metal powder or debris contained in
IO
the oil drained.

Trouble (2) ● Upper structure only fails to swing in one direction.

Related information


ning at high idle.
Malfunction of pilot Left control lever Pilot valve output pressure
1
valve
normal state
"NEUTRAL" 0 {0}
Swing ≥3.5MPa {≥36 kg/cm²}
2 Spool of swing control valve may have malfunction. Check it directly.
Defective seal of Seal of makeup valve in swing motor may have defect. Check it directly.
3 swing motor (makeup ● Failure of the seal can be determined by swapping the right and left
valve) PD
makeup valves and check for any changes.
IO

H-20 Swing acceleration poor or swing speed low
Trouble (1) ● Swing acceleration is poor, or swing speed is low.

Related information

1 Parking brake of swing motor may have malfunction. Check it directly.
ning at high idle.
Improper adjustment Swing control lever Swing relief valve
or malfunction of 25.5~28.5 MPa
2 Swing relief
swing motor (relief {260~291 kg/cm²}
valve) If oil pressure does not become normal after adjustment, swing motor
3
Failure of swing mo-
tor
PD
valve directly.
ning at high idle.
Swing control lever Leakage from swing motor
Swing relief ≤10 ml/min
Clogging of brake
4 Disassemble, clean and check.
control lines
IO

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

Trouble (2)
low.
Related information

ning at high idle.

Malfunction of pilot Swing control lever Pilot valve output pressure
1
valve "NEUTRAL" 0 {0}
Left swing
≥3.5MPa {≥36 kg/cm²}
Right swing
Pressure compensation valve of swing motor may have malfunction.
2 motor (pressure com-
Check it directly.
pensation valve)
Seal of makeup valve in swing motor may have defect. Check it di-
PD
Defective seal of swing rectly.
3
motor (makeup valve) ● Swap the left and right makeup valves and observe the result in
order to determine whether the seal fails.
ning at high idle.
One-side leakage of
Swing control lever Pilot valve output pressure
4 swing pilot pressure
"NEUTRAL" 0 {0}
sensor (shuttle valve)
Left swing
3.5~3.9MPa {36~40 kg/cm²}
Right swing
IO

H-21 Upper structure overruns remarkably when it stops swinging
● Upper structure overruns remarkably when it stops swinging in

Trouble (1)
both directions.
Related information


ning at high idle.
Swing control lever Swing relief pressure
Improper adjustment
25.5~28.5 MPa
1 or malfunction of swing Swing relief
mal state
{260~291 kg/cm²}
motor (relief valve)
If oil pressure does not become normal after adjustment, swing motor
valve directly.
PD
ning at high idle.
2 Failure of swing motor Control lever Leakage from swing motor
Swing relief ≤10 ml/min
Trouble (2) ● Swing acceleration is only poor on one side, or swing speed is low.
● Set the working mode at gear (10) of power mode (S) to perform
Related information
troubleshooting.
IO

Swing control lever Pilot valve output pressure
1 Malfunction of pilot valve
"NEUTRAL" 0 {0}
mal state
Left swing
≥3.5MPa {≥36 kg/cm²}
Right swing
Malfunction of swing con- Spool of swing control valve may have malfunction. Check it direct-
2
trol valve (spool) ly.
Seal of makeup valve in swing motor may be defective. Check it
Malfunction or defec-
directly.
3 tive seal of swing motor
● Swap the left and right makeup valves and observe the result
(makeup valve)
in order to determine whether the seal fails.

H-22 Large shock is produced when upper structure stops swinging
Trouble ● Large shock is produced when upper structure stops swinging.

Related information

ning at high idle.
Malfunction of swing Swing control lever Pilot valve output pressure

1
pilot valve "NEUTRAL" 0 {0}
Left swing
state
≥3.5MPa {≥36 kg/cm²}

Right swing
Reverse prevention valve of swing motor may have malfunction.
Check it directly.
2 reverse prevention PD
● Replace the valve with a new on in order to determine whether the
valve
valve fails.
3 Swing relief valve may be worn or sluggish.
relief valve
H-23 High noise is produced when upper structure stops swinging
Trouble ● High noise is produced when upper structure stops swinging.

IO
Related information

Malfunction of back
1 Back pressure valve may have malfunction. Check it directly.
pressure valve
2 Relief valve of swing motor may have malfunction. Check it directly.
motor (relief valve)
Seal of makeup valve in swing motor may have malfunction. Check it
state
Malfunction of swing directly.

3
motor (makeup valve) ● Swap the left and right makeup valves and observe the result in
order to determine whether the seal fails.
The swing mechanism is suspected of an internal failure. Check the
inside of the machinery itself.
Failure of swing mecha-
4 ● Internal defect of swing mechanism can be determined with ab-
nism
normal noise, overheat, and metal powder or debris contained in
the oil drained.

H-24 Swing drift excessive
● Hydraulic drift of swing is large (when swing holding brake is ap-

Trouble (1)
plied).
● When swing lock switch is turned ON or when swing holding
Related information brake release switch is in normal position, swing holding brake
operates and upper structure is fixed with disc brake.
Failure of swing hold- Swing holding brake control lines and holding brake pilot valve may be
in normal state
1
ing brake control lines defective. Check them directly.
2
PD
Parking brake of swing motor may have malfunction. Check it directly.
● Hydraulic drift of swing is large (when swing holding brake is re-

Trouble (2)
leased).
● When swing holding brake release switch is in release position,
IO
Related information swing holding brake is released and upper structure is secured
by only hydraulic pressure.
Malfunction or defec-
Swing control valve spool may have malfunction or defective seal.
1 tive seal of swing
Check it directly.
in normal state
Failure of swing motor

2 Seal of relief valve in swing motor may be defective. Check it directly.
(relief valve)
Failure of swing motor Seal of makeup valve in swing motor may be defective. Check it di-
3
(makeup valve) rectly.

E
PPDAG
IOK
AN
BL

SY195-205-215C9 Crawler Hydraulic Excavator Disassembly and Assembly
Disassembly and Assembly

8 Disassembly and Assembly
8.1 How to Read This Manual ....................................................................................... 8-3
8.2 Operating Precautions ............................................................................................. 8-4
PD
8.3 Start Motor AS - Remove and Install ....................................................................... 8-8
8.4 Injection Pump AS - Remove and Install ................................................................. 8-9
8.5 Engine Front Seal - Remove and Install ................................................................ 8-13
8.6 Engine Rear Seal - Remove and Install................................................................. 8-14
8.7 Cylinder Head AS - Remove and Install ................................................................ 8-16
8.8 Radiator AS - Remove and Install.......................................................................... 8-22
8.9 Engine and Hydraulic Pump AS - Remove and Install .......................................... 8-26
8.10 Final Drive AS - Remove and Install .................................................................... 8-33
IO
8.11 Final Drive AS - Disassemble and Assemble ....................................................... 8-35
8.12 Swing Motor and Swing Drive AS - Remove and Install ...................................... 8-44
8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble......................... 8-46
8.14 Idler AS - Disassemble and Assemble ................................................................. 8-56
8.15 Sprocket - Remove and Install............................................................................. 8-60
8.16 Track AS - Remove and Install ............................................................................ 8-61
8.17 Swing Bearing AS - Remove and Install .............................................................. 8-64
8.18 Swing Platform AS - Remove and Install ............................................................. 8-66
8.19 Swivel Joint AS - Remove and Install .................................................................. 8-70
8.20 Swivel Joint AS - Disassemble and Assemble ..................................................... 8-73
8.21 Hydraulic Tank AS - Remove and Install.............................................................. 8-75
8.22 Control Valve AS - Remove and Install ................................................................ 8-78
8.23 Hydraulic Pump AS - Remove and Install ............................................................ 8-83
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install .................... 8-88
8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......................... 8-89
8.26 Pilot Valve AS (Travel) - Disassemble and Assemble .......................................... 8-91

Disassembly and Assembly SY195-205-215C9 Crawler Hydraulic Excavator
8.27 Hydraulic Cylinder AS - Disassemble and Assemble........................................... 8-92

8.28 Work Equipment AS - Remove and Install......................................................... 8-103
8.29 Air Conditioner AS - Remove and Install............................................................ 8-106
8.30 Counterweight AS - Remove and Install .............................................................8-111
8.31 Cab AS - Remove and Install..............................................................................8-113
8.32 Cab Window Glass – Disassemble and Assemble .............................................8-118
8.33 Front Window AS - Disassemble and Assemble................................................ 8-136
8.34 Monitor - Remove and Install ............................................................................. 8-144
8.35 Controller AS - Remove and Install.................................................................... 8-145
8.36 Radio ................................................................................................................. 8-146
8.37 Battery ............................................................................................................... 8-149
8.38 Start Switch........................................................................................................ 8-152
8.39 Fuse Box............................................................................................................ 8-155
8.40 Wiper ................................................................................................................. 8-156
8.41
8.42
8.43
PD
Relay.................................................................................................................. 8-159
Sensor ............................................................................................................... 8-163
Connector Terminals - Insert and Remove ........................................................ 8-165
IO
WARNING
jury or death.

8 DISASSEMBLY AND ASSEMBLY
8.1 How to Read This Manual
8.1.1 Removing and Installing an Assembly
Removal
● The "Removal" section contains procedure, precautions and the amount of oil or water to be
discharged.
Installation
● Unless specified otherwise, installation of a part is a reverse procedure of removing the part.
Disassembly
PD
8.1.2 Disassembling and assembling an assembly
● The "Disassembly" section contains procedure, precautions and the amount of oil or water to
be discharged.
Assembly
IO
● The "Assembly " section contains operating procedure, precautions, technical specification
and the amount of oil or water to be added.
8.1.3 Special tools
● Special tools for parts disassembly and assembly are listed.
● Necessary characteristics of the tools are noted in the list of special tools.
■ : Special tools that cannot be replaced and must be used.
● : Very useful tools, which can be replaced with commercially available ones.

8.2.1 The symbols used in this section
This section uses some symbols and icons that are not used elsewhere in this manual. They in-
clude:
This symbol indicates the amount of oil or water to be discharged.
This symbol indicates that specific coating agent must be used.
This symbol indicates the lubricant required.
This symbol indicates a torque specified.
This symbol indicates the amount of oil or water to be added.
This symbols indicates the weight of a component or an assembly.
8.2 Operating Precautions

PD
The following precautions must be observed before removing or installing (disassembling or as-
sembling) a component.
1. Precautions to be observed prior to removal operation
● Dispose the engine coolant properly if antifreeze is contained in the engine coolant.
IO
● After disconnecting a hose or tube, cover or plug must be used to prevent invasion of dirt
or dust.
● A suitable container must be prepared to collect oil when draining the oil.
● Matching mark must be made at where is necessary before removing in order to avoid
mistake during reinstallation.
● Do not pull the wire and avoid the wire coming off. 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 components, be sure to use proper lifting equipment of ample
strength and safety.

● When forcing screws are used to remove any components, tighten the screws evenly in
turn.
● The surrounding area must be cleaned before removing a unit. Cover the unit after remov-
al 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
I.D. (mm) Code Description

Light Thread Connection
6 B210780001189 Plug
8 B210780001190
PD 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
IO
20 B210780000080 Plug
25 B210780000081 Plug
B: Thread-connected adaptors (plug and nut used in combination)
I.D. (mm) Code Description Code Description

Light Thread Connection
6 B210780000903 Taper bore 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 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 parts.
● Bend the cotter pin or lock plate securely.
sive to the threaded portion.

PD
● Before applying the adhesive, clean the parts of oil and dust. Apply 2 or 3 drops of adhe-
● 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.

IO
● Before installing a snap ring, make sure that the snap ring is mounted properly in the cir-
cular 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
eyebolt as far as possible and align it to the direction of the hook.
● Before tightening the split flange, tighten it evenly in turn in order to prevent over tighten-
ing on one side.
NOTE: After reassembling the hydraulic cylinder, main pump or other hydraulic equipment
that has been disassembled and repaired, it is necessary to bleed the air from the hydraulic
cylinder prior to initial operation of the cylinder. The purging procedure is performed as the
following:

1) Start the engine and run the engine at low idle.
2) Operate the work equipment control lever in order to cycle the movement of the hydraulic
cylinder 4 or 5 times. Hold the cylinder at where it is 100 mm from its stroke end.
3) Go on operating the hydraulic cylinder 3 or 4 times to its stroke end.
4) You can run the engine at normal speed after this operation.
NOTE: 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
specified level. Run the engine to circulate the coolant through the system. Check the
coolant level again. PD
● 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.
● Bleed the air from the system after removing and repairing the lines or hydraulic unit and
reassembling the parts.
For more information, see “Air in Each Component - Bleed” on page 6-45.
IO
● Add the specified amount of grease (molybdenum disulphide) to the work equipment re-
lated parts.

8.3 Start Motor AS - Remove and Install
8.3.1 Removal
CAUTION
● Before removing the start motor assem-
bly, disconnect the cable from the nega-
tive (-) post of the battery, and insulate
between the cable and the negative post
with insulation tape.
1. Open the engine hood.
2. Disconnect the cables (1), (2), (3), (4) and

(5).
PD Starter
3. Unscrew the bolts (6) and (7) used to fix Terminal B

the start motor. Remove the start motor as-
sembly.
Terminal S
Starter relay
IO
ZX215-1006001
8.3.2 Installation
1 2 3 4 6
● Installation is to be performed in the re-
verse order of removal.
Terminal B locknut (start motor):
18 ~ 25 N·m {1.8 ~ 2.6 kgf·m}
Fixing bolts (start motor):

5
43±6 N·m {4.4±0.6 kgf·m} 7
ZX215T-1006002

8.4 Injection Pump AS - Remove and Install
8.4.1 Removal
CAUTION
● Disconnect the negative (-) post of the
battery.
ZX215T-1006003
PD
2. Disconnect the air intake hose (1).
1
IO
ZX215T-1006004
3. Disconnect fuel supply tube (2), fuel deliv-

ery hose (4), fuel return hose (3) and fuel
supply tube (5). 5
● Block the hose with a cork in order to

prevent flow of fuel from the hose.
3
4 ZX215T-1006005

4. Disconnect the lubrication tube (6).
ZX215T-1006006
5. Disconnect six fuel delivery tubes (7).

7
PD
ZX215T-1006007
IO
6. Disconnect the air hose (8).
7. Remove the bolt (9) fixing the electronic 8

choke. Disconnect the bolt (10) fixing the
governor motor.
10
ZX215T-1006008

8. Adjust the injection timing of the timing

gear. For more information, see “Fuel In-
jection Timing - Test and Adjust” on page 6-12.
9. Remove the injection pump mounting nuts

in order to disassemble the injection pump
assembly.
B
A: 4 nuts on the flange
A
B: 1 nut
ZX215-1006009
8.4.2 Installation

PD
Bolts for installation of fuel supply

tube:
20~29 N·m {2.1~3.0 kgf·m}
Relief valve:
IO
20~29 N·m {2.1~3.0 kgf·m}
Bolts for installation of engine oil line:
10~13 N·m {1.0~1.3 kgf·m}
Fuel injection tube:
24 N·m {2.5 kgf·m}
Bolts for installation air hose:
12~15 N·m {1.2~1.5 kgf·m}
● Adjust the engine speed. For more in-

formation, see “Engine Speed - Test
and Calibrate” on page 6-3.

● Installation of the fuel injection pump is to

be performed as the following:
1) Check the fuel injection timing to see if it

has been adjusted properly.
● For more information, see “Fuel Injec-

tion Timing - Test and Adjust” on page 6-12.
2) Assemble the fuel injection pump assem-

bly and tighten the 4 nuts at position A and B
1 nut at position B.
A
Nut: 9.8±2 N·m {10±0.2 kgf·m}
ZX215-1006009
● Air bleeding
PD
Bleed the air from the fuel injection system.
IO

8.5 Engine Front Seal - Remove and Install
8.5.1 Removal
1. Remove the radiator assembly.
For more information, see “Radiator AS -

Remove and Install” on page 8-22. Water pump
3
2. Remove the engine fan (1), the belt (2) and 1
the pulley (3).
ZX215-1006010
PD
3. Remove the mounting nut (4) and replace
the cone (5) and the O-ring (6). Remove
the crankshaft belt pulley (7).
6
Ta 4
IO
7
5 ZX215-1006011
4. Disassemble the front oil seal (8).
8
8.5.2 Installation
ZX215-1006012

Nut: 490 N·m {50 kgf·m}

8.6 Engine Rear Seal - Remove and Install
8.6.1 Removal
1. Remove the hydraulic pump assembly.
For more information, see “Hydraulic Pump

AS - Remove and Install” on page 8-83.
2. Remove the bolt (1), the latch piece (2)

and the bearing (3).
5
3. Remove the flywheel (4). 3

6
Ta 1
4. Remove the engine speed sensor (5) and
the flywheel shell (6). 2 4
ZX215-1006013
5. Remove the rear seal (7).

PD
Lip
IO
7 ZX215-1006014

8.6.2 Installation
● The installation is to be performed in the

reverse order of removal.
Bolt:
39 N·m {4.0 kgf·m} + 47°
● The rear oil seal is to be installed accord-

ing to the following procedure:
Sealant
1. Apply engine oil to the lips of the rear seal.
2. Clean the oil-sealing surface. ø2mm
3. Apply the sealant evenly and continuously

PD
align the line of the rear seal.
Line
ZX215-1006015
Sealant (Tonsun 1596)
4. The installation is to be performed 3 min-

utes after application of the sealant. Be
careful not to deviate the line while apply-
ing the sealant.
IO

8.7 Cylinder Head AS - Remove and Install
8.7.1 Removal
CAUTION
● Disconnect the negative (-) post of the
battery.
1. Drain the engine of coolant.
Coolant: 22.5 L

ZX215T-1006016

PD 1
IO
ZX215T-1006017
4. Remove piping (2) and piping (3) between

the fuel filter and the injection pump.
ZX215T-1006018

5. Remove the fuel filter bracket (4) and the

fuel filter assembly (5).
6. Remove the six delivery hoses (6).
ZX215T-1006019
7. Remove the exhaust muffler connector

cover (7). 6
PD
ZX215T-1006020
IO
8. Remove the air cleaner suction hose (8).
9
9. Remove the air intake tube (9) and its

7 10
clamps (10) between the turbocharger and
the intercooler.
10. Remove the engine oil delivery tube (11)

and the oil return tube (12).
8
ZX215T-1006021

11. Remove the turbocharger assembly.
11
12
ZX215-1006022
12. Remove the exhaust manifold (13). 13

PD
IO
ZX215-1006023
13. Remove the radiator inlet hose (14) and

outlet hose (15).
14
15
ZX215T-1006024

14. Remove the six nozzle seats (16).
16
ZX215T-1006025
15. Remove the rocker arm housing (17).

17
16. Remove the rocker arm assembly (18).

PD
17. Remove the pushrod (19).
18
18. Remove the 25 mounting bolts from the
cylinder head assembly. Lift the cylinder
head assembly in order to disassemble it. 19
20
19. Remove the cylinder head gasket (21).
IO
21
ZX215-1006026

8.7.2 Installation
● The installation is to be performed in the

reverse order of removal.
Installation of cylinder head gasket
Choose a cylinder head gasket as per the

following.
1. Measure the amount of piston projection of

each cylinder.
2. Select from the following table a gasket

with a thickness suitable for the maximum
piston projection after measurement. In ad-
dition, even if one cylinder's piston projec-
PD
tion is 0.05 mm greater than the average,
the gasket with a thickness one grader
higher (A→B, B→C) is to be used.
Unit: mm
Piston Projection Cylinder Head Gasket

Size mark
Thickness A B
Average Size C
Tightened
IO
0.546~0.610 A 1.3
0.610~0.674 B 1.35
0.674~0.738 C 1.4
3. The size of cylinder head gasket is deter-

“UP”
mined according the notch.
4. Install the cylinder head gasket to the

crankshaft case as indicated by the arrow.
Notch
NOTICE
The amount of piston projection must be
ZX215-1006027
measured as the amount of piston projec-
tion may vary when replacing a piston or
connecting rod.

Bolt (rocker cover installation):
4.9~6.9 N·m {0.5~0.7 kgf·m}
Bolt (cylinder head):
147 N·m {15 kgf·m}+90°
Bolt threads (cylinder head):
Engine oil
Tappet circumference:
Engine oil
Tappet ends: PD Engine oil
● Adjustment of valve clearance
F o r m o r e i n f o r m a t i o n , s e e “ Va l v e
Clearance - Adjust” on page 6-7.
● Adding coolant
IO
Add engine coolant to the specified level.
Start the engine to circulate the coolant in
order to release all foams. Check the cool-
ant level again.

8.8 Radiator AS - Remove and Install
8.8.1 Removal
2. Open the pressure cap (1). Open the drain

valve to discharge engine coolant from the
coolant tank.
Coolant: approx. 22.5 L 1

盖板
3. Remove the coverplate.
ZX215T-1006028
4. Remove the two U-bolts (2).

PD
5. Disconnect the hydraulic oil cooler inlet
connector (3) and outlet connector (4).
Block the openings to prevent leakage of 3
hydraulic oil.
6. Discharge hydraulic oil from the hydraulic

cooler.
IO
Hydraulic oil radiator: approx. 5.6 L 4 2
ZX215T-1006029
7. Disconnect the coolant tank hose (5).
8. Disconnect the cooler inlet hose (6) and

outlet hose (7).
ZX215T-1006030

9. Disconnect the intercooler air inlet tube (8)

and outlet tube (9).
6
7 ZX215T-1006031
10. Remove the four bolts (10) from the air

conditioner radiator. Remove the air condi-
tioner radiator and store it properly.
PD 10
10
ZX215T-1006032
IO
11. Remove the radiator fan guard (11).
11
ZX215T-1006033

12. Remove the four mounting bolts (12) from

the radiator bottom and the two mounting 13
bolts (13) from the left and right brackets.
12
ZX215T-1006034
13. Mount the hoisting bolts (14) to both sides

of the radiator in order to hoist the radiator
assembly. PD
NOTE: Before the radiator assembly is
hoisted, move the radiator assembly axially
until the fan avoids its guard.
14
ZX215T-1006035
IO

8.8.2 Installation

NOTE:
● Adjust the clearance (a) between the fan

and the fan guard in order to have a uni-
form clearance surrounding the fan.
● Check the values (a) at the four measuring

points in the left, right, top and bottom di-
rections, which should be as the following:
Standard clearance (a) in all directions:

15±1.5 mm PD
Fan diameter (b): ø620 mm
Fan guard inner diameter (c): ø650 mm
● Engine coolant and hydraulic oil adding
Add a specific amount of coolant and

hydraulic oil. Start the engine to circulate
the coolant and hydraulic oil. Check the
IO
coolant level and the oil level.
Engine coolant: approx. 22.5 L
Hydraulic oil radiator: approx. 5.6 L

8.9 Engine and Hydraulic Pump AS - Remove and Install
8.9.1 Removal
CAUTION
ground. Stop the engine. Disconnect
the cable from the battery negative (-)
post.
● Loosen the butterfly nut on the breather

lieve internal pressure.
NOTE: Mark the lines to avoid mistakes during

reinstallation. PD
1. Remove the hydraulic tank suction filter el-
ement and block the opening.
2. Drain the engine of coolant.
Coolant: approx. 22.5 L

IO
ZX215T-1006028
4. Disconnect piping (1), (2) and (3).
3
2
ZX215T-1006036

5. Disconnect piping (4), (5) and (6).

5
6. Remove the sensors (7) and (8). 6
8
ZX215T-1006037
7. Remove the clamps (9) and (10). Remove

the line (11) and the cable (12).
PD 11
10
IO
12
ZX215T-1006038
8. Unscrew the connection bolt (13) of the

governor motor and the connection bolt (14) 15
of the engine stopper.
9. Disconnect the external cable from the 14

starter (15).
13
10. Remove the mounting bolt (16) from the
hose clamp.
16
ZX215T-1006039

11. Disconnect the cables (17) and (18) as

well as the tubes (19) and (20) from the 18 20
compressor. 17
19
ZX215T-1006040
12. Disconnect the hoses (21), (22), (23) and

(24) between the engine and the radiator
24
PD 21
22
23 ZX215T-1006041
IO
25
ZX215T-1006042

14. Disconnect the external cable (26) of the

rpm sensor.
15. Disconnect the external cable (27) of en-

gine oil pressure sensor.
26 27
ZX215T-1006043
16. Disconnect the engine oil inlet tube (28)

and outlet tube (29).
PD 30
17. Disconnect the wiring (30) of the engine oil
pressure switch.
29
28
ZX215T-1006044
IO
18. Disconnect the cables (31) and (32), and
remove the hose clamp (33).
33
32
31
ZX215T-1006045

19. Remove the hose clamp (35).
20. Disconnect the wiring (34) of the water

temperature sensor.
35
34
ZX215T-1006046
21. Disconnect the cables (36) and (37) of the

water temperature switch.
PD 37
36
ZX215T-1006047
IO
22. Disconnect the oil return hose (38).
23. Disconnect the A/C water pipe (39). 38
39
ZX215T-1006048

24. Disconnect the radiator fan guard (40).
40
ZX215T-1006049
25. Remove the fixing bolt (41) on each of the

four mounting plates of the damper. Lift the
engine and main pump assembly.PD
Engine and hydraulic pump AS:
640 kg
41
41
ZX215T-1006050
IO

8.9.2 Installation

● Open the radiator tank cover to add cool-

ant. Also add coolant to the coolant reser-
voir.
Engine coolant: approx. 22.5 L.
● Refill the hydraulic tank with hydraulic oil.
Hydraulic tank: approx. 225 L

PD
● Start the engine to circulate the coolant
in order release the foams, and check
the coolant level again.
● Start the engine to circulate the hy-

draulic oil in the hydraulic system, and
check the oil level again.
● Air bleeding
IO
For more information, see “Air in Each
Component - Bleed” on page 6-45.

8.10 Final Drive AS - Remove and Install
8.10.1 Removal
CAUTION
ground. Stop the engine. Operate the
breather valve to release internal pres-
sure.
1. Remove the sprocket.
For more information, see “Sprocket -

Remove and Install” on page 8-60.
PD
2. Remove the motor cover plate (1).
1
ZX215-1006051
IO
3. Disconnect the four hoses (2) of the travel
motor and the corresponding hose connec- 2
tors.
ZX215T-1006052

4. Remove the 30 mounting bolts from the

final drive assembly (3), and lift the assem-
bly for disassembling.
3
Final Drive Assembly: 250 kg
NOTICE
● Be careful not to damage the surface
of mounting seal installed on the hose
base. ZX215-1006053
● Never use the threaded holes to lift the

cover when lifting the final drive.
8.10.2 Installation PD
Mounting bolts (final drive assembly):
245~309 N·m {25~31 kgf·m}

IO
● Hydraulic oil adding
Add hydraulic oil through the filler opening

to the specified level. Start the engine to
circulate oil in the hydraulic system, and
● Air bleeding


8.11 Final Drive AS - Disassemble and Assemble
8.11.1 Disassembly
1. Oil draining
Open the drain plug to drain the oil from

the final drive tank.
Final drive tank: approx. 4.7 L
2. Cover
①
Remove the bolts. Use eyebolts ① to the
cover (1).
PD 1
ZX215-1006054
IO
3. Spacer
2
Remove the spacer (2).
ZX215-1006055

4. No. 1 planetary carrier assembly

3
1) Remove the No.1 planetary carrier as-
sembly (3).
ZX215-1006056
2) Disassembly of No.1 planetary carrier

assembly. PD 9 7 4 5 10 8
3) Remove the screws (4). Remove the

coverplate (5) from the planetary carrier
assembly (6).
4) Remove the thrust washer (7), gear (8), 11

bearing (9), bearing inner race (10) and 6
ZX215-1006057
a second thrust washer (11).
IO
5. No.1 sun gear shaft 12
Remove No.1 sun gear shaft (12).
ZX215-1006058

6. Thrust washer 13 14
Remove the thrust washer (13).
7. No.2 sun gear
Remove No.2 sun gear (14).
ZX215-1006059
8. Disassembly of No.2 planetary carrier

assembly 18 19 15
PD
1) Remove the screws (15). Remove the
plate (16) and the planetary gear (17)
from the carrier assembly (22).
2) Remove the bearing inner race (19)

17
20
21
16
23
and outer race (18). Remove the plate 22

(20).
ZX215-1006060
3) Remove the screw (21) to take the
IO
planetary carrier assembly (22) and the
shim (23) from the body.
9. Hub assembly
②
1) Use eyebolts ② to remove the hub as-

sembly (24) from the travel motor.
24
ZX215-1006061

2) Disassemble the hub assembly as the

following. 26 27
3) Remove the float seal (25).
4) Remove the bearing (26) and bearing

(27) from the hub (28).
NOTE: Do not damage the bearing retainer

when removing the bearing (26).
25 28
ZX215-1006062
5) Remove the float seal (29) from the

travel motor.
PD 29
30
ZX215-1006063
IO

8.11.2 Assembly
NOTE: Clean all the parts. Check that these

parts are free from any contamination or dam-
age. Apply some engine oil to the sliding sur-
face prior to installation.
1. Hub assembly
1) Install the bearing 26 and bearing (27)

by pressing them onto the hub (28). 26 27
2) Install the float seal (25).
PD 25 28
ZX215-1006062
● Remove any oil or dust from the O-ring

or O-ring contact surface. Dry the parts
before installing the float seal.
IO
● After installing the float seal, check that
the angle of the floating seal is within 1
mm.
● Apply a thin layer of engine oil to the ZX215-1006064

sliding surface after the float seal has
been installed.
3) Install the float seal (29) to the travel

motor (30). 29
● See the above step 2 for the installation

procedure.
30
ZX215-1006063

4) Use eyebolts ② to carefully place the

②
hub assembly (24) onto the travel mo-
tor. Tap to press fit the bearing.
24
ZX215-1006061
2. Calculation of shim thickness

PD
1) Measure the thickness (H) of the raised
part of No.2 carrier assembly (22).
H
22
ZX215-1006065
IO
2) Measurement of raised thickness
Apply 3000 Kg load to the bearing and
measure the value (H) of the raised
part of the bearing.
加负荷3000Kg
● Turn the hub 2-3 times before applying
h
a pushing force.
● Do not use a spray gun to cushion the

bearing.
ZX215-1006066
● Do not push or strike the resin retainer.
3) Shim thickness calculation: C=H-h.

4) Place the shims on the body and insert

the dowel pin. Press the carrier assem-
bly onto the dowel pin and tighten it
with screw (21). Apply locking adhesive Tensiometer
to the threads.
Screw-locking adhesive:
(Kesaixin 1277)
ZX215-1006067
Screw (21):
539±28 N·m {55±2.9 kgf·m}
● Use a tensiometer to measure the tan-

gential force of hub to motor rotation.
PD
Tangential force: Max.294 N {30 kg}
Maximum tangential force occurs when

the rotating direction begins to change.
3. Assembly of No.2 planetary carrier as-

sembly 18 19 15
1) Assemble the No.2 planetary carrier 16

IO
assembly according to the following 17
procedure.
20
23
NOTE: Replace the plates (20) and (16) 21
with new parts.
22
2) Assemble the bearing (18) and bearing
(19) to the gear (17). Assemble the top
ZX215-1006060
and bottom plates (16) and (20), and
place the gear assembly into the carrier
assembly (22).
3) Tighten the screw (15).
Screw (15):
539±28 N·m {55±2.9 kgf·m}
● Check the flexibility of gear (17) after

assembling the planetary carrier as-
sembly.

4. Thrust washer 13 14
Install the thrust washer (13).
5. No.2 sun gear
Install No.2 sun gear (14).
ZX215-1006059
6. No. 1 sun gear shaft 12
Install No.1 sun gear shaft (12). PD

ZX215-1006058
IO
7. No.1 planetary carrier assembly
1) No. 1 planetary carrier assembly is as- 9 7 4 5 10 8

sembled as the following.
NOTE: Replace the thrust washers (7)

and (11) with new parts.
2) Assemble the bearings (9) and (10) 11

6
onto the gear (8). Assemble the top ZX215-1006057
and bottom thrust washers (7) and (11).

Place the gear assembly into the car-
rier assembly (6).
3) Fix the coverplate (5) to the carrier as-

sembly (6) with screw (4).

4) Install No.1 planetary carrier assembly

(3). 3
ZX215-1006056
8. Spacer
2
Install the spacer (2).
9. Cover
PD
Use eyebolts ① to assemble the cover (1).
Use a torque spanner to tighten the bolts.
Bolts: ZX215-1006055
IO
73.4±3.63 N·m {7.5±0.4 kgf·m}
10. Oil adding
Tighten the drain plug and add engine oil

through the filler.
Final drive case: approx. 4.7 L

Torque wrench
● Check the oil level after the final drive

has been successfully installed to the
chassis.
ZX215-1006068

8.12 Swing Motor and Swing Drive AS - Remove and Install
8.12.1 Removal
CAUTION
ground. Stop the engine. Press the re-
lease button of the breather valve to re-
lease residual pressure in the hydraulic
tank. Place the hydraulic lockout con-
trol in the LOCK position.
Release the residual pressure in the hy-

draulic circuit. Refer to “Residual Pressure
in Hydraulic Circuit - Release” on page 6-39.
1. Disconnect the hoses (1) to (7). PD

● Between hydraulic tank and swing motor
(port DR)
● Between central swivel joint and swing mo-
3
tor (port DR)

● Between swing motor and main valve (port
M) 5
7
● Between swing motor and main valve (port 4 1 6
2
IO
HA) ZXT225-1106002
● Between swing motor and main valve (port

HB)
● Between swing motor and main valve Px
port (port SH)
8
● Between swing motor and solenoid valve
block (port PG) 9
2. Remove the 11 fixing bolts (8).
3. Lift the swing motor and swing drive as-

sembly (9) for disassembling.
NOTE: Slowly lift the swing motor and

swing drive assembly in order to avoid ZXT225-1106003
damaging the hoses and other parts.
Swing motor and swing drive as-

sembly: 260 kg

8.12.2 Installation
● Installation is performed in the reverse or-

der of removal.
Mounting bolts (swing motor and

swing drive assembly):
490~608 N·m {50~62 kgf·m}

● Air bleeding
PD
IO

8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble
8.13.1 Disassembly
1. Draining of oil
Open the drain plug to drain the oil from

the swing drive.
Swing drive: approx. 4.4 L
2. Swing motor assembly

1
1) Place the swing motor and swing drive
assembly on a suitable cribbing. Be
careful not to damage the drive gear or
let it contact the ground. PD
2) Unscrew the 14 bolts in order to re-
move the swing motor assembly (1).
Swing motor assembly: 70 kg
ZX225-1006077
IO
3. No.1 sun gear
2
1) Remove No.1 sun gear (2).
ZX215-1006072

4. No.1 planetary carrier assembly 3 4
1) Remove No.1 carrier assembly (3) and

the plate (4).
ZX215-1006073
PD
2) Disassemble the carrier assembly.
Cut the rivets on the shaft (8) to remove

the shaft (8), and remove in turn the
5
6 7 8 9
gear (6), bearing (9) and plate (7).
ZX215-1006074
IO
5. Ring gear
10
Unscrew the mounting bolts to remove the

ring gear (10).
ZX215-1006075

6. No. 2 sun gear 11
Remove No. 2 sun gear (11).
ZX215-1006076
7. No.2 planetary carrier assembly

PD
1) Remove No.2 carrier assembly (12).
12
2) Disassemble No. 2 carrier assembly as

IO
ZX215-1006077

3) Insert pin (13) and push the shaft (14)

19 16 15
out of the carrier assembly (19). 18
17
NOTE: Pull out the pin (13) after
removal of the shaft. 14
4) Remove the thrust washer (16), gear 13

ZX215-1006078
(17) and a second thrust washer (19).
5) Insert the pin (15) to remove the bear-

ing (18) from the shaft. Remove the pin
(15).
20
8. Snap ring
Remove the snap ring (20).

PD
ZX215-1006079
9. Disassembly of main shaft

IO
1) Place the shaft housing assembly on a 压出 21 22
press and push the shaft assembly (21)
out of the shaft housing assembly (22).
ZX215-1006080

2) Disassemble the shaft assembly in the

压出
following procedure.
Remove the bearing (23) from the shaft

(24).
23
24
ZX215-1006081
10. Bearing
PD
Remove the bearing (25) and the oil seal
26
27
(26) from the housing (27).

IO
25 ZX215-1006082

8.13.2 Assembly
NOTE: Clean all the parts and check for any

contamination or damage. Apply engine oil to
the sliding surface of the parts.
1. Bearing 23
Press the bearing (23) into the housing

(27).
2. Oil seal
PD
Press the oil seal (26) into the housing (27). 27
27
26
ZX215-1006083
Oil seal installation surface:
Gasket sealant (Loctite 515)

IO
ZX215-1006084
3. Housing assembly
24
1) Position the plate (28) on the shaft (24).
2) Position the housing assembly (22) on

the shaft (24). Press in the bearing. 22
28
ZX215-1006085

4. Bearing 22 25
Press in the bearing (25).
● When press fitting the bearing, press

the bearing inner race and outer race
simultaneously. Never press only the
inner race.
● After assembling the bearing, check if

the housing rotates freely.
ZX215-1006086
5. No. 2 Planetary carrier assembly

19 16 15 18
PD
1) Reassemble No. 2 carrier assembly ac-
cording to the following procedure.
2) Assemble the plate (16) in the carrier

assembly (19).
17
14
13
ZX215-1006078
3) Assemble the gear (17) in the carrier
assembly (19). Put the bearing (18)
on the shaft (14). Slightly tap the pin
(15) into the bore after alignment. Use
IO
a rubber hammer to tap the pin. Make
sure that the pin (15) must not higher
than the bearing (18).
4) Push the shaft assembly into the car-

rier assembly (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 install the pin
(13). Carefully tap the pin with a rubber
hammer during installation.
NOTE: Installation of the shaft requires

rotating the planetary gear. Be careful not
to damage the thrust washer.

6. Assemble in turn the snap ring (20),

11
No.2 carrier assembly and No.2 sun No.2 planetary carrier 20
gear (11).
ZX215-1006087
7. Installation of ring gear PD

Apply sealant on the mating surface
indicated by (C) and tighten it with screws.
Never get the sealant onto the ring gear
(10).
10
Mating surface:
Sealant (Loctite 515)

IO
8. No. 1 planetary carrier assembly
1) No. 1 carrier assembly is assembled as

2) Install the plate (7) into the carrier as-

ZX215-1006088
sembly (5).
3) Install the gear (6) onto the plate after

6 7 8 9
installing the bearing (9) into the gear. 5
4) Press the shaft (8) into the gear (6) and

the carrier assembly (5). Rivet one end
of the shaft. ZX215-1006074
● Check if the gear rotates freely.

5) Install No. 1 carrier assembly (3) and 3 4

the plate (4).
ZX215-1006073
9. No. 1 sun gear assembly
Install No. 1 sun gear (2).

PD 2
IO
ZX215-1006072

10. Installation of swing motor assembly
Apply sealant to the contact surfaces of the

ring gear and the motor cover, and install
the swing motor assembly.
Contact surface:
Sealant (Loctite 515)
Swing motor assembly: 62 kg
Mounting bolts (swing motor):
156±5 N·m {16±0.5 kg}
NOTE: The 14 bolt holes of the swing

PD
motor and swing drive assembly are
distributed nonuniformly. The mating direc-
tion of each hole is fixed, 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 instal-
lation orientation.
IO
11. Lubricant adding
Screw on the drain plug and add lubricant

through the filler to the specified level (the
upper mark of oil stick).
ZX215-1006089
Swing drive: approx. 4 L

8.14 Idler AS - Disassemble and Assemble
8.14.1 Disassembly
1. Remove the dowel pin (1) and the support 7
(2). 8
6
13
12
2. Remove the float seals (3) from the sup- 10
5
port (2) and the idler (4).
3. Remove the O-ring (11). Remove the idler

(4) from the shaft (5) and the support as-
9
sembly (7). 11
3
1
NOTE: The idler contains 80 ml oil, which
should be drained completely before disas-
sembling. Spread a cloth on the floor to
PD
prevent smearing the floor with oil.
4
2 ZX215-1006090
4. Remove the float seals (6) on the other

4 6
side from the idler (4), shaft (5) and sup-
port assembly (7). 5
IO
6 7
ZX215-1006091
5. Remove the dowel pin (8) in order to re-

move the support (7) from the shaft (5).
5
9，10 4
6. Remove the bushings (9) and (10) from the
idler (4).
7 8
ZX215-1006092

8.14.2 Assembly
1. Install the bushings (9) and (10) in the idler

(4).
9 10 4
ZX215-1006093
2. Assemble the O-ring. Install the support (7)

PD
to the shaft (5) with the dowel pin (8).
9，10 4
5
7 8
ZX215-1006092
IO
3. Install the float seals (6) to the idler (4),
shaft (5) and support (7) assembly.
6
● Float seals
Completely remove the grease from the

contact surfaces (hatched area in the
illustration on the right) of O-ring and ZX215-1006094
float seal before installing the float seal.
In addition, care must be taken to keep
the contact surface of float seal free
from dust.

● After installation of the float seals,

check that the sealing inclination should
be less than 1 mm and the seal protru-
a
sion between 5 and 7 mm.
ZX215-1006095
4. Install the shaft (5) and support (7) assem-

bly to the idler (4). 7 5
4
PD
ZX215-1006096
IO

5. Install the float seal (3) to the idler (4) and

support (2). 4 3
2 3
NOTE: Apply oil to the sliding surface of
float seal. Care must be taken to keep the
sliding surface from any contaminants or
dust.
NOTE: Remove the oil and dust from the ZX215-1006097

contact surfaces of the O-ring and float
seal.
PD ZX215-1006098
6. Install the O-ring. Install the support (2) 7

with the dowel pin (1). 8
6
13
12
7. Add oil and screw on the plug. 10
IO
5
Oil: approx.
80 ml (No.18 hyperbola gear oil) 9

11
3
1
Plug:
205.8±49 N·m {21±5 kgf·m}
4
2 ZX215-1006090

8.15 Sprocket - Remove and Install
8.15.1 Removal
1. Remove the track assembly.
Refer to “Track AS - Remove and Install”

on page 8-61. 1
2. Swing the work equipment 90°and lift the

chassis with the work equipment. Place a
block ① between the track frame and the
①
track shoe.
3. Remove the sprocket (1).
Sprocket: 58 kg
PD ZX215-1006099
8.15.2 Installation

IO
Threads (bolt - sprocket):
Thread sealant (Kesaixin 1277)
Bolts (sprocket):
339±20 N·m {35±2 kgf·m}

8.16 Track AS - Remove and Install
Special tools
Mark Part Name Necessity Qty

Manual/electric hydraulic
M track removing/installing ● 1
machine
8.16.1 Removal
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
PD
carrier roller.
2. Lower the work equipment. Loosen the

grease fitting (1) and release the track ten-
sion.
1
WARNIN G
● The adjustment cylinder is under ex- ZX215T-1006100
IO
tremely high pressure. Never loosen the
grease fitting by more than one turn.
3. Pull out the master pin (2) with the tool (M).
ZX215-1006101

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

②
dust seal. Move the machine backward to 3
spread the track (3).
ZX215-1006102
PD
IO

8.16.2 Installation
● Installation is to be performed in the re- Corner Track shoe nut

(Square)
For more information, see “Track Tension - R

Test and Adjust” on page 6-23.
R
Corner
● Installation procedure of track shoe bolts
Corner
and nuts R
1. Bring the R side of the track shoe nut (1)

to the link seat surface. Both seat surfaces Seat surface
should be in close contact when assem- in close contact
bling the track shoe.
NOTE: If the track shoe bolts are installed

PD
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.
2. Tighten the bolts of track shoe to the

torque below.
ZX215-1006103
Track shoe bolts:
750±30 N·m {77±3 kgf·m}

IO
● 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): 2.5±1 mm
● Before installing the dust seal, apply

a
grease (No.2 lithium base) to its contact
surface with the bushing.
ZX215-1006104

8.17 Swing Bearing AS - Remove and Install
8.17.1 Removal
1. Remove the swing platform assembly.
For more information, see “Swing Platform

2. Dismount the 36 bolts (1) to remove the

2
swing bearing assembly.
PD 1
ZX215T-1006105
3. Hoist the swing bearing assembly (2).
Swing bearing assembly: 314 kg

2
IO
ZX215T-1006106

8.17.2 Installation

Threads (bolt - swing bearing):
Thread adhesive (Tonsun 1277)
Mounting bolts (swing bearing):
Step 1:
Use a pneumatic spanner to tighten the

bolts.
Step 2: PD
Torque to: 549±59 N·m {56±6kgf·m}
1) When a torque spanner is used to tighten

the bolts, tighten first the four corners and
mark them.
2) Other bolts will be tightened clockwise or

counterclockwise. After one bolt is tight-
ened, tighten the next one on the diagonal
IO
position and make a mark.
3) Tighten the rest bolts in this 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 bearing to the track
frame.
Inner race soft zone

● Apply grease to the inside of the gear
ring of the swing bearing.
NOTE: All gear teeth must be covered

ZX215T-1006107
by grease .
Swing bearing:
Grease(supramoly lithium base):15 L

8.18 Swing Platform AS - Remove and Install
8.18.1 Removal
CAUTION
● Fully extend the arm and the bucket.
Lower the work equipment to the
ground and move the hydraulic lockout
control lever to the LOCK position.
1. Disassemble the work equipment assem-

bly.
For more information, see “Work

Equipment AS - Remove and Install” on
page 8-103. PD
2. Remove the counterweight assembly. 1
For more information, see “Counterweight

ZX215T-1006108
3. Remove the four hoses (1) of boom cylin-
der.
IO
NOTE: Plug the hoses to prevent flow of
oil.
4. Lift the boom cylinder assembly (2).
ZX215T-1006109

5. Remove the plate (3) and the pin (4). Lift

the boom cylinder assembly (2) in order to
remove it. 4
● Remove the boom cylinder assembly

on the other side in the same way.
Boom cylinder AS: 230 kg

3
ZX215T-1006110
6. Remove the plate (5), air intake hose (6)

and fan guard (7).
PD
NOTE: Removal of the swing platform
requires removing other parts that interfere
with the lifting of swing platform.
5
7
7. Disconnect the six hoses above the swivel
ZX215T-1006111
joint assembly.
IO
● Central swivel joint (port A) - Left travel
control valve (port BTL)
● Central swivel joint (port C) - Left travel

control valve (port ATL)
● Central swivel joint (port F) - Solenoid

valve
10 11
● Central swivel joint (port G) - Swing 9
motor (port T) 12
8
13
● Central swivel joint (port D) - Right trav-
14 ZX215T-1006112
el control valve (port ATR)
● Central swivel joint (port B) - Right trav-

el control valve (port BTR)

8. Remove the bolt (14).
9. Unscrew the 32 swing platform mounting

bolts in order to remove the swing platform
assembly (15). Lift the swing platform as-
sembly off the machine.
NOTE: Remove the front and rear mount-

ing bolts of the platform. Use a lever block
to adjust the swing platform so that the
platform can reach a balance both longi-
tudinally and laterally. Remove the last two
bolts finally.
NOTICE
● Be careful not to impact the central
PD
swivel joint while removing the swing
platform assembly.
Swing platform assembly:
Swing Platform 15
Assembly
Only (Ref.)
SY195C9 8,427 kg 1,689 kg
IO
SY205C9 8,382 kg 1,689 kg
SY215C9 8,427 kg 1,689 kg
ZX215T-1006113

8.18.2 Installation

Clamping screws (air intake hose):
5.4~6.4 N·m {0.55~0.65 kgf·m}
Mating surface (swing bearing):
Flat surface sealant (Tonsun 1596)
Threads (bolt - swing platform):
Thread adhesive: (Tonsun 1277)

PD
Mounting bolts (swing platform):
Step 1: Tighten the bolts with a pneumatic

spanner.
Step 2: tighten them again.
490~608 N·m {50~62 kgf·m}

IO
Add through the filler opening the hydraulic

oil to the specified level. Start the engine
to circulate oil in the hydraulic system, and
● Air bleeding
Bleed the air from the travel motor.


8.19 Swivel Joint AS - Remove and Install
8.19.1 Removal
WARNIN G
● Release residual pressure in the hy-
draulic circuit before disconnecting the
hydraulic hoses.
Refer to “Residual Pressure in Hydraulic Cir-

cuit - Release” on page 6-39.
NOTE: Tag each line so as to ensure correc-

tion installation.
1. Disconnect the six hoses from (1) to (6) on

PD
the central swivel joint of the travel motor.
4
1) Central swivel joint (port T) - Left travel 3 5
motor (port T)
2) Central swivel joint (port T) - Right trav-

el motor (port T) 6
3) Central swivel joint (port B) - Left travel 2 1

motor (port PA)
IO
4) Central swivel joint (port D) - Right trav- ZX215T-1006114
el motor (port PB)
5) Central swivel joint (port A) - Left travel

motor (port PB)
6) Central swivel joint (port C) - Right trav-

el motor (port PA)

2. Disconnect the eight hoses from (7) to (14).

10
7) Central swivel joint (port F) - Left travel 9
motor (port P)
13
8) Central swivel joint (port F) - Right trav-
el motor (port P)
7
9) Central swivel joint (port G) - Swing 11 12 8
motor (port T)
14
10) Central swivel joint (port F) - Solenoid
valve 15
ZX215T-1006115
11) Central swivel joint (port C) - Left travel

control valve (port ATL)
12) Central swivel joint (port A) - Left travel

control valve (port BTL) PD
13) Central swivel joint (port D) - Right trav-
el control valve (port ATR)
14) Central swivel joint (port B) - Right trav-

el control valve (port BTR)
16
IO
ZX215T-1006116
3. Remove the fixing bolt (15).
4. Remove the four mounting bolts (16).

18
5. Remove the six mounting bolts (17) from
the transition plate. Remove the swivel
joint assembly (18).
Central swivel joint: 56 kg
Transition plate
16
17 ZX215-1006117

8.19.2 Installation

verse order of removal. B D
NOTE: Install the central swivel joint facing

the direction indicated in the illustration.
Central swivel joint
● Oil adding (hydraulic tank) Sprocket
Add through the filler opening the hydraulic

oil to the specified level. Start the engine
to circulate oil in the hydraulic system, and
A C
ZX215-1006118
● Air bleeding PD
Bleed the air from the travel motor.

IO

8.20 Swivel Joint AS - Disassemble and Assemble
8.20.1 Disassembly
1. Remove the bolt (1) and the spring washer 1

(2). 2
3
2. Remove the cover (3).
4
3. Remove the gasket (4), O-ring (5) and 5

snap ring (6). 6
7
4. Remove the rotor (13) from the housing (9).
8
NOTE: Be careful not to damage the slid-

ing surface of the seal of the rotor (13).
PD 9
5. Remove the spacer (7) and the gasket (8)
from the housing (9).
6. Remove the dust seal (12) from the swing 10

shaft (13).
7. Remove the O-ring seal (11) and the seals 11
(10) from the housing (9). 12

IO
13
ZX215-1006119
ZX215-1006120

8.20.2 Assembly
1. Install the dust seal (12) on the rotor (13).

Dust seal
NOTE: Let the lip face the housing while
installing the dust seal.
Lip
2. Install the six seals (10) in the housing (9).
3. Fix the rotor (13) on a work bench. Install Body

the housing (9) on the rotor (13).
ZX215-1006121
NOTE: Since the clearance between

the housing (9) and the rotor (13) is ap-
proximately 0.1 mm, install the housing (9)
on the rotor (13) slowly and vertically. Be
careful not to damage the seals (10) and
PD
the O-ring seal (11).
4. Use a rubber hammer to tap the housing (9)

in order to match the rotor (13) properly.
5. Install the spacer (7) and gasket (8) in the

housing (9).
6. Install the gasket (4), O-ring seal (5) and

snap ring (6) on the rotor (13).
IO
7. Install the cover (3). Tighten the bolts (1)
and the spring washer (2).
Fixing bolts: 49 N·m{5 kgf·m}

8.21 Hydraulic Tank AS - Remove and Install
8.21.1 Removal
1. Drain the hydraulic oil into a suitable

container for storage or disposal. 1
Hydraulic oil: approx. 225 L 2 5 4

3
3. Remove the engine hood (1), cover (2) and

control valve cover (3).
4. Remove the cover mounting frame (4) and

the screen (5). ZX215T-1006122
PD
5. Remove the screen (6) and the partition
frame mounting bolt (7) on the hydraulic
tank side.
6 7
6. Remove the screw (8) and the fuel control

motor (9).
IO
8
9
ZX215T-1006123
7. Remove the two oil return hoses (10) from

the hydraulic tank.
10
ZX215T-1006124

8. Disconnect the seven hoses.
● (11): Oil return - pilot T block
● (12): Oil return - main pump

17
● (13): Oil return D2 - main valve
● (14): Sensor - temperature 18

● (15): Oil return - solenoid valve 15 11
12
● (16): Oil return D1/D3 - main valve 13
16 14
ZX215T-1006125
● (17): Oil return - swing motor
NOTE:
● Disconnect the oil inlet hose (18) from the

PD
hydraulic tank after disconnection of the oil
inlet tube from the pump.
● Attach each hose with an identification tag.
● Use a sleeve nut to prevent the fitting and

19
the cone seal from damage.
9. Remove the hose clamp (19).

ZXT225-1106008
IO
10. Lift the hydraulic tank assembly and re-
move the six bolts (20).
11. Lift off the hydraulic tank assembly for dis-

assembling. 20
Hydraulic tank assembly: 130 kg
ZX215T-1006127

8.21.2 Installation

verse order of removal. Screw
Drain plug (hydraulic tank):
58.8~78.5 N·m {6.0~8.0 kgf·m}

Up
Down
NOTE: After tightening the hose clamping
screw, check that the screw should be in
the range indicated in the illustration.
ZX215-1006128
Screw (hose clamp):
8.8±0.5 N·m {0.9±0.05 kgf·m}

PD Pipe Clamp Hose
● Install the hose clamp and tighten the
screw according to the illustration on
the right.
Bolt:
245.2~308.9 N·m {25~31.5 kgf·m}

Bulge
ZX215-1006129
IO
● Oil adding (hydraulic tank)

● Air bleeding


8.22 Control Valve AS - Remove and Install
8.22.1 Removal
WARNIN G
1
ground. Stop the engine. Press the re-
lease button of the breather valve to re-
lease residual pressure in the hydraulic 2
tank. Place the hydraulic lockout con-
trol in the LOCK position.

tion installation. ZXT225-1106009
1. Lift the hood (1). PD

2. Remove the cover (2) above the control
valve.
3. Remove the engine silencing hood (3).

IO
3
ZXT225-1106010
4. Remove the baffle (4) to (9) of the pres-

sure transducer and tag them.
(4): XAK Bucket DIG

7
(5): XBb1 Boom DOWN 4
8
(6): XAtL Travel LEFT 5
9
(7): XBa1 Arm IN 6
(8): XBs Swing RIGHT
(9): XAtr Travel RIGHT ZXT225-1106011

5. Disconnect the pilot hoses (10) to (18) and

tag them properly. 10 11 12 13 14
(10): XBtr Travel RIGHT
(11): XAs Swing LEFT

18
(12): PSP Swing priority
(13): XAa1 Arm OUT 15

16
(14): XBp2 Bucket confluence 17
(15): XBtL Travel LEFT ZXT225-1106012
(16): XAb1 Boom UP
(17): XBK Bucket DIG
(18): XAa2 Arm OUT

PD
6. Remove the port (19) (accumulator to
solenoid valve), port (10) (pilot filter to ac-
cumulator). Remove hose clip (21) of the
central swivel joint.
IO
21
19 20
ZXT225-1106013
7. Remove bucket hoses (22) and (23) and

seal the ports.
8. Remove arm hoses (24) and (25) and seal

the ports.
9. Remove boom hoses (26) and (27) and

seal the ports. 22 24 25 23
26
27 ZXT225-1106014

10. Remove central swivel joint hoses (28),

(29), (30) and (31). Remove travel speed 32
switching hose (32) and seal the ports.
30
29
28 31
ZXT225-1106015
11. Remove swing motor hoses (33) and (34).

Remove swing motor oil complement hose
(35). Seal the ports properly. 33
PD 35
34
ZXT225-1106016
IO
12. Remove pipe (36) (main valve to radiator).
36
ZXT225-1106017

13. Remove pipe (37) (main valve to return oil

tank). Seal the ports properly.
37
ZXT225-1106018
14. Remove hydraulic pump hoses (38) and

(39).
PD
38 39
ZXT225-1106019
IO
15. Remove hoses (40) to (44) on the solenoid
valve and tag them properly.
(40): PPC lockout valve
(41): Main valve PnA2
(42): Main valve XBP2 44 43 42 41 40
(43): Main valve PSP

ZXT225-1106020
(44): Travel PT port

16. Remove the fixing bolts (45). Lift the con-

trol valve assembly (46) for disassembling.
Control valve assembly: 220 kg
45
45
46
ZXT225-1106021
8.22.2 Installation
PD

IO
● Air bleeding
Bleed the air from the circuit between the

valve and the hydraulic cylinder.


8.23 Hydraulic Pump AS - Remove and Install
8.23.1 Removal
WARNIN G
ground and stop the engine. Press the
release button of the breather valve to
release residual pressure in the hydrau-
lic tank.
● Disconnect the cable from the negative

(-) post of the battery before performing
the job.
PD
tion installation.
1. Remove the oil inlet filter element from the

hydraulic tank and stop oil outflow with an
oil stopper.
Oil stopper
NOTE: If no oil stopper is used, remove
the drain plug and drain the oil from the
hydraulic tank and from circuits.
IO
ZX215-1006144
Hydraulic tank: Approx. 225 L
2. Lift the hood (1).
ZX215T-1006145

3. Remove the pin (2) and the bolts (3). Lift

the engine hood in order to remove it.
2
ZX215T-1006146
4. Remove the right upper cover (4).

4
PD
3
IO
ZX215T-1006147
5. Disconnect the hose (5) supplying oil to the

lower proportional valve and the hose (6)
delivering oil from the pilot pump.
5 6
ZX215T-1006148

6. Disconnect the shutdown wire (7).
7
ZX215T-1006149
7. Remove the right door (8).
8. Remove the hydraulic pump cover (9).

PD
8
9
ZX215T-1006150
IO
9. Disconnect the oil drain hose (10) and seal
10
the openings properly.
10. Disconnect the high-pressure hoses (11)

and (12) connecting to the control valve,
and seal the openings properly.
12
11. Disconnect the harness (13) of the pres- 11
sure transducer.
13
12. Disconnect the pilot pump oil inlet hose (14) 14
and seal the openings properly. 15
ZX215T-1006151
13. Disconnect the pilot pump oil inlet tube (15)

and seal the openings properly.

14. Disconnect the solenoid valve harnesses

(16) and (17). Remove the cable straps (18)
and (19).
16 18 19 17
ZX215T-1006152
15. Remove the four bolts (20) of the hydraulic

PD
pump. Lift the hydraulic pump assembly
(21) to remove it.
Hydraulic pump assembly: 112 kg

21
20
IO
ZX215T-1006153

8.23.2 Installation

verse order of removal. Screw
NOTE: After tightening the hose clamping

screw, check that the screw should be in
the range indicated in the illustration.
Up
Down
Screw (hose clamp):
8.8±0.5 N·m {0.9±0.05 kgf·m}

ZX215-1006128
● Install the hose clamp and tighten the

Clamp Hose
screw according to the illustration on Pipe
the right. PD
Mating surface (hydraulic pump
housing):
Gasket sealant: (Loctite 515)

Bulge
ZX215-1006129
IO

Hydraulic tank: approx. 225 L
● Air bleeding


8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install
8.24.1 Removal
1. Remove the hydraulic pump assembly (1).

1
For more information, see “Hydraulic Pump
AS - Remove and Install” on page 8-83. 2
3
4
2. Remove the screw (2). Remove the bear-
ing cover (3).
3. Pry the oil seal (4) out with a screwdriver.
NOTE: Be careful not to damage the shaft

while prying the oil seal.
ZX215-1006154
8.24.2 Installation
PD
4
Seal lip:
IO
Grease (No.1 Calcium base grease)
Seal circumference:
● Apply a thin layer of grease to the oil

seal circumference. ZX215-1006155

8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble
NOTE: This section discusses only the precautions when reassembling the work equipment pilot
valve assembly.
8 9
1 2 3 4 5 6 7 10
ZX215T-1006156
8.25.1 Assembly
valve assembly
PD
● Reassembly of the work equipment pilot Plug (5) circumference:

1. Install the plate (9) in the valve body (8)
with O-ring seal. Tighten the socket bolt
U-joint moving surface:
(10).
Socket bolt: Grease (No.1 Calcium base grease)

IO
25~33 N·m {2.55~3.36 kgf·m} Threads in valve body:
2. Insert the spring (7) into the spool hole in Thread adhesive (Tonsun 1277)
the valve body (8). Put the spool (6) in the
spring. Install the plunger (5) on the spool.
Push the plug (5) to the spool hole.
3. Install the plate (4) on the plunger (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 N·m {10~13.5 kgf·m}
NOTE: Location of each oil port is stamped

on the bottom of valve body.

● A p p l y t h e t h r e a d a d h e s i v e ( To n -
sun 1277) to two points on the inner 5~7 mm
threads. The amount of application is
approximately 0.02 g.
U-joint (3):
98~133 N·m {10~13.5 kgf·m}
NOTE: Tightening is to be made to the ZX215-1006157
specified torque.
Contact surface between

plunger (5) and plate (2):
Grease 0.3~0.8 ml (No.1 Calcium base

grease) PD
IO

8.26 Pilot Valve AS (Travel) - Disassemble and Assemble
NOTE: This section discusses only the precautions when reassembling the travel pilot valve as-
sembly.
Plunger
9 8 7
PD 6
5
4 3 2 1
ZX215T-1006158
8.26.1 Assembly
● Reassembly of the pedal pilot valve assembly

IO
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 bolts (1).
Bolt (socket): 98~114 N·m {10~11.6 kgf·m}
3. Install the dust ring (3) on the plunger. Install the cover (2) and fix the cover (2) with the cam-
shaft (5).
Contact surface between plunger and dust ring (5):

8.27 Hydraulic Cylinder AS - Disassemble and Assemble
Special tools
Application Tool Shape Necessity Quantity
Pulling out/pushing
■ 1
in the bushing
ZX215-1006159
Press fitting the

■ 1
dust ring
ZX215-1006160
O-ring seal correc-

tion
PD ■ 1
Inserting tool Correcting tool

ZX215-1006161
IO
Inserting the cylin-
■ 1
der head ZX215-1006162
Inserting the piston ■ 1
ZX215-1006163

8.27.1 Disassembly
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 disassembled and assembled eas-
ily.
● The pin bore in the head end can be

used for fixing of the cylinder. The pin
roll can prevent the cylinder from turn-
ing.
● Remove the tubing in case of tubing in-

PD Fix the cylinder
terference while fixing the cylinder.
IO
ZX215-1006164
3. Removal of cylinder head

Approx 1.5m
● Unscrew the bolts with Allen Wrench.
● Using an extension rod, as shown in

the illustration on the right, will make
the work easy.
ZX215-1006165

4. Pulling out the piston rod
● Be sure to have removed the tubing

cover.
● Prepare a suitable container to collect 1 2

oil coming out of the oil port.
● After pulling out the piston rod to its

limit, slowly loosen the cylinder head Sleeper
and pull it out.

ZX215-1006166
● Remove the piston rod (1) with the
cylinder head (2) and place them on a
wooden sleeper.
5. Fixing the piston rod

PD
● Use pin bore on the rod end or the flat
part of the ear to prevent turning of the
Fixing
5
piston rod.
ZX215-1006167
IO

6. Remove of the piston nut (5)

Drill bit
1) Remove the fixing screw (3) from the 3

piston nut (5).
NOTE: 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).
2) Remove the steel ball (4). 4 ZX215-1006168
3) Remove the piston nut (5). 5
NOTE: The piston nut (5) is very tight.

To loosen the piston nut (5), prepare
PD
a hydraulic jack or a spanner powered
by hydraulic cylinder. An extension rod
should be ready when removing the Hydraulic jack
piston nut (5) manually.
Hydraulic cylinder
ZX215-1006169
7. Removal of piston assembly

IO
2 6 7
● Remove in turn the piston (7), buffer
sleeve (6) and cylinder head (2).
ZX215-1006170

8. Removal of the buffer sleeve (8) on the

Thread
bottom end
1) Remove first the piston nut (5).

Piston rod
2) Use a tool like rubber hammer to tap
the piston nut (5) slightly for removal
while keeping the piston rod and the
buffer sleeve (8) intact. Remove the
elastic ring (9).
9 10 8 11
3) Slide the buffer sleeve (8) toward the one gap (2 pcs)
piston threads in order to remove the ZX215-1006171
two-piece stopper ring.
4) Remove the buffer sleeve (8).

PD
5) 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

Screwdriver
1) The slide ring (12) and the guard
ring (13) can be simply removed with 14 12
Piston
hands.
IO
2) The seal (14) can be removed with a Bench clamp
hammer and a flat-head screwdriver.
3) Remove the O-ring seal (15) with a pry

bar. 15 13 ZX215-1006172
NOTE: The removed seals should not

be reused.
10. Removal of buffer ring (16)
NOTE: The buffer ring (16) is installed 18

in the inner groove in the cylinder head.
Use a tool with sharp end to pry it out and
remove it with a scraper.
20
17 16 19
ZX215-1006173

11. Removal of the U-ring (17) and the dust

ring (18)
Press
1) Remove the U-ring (17) with a tool such
as screwdriver.
2) Pierce a tool (such as a screwdriver)

Cushion
into the dust ring (18) and hammer the
screwdriver to remove the dust ring
(18).
21
NOTE: The removed seals should not
be reused.
12. Removal of bushing (19)

Support
ZX215-1006174
1) Remove the elastic ring (20) from the
PD
cylinder head (2) with a screwdriver.
2) Push the bushing (19) out with the help

of clamps and press.
13. Removal of bushing (21)
1) Remove the dust ring (22) on the side

of cylinder barrel and piston rod with a
tool such as screwdriver.
IO
2) Remove the bushing (21) with the help
of a suitable cushion block.

8.27.2 Assembly
1. Installation of bushing (21)

Press
1) Use a mounting tool to press the bush- Mounting tool

ing (21) into the bushing (lubricated Cushion
with hydraulic oil) on the side of piston 21 Piston rod
rod and cylinder barrel. 22
21
2) Install the dust ring (22) with the help of
a suitable cushion block. ZX215-1006175
2. Assembly of cylinder head (2)

Hydraulic press
1) Use the press to push in the bushing
(19). PD 2
NOTE: Apply hydraulic oil to the inside Tool
of cylinder head in advance. Make
sure that the bushing (19) pushed in is
free from a raised shoulder.
Surface 19
under pressure
IO
ZX215-1006176
2) Use the press to push in dust ring (18).
3) Install the guard ring and the U-ring (17)

sequentially in the U-groove. 18
Tool
U-groove
NOTE:
● Install the U-ring (17) in correct direc- Press in

tion. Make sure that the U-ring is intact
before installation.
ZX215-1006177
● Inverse installation will cause leak of
oil.
● Make sure that the U-ring is free from

any corrugation or permanent deforma-
tion after installation.

4) Installation of buffer ring (16)

18
NOTE: Make sure that the seal is
installed in correct direction. Inverse
installation can cause high pressure be-
tween the buffer ring (16) and the U-ring
(17), which may lead to deformation or 20
17 16 19
breakage of oil cylinder. ZX215-1006178
5) Install the elastic ring (20) to prevent

the fall of the bushing (19).
3. Assembling the piston assembly

Press
Block Press
1) Installation of seal (14).
Tool
NOTE: Install first the O-ring seal and
PD 13
the one-side guard ring (13) on the
piston. Place the piston on the press. Tool
As shown in the illustration on the right, Corrector
the seal (14) is installed with the tools

Piston
indicated.
12 O-ring
2) Correction of seal (14) 14
13
NOTE: Install the seal (14) and the
guard ring (13) on the other side. In
IO
ZX215-1006179
order to prevent the expansion 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.
3) Installation of slide ring (12)
NOTE: 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

Assembly tool 2
1) Fix the piston rod (1).
2) Install the cylinder (2) on the piston rod.
NOTE: Make sure that the dust ring lip

or the U-ring lip is not stopped by the
shoulder of any part. Install the cylinder 1 ZX215-1006180
head and the piston rod with the tools.
3) If the bottom side of cylinder contains

a buffer (not for bucket cylinder), install Gap facing thread direction
the buffer bearing and the buffer seal in Thread
the following order.
PD
4) Let the notched side of the buffer seal
(10) face the piston while installing the
buffer seal (10) in the groove.
5) Install the buffer sleeve (8) according to

Piston rod
the indication in the illustration on the

right. 9 11
10 8
One gap (2 pcs)
6) Install the stopper ring in the groove.
Install the elastic ring after the buffer Head end buffer
IO
ZX215-1006181
sleeve (8) is pushed to the bottom. A
rubber hammer should be used for the
tapping job in order to avoid damaging
the piston rod and the buffer bearing.
7) If the head side of cylinder contains a

buffer, install the buffer sleeve (6) and
the buffer seal (23) according to the fol-
lowing order.
8) The piston nut must be installed after

installation of the buffer bearing.
9) The buffer seal (23) must be installed in

the groove, with its notches facing the
piston.

10) The buffer sleeve (6) must be installed

according to the illustration on the right. 23 6
5
11) Tighten the piston nut (5).
Piston nut (arm):
9600 N·m {979.6 kgf·m}
Piston nut (boom and bucket):

Gap facing piston side
6200 N·m {632.6 kgf·m} Rod end buffer
ZX215-1006182
NOTE:
● Insufficient tightening can cause oil

leakage, loose nut and thread break-
PD
age. In addition, 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 ba-

nana oil) the threaded portions of the
piston, nuts and piston rod before tight-
ening the nuts.
IO
12) Treatment of the piston against loosen-
ing
NOTE: After the piston nut (5) is tight-

ened, put in the steel ball (4), tighten Punch
the setscrew (3) and punch to rivet the Rivet
two peripheral points.
Setscrew (3):
66.9 N·m {6.8 kgf·m} 3
ZX215-1006183

5. Install the piston into the cylinder barrel

Tool
Nylon sleeve
1) Fix the barrel in a vertical or level man- (2 pcs type)
ner.
2) Install the piston rod into the cylinder

barrel. (Spread the
gaps by 180°)
NOTE:
● 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.
PD ZX215-1006184
6. Tightening of cylinder head

8 1
IO
Tighten the cylinder head according to the
sequence shown in the illustration on the 4 9
right.
12 5
Bolt: 267 N·m {27.2 kgf·m}
7. Install the tubing.

6 11
10 3
2 7
Tightening sequence
ZX215-1006185

8.28 Work Equipment AS - Remove and Install
8.28.1 Removal
WARNIN G
● Fully extend the arm and the bucket.
Lower the work equipment to the
ground. Move the hydraulic lockout
control to the LOCK position.
● Release residual pressure in the hy-

draulic circuit.
See “Residual Pressure in Hydraulic Circuit -

Release” on page 6-39. 5
1. Disconnect the grease hose (1).

PD
2. Lift the boom cylinder assembly (2). Re-
move the lock bolt (3).
2
1
3
4
3. Remove the plate (4) and then the pin (5).
NOTE: There are shims installed. Count ZX215T-1006186
the shims and check the thickness. Place

IO
the shims in a safe place.
4. Start the engine and retract the piston rod.
NOTE: Secure the piston rod with a wire

rope in order to prevent the piston from
slipping out. Put the cylinder on a bench or
support. Remove the grease fitting on the
bottom side in the later case. Remove the
other boom cylinder in the same way.
6 10 7
8 9
5. Remove the two hoses (6) of bucket cylin-
der and the those (7) of the arm cylinder.
ZXT225-1106028
NOTE: Cork the hoses to prevent outflow
of oil. Secure the hoses to the valve side.
6. Remove the inter-connector (8) used for

work lamp.

7. Lift the work equipment and remove the

plate (9). Remove the pin (10) from the
bottom.
NOTE: There are shims installed. Count 10

the shims and mark their locations.
9
ZX215T-1006188
8. Lift and disassemble the work equipment

assembly. 11
SY195C9
Work equipment assembly:
Model Weight
3450 kg
PD
SY205C9 3418 kg
SY215C9 3451 kg ZX215T-1006189
IO

8.28.2 Installation
CAUTION
● Do not put your finger in the pin bore
while aligning the pin bore.

NOTE: A clearance (a: 0.5~1.5 mm) shall

be left between the plate and the nut when
tightening the locknut.
Greasing after assembling the pin:

a
ZX215-1006190
Grease (supramoly lithium base)
PD
NOTE: Adjust the shim thickness in order
to have a desired clearance (a: 0.5<a<1
mm) between the piston end (12) and the
12 a
4
plate (4).
Standard shim thickness: 1.0 mm and 2.0

mm.
IO
Greasing after assembling the pin: ZX215-1006191
Grease (supramoly lithium base)
Add 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.
● Air bleeding
Bleed the air from travel motor.


8.29 Air Conditioner AS - Remove and Install
Special tools
ID Part Name Model Necessity Qty

Refrigerant Robinair
● 1
charger 34711-2K
S
Refrigerant Inoue Qing-
● 1
charger Hua
8.29.1 Removal
CAUTION
● Disconnect the cable from the negative
(-) post of the battery.
1. Drain the coolant.
Coolant: approx. 22.5 L

PD
2. Recover refrigerant from the air-condition-
ing system with the tool (S).
IO
S
ZX215T-1006192
3. Remove the pad (1) on the cab floor.
ZX215T-1006193

4. Open the left rear cover of the cab with the

ignition key. Remove the outer filter ele-
ment (2).
盖
ZXT225-1006202
5. Remove the fuse box (3) and storage box

(4).
6. Remove outer covering (5).

PD
7. Remove the air conditioner cover (6). 5
3 6
4
SY195, SY205 ZXT225-1006203
IO
4
3
SY215 6 ZX215T-1006196

8. Remove the back air duct (7).
9. Remove the left air duct (8).
10. Remove the baffle (9). 10 7

8
11. Remove the right air duct (10).
9
ZXT225-1006205
12. Remove the cover (11).

PD
13. Remove the cab's center connector (12).
14. Remove the radio antenna(13).
13
12
11
IO
ZXT225-1006206
15. Remove the air duct (14), connector (15)

and air conditioner wiring connection (16). 17
Remove the two air conditioner relays (17),
three mounting bolts (18). Remove the 16
electrical mounting plate (19).
19
14
15 18 ZXT225-1006207

16. Remove the air conditioner water pipes (20)

and (21) as well as the dripping tube (22).
17. Remove the air conditioner unit (23). 22 20 21
ZX215T-1006200
NOTE: Also disconnect the two hoses con-

necting to the bottom of the air conditioner
PD
when removing the air conditioner unit.
23
IO
ZX215T-1006201

8.29.2 Installation

NOTICE
● 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 pres-

ent 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.
PD
NOTE: Apply compressor oil (ND8#) to the
threads of the parts connected with the re-
frigerant lines. Tighten the line connections
with a double-end spanner.
Screw (hose clamp):
8.83~14.7 N·m {0.9~1.5 kgf·m}

IO
Bolt (pressure plate):
13.5±1.2 N·m {1.38±0.12 kgf·m}
● Refrigerant charging
Charge refrigerant (HFC-134a) into the air

condition return lines with tool (S).
For more information, see “Refrigerant” on

page 4-139.

8.30 Counterweight AS - Remove and Install
8.30.1 Removal
1
1. Remove the cover (1) from the counter-
weight. Install eyebolts to the counter-
weight. Hold the counterweight.
ZX225-1106004
2. Remove the four bolts (2).

PD Wire rope
2
IO
ZX225-1106005
3. Lift the counterweight levelly with wire rope

or chain hoist.
NOTE: Be careful not to damage the

engine, radiator or cooler.
Counterweight assembly:
3901 kg
3
ZX225-1106006

8.30.2 Installation

Threads (mounting bolt - counter-

weight):
Thread adhesive (Tonsun 1277)
Mounting bolt (counterweight):
1,180~1,470 N·m {120~150 kgf·m}
Counterweight adjustment
1. Move the counterweight with a crane to a Unit: mm

PD Door
suitable position on the frame.
c=0±5
Counterweight
2. Push the counterweight and install the
bolts. Adjust the position of the counter- a=10±4
weight in such a manner that the following
dimensions can be obtained.
b=0±5
● Clearance with swivel:
Swivel
ZX215-1006205
10±5 mm(L&R)
IO
● Clearance with bodywork door:
10±5 mm(L&R)
● Step from swivel in left to right direction
b: max. 5 mm
● Step from bodywork door in left to right

direction
a: 10±4
● Step from bodywork top cover in upper

to lower direction
c: max. 5 mm

8.31 Cab AS - Remove and Install
8.31.1 Removal
CAUTION
● Disconnect first the cable connecting to
the negative (-) post of the battery.
1. Remove the floor mat (1). 1
ZX215T-1006206
PD
(3).
3. Remove outer covering (4).

4
4. Remove the air conditioner cover (5).
IO
2 5
3
SY195, SY205 ZXT225-1006215
3
2
SY215 5 ZX215T-1006001

5. Disconnect the left wire harness (6), moni-

tor harness connector (7) and window
washer harness (8).
7]’ 6
6. Remove the right side air duct (9).
ZXT225-1006216
7. Remove external air filter (10).
PD
10
ZXT225-1006217
IO
8. Disconnect the external air duct (11).
11
ZX215T-1006210

9. Remove the storage box on the armrest

(12).
12
ZX215T-1006211
10. Remove the radio connector (13).

PD
11. Remove the radio wire harness (14).
13
14
ZX215T-1006212
IO
12. Remove the window washer reservoir (15).
15
ZX215T-1006213

13. Remove the window washer pipe (16).
16
ZX215T-1006214
14. Remove the decor cover (17).

PD
17
ZX215T-1006215
IO
15. Remove the four mounting nuts (18) and
the five mounting bolts (19).
18
19
ZXT335-1006995

16. Lift the cab assembly (20) for removal.
20
Cab assembly: 450 kg
ZX215T-1006217
8.31.2 Installation

PD
Bolt: 200 N·m {20.4 kgf·m}
Nut: 210 N·m {21.4 kgf·m}

IO

8.32 Cab Window Glass – Disassemble and Assemble
10 10
9
8
1
10
2 7
10 11
PD 10
6
4 5
12
IO
3 10
ZX225-1006226
1) Right window glass 7) Left side rear window glass

2) Front window glass 8) Rear window glass
3) Lower front glass 9) Roof window glass
4) Cab door window glass (upper) 10) Rubber sealing strip
5) Cab door window glass (lower) 11) Center adjusting seal
6) Cab door window glass (upper) 12) Front window AS (Glass and frame)
● Cab window glasses (1), (2), (5), (7) and (9) are adhered to the window frame.
● When replacing front window glass (2), disassemble front window assembly (12). (If the cab
is install with a front window assembly, do not only replace the front window glass.) For more
information about front window replacement, see “Front Window AS - Disassemble and As-
semble” on page 8-136.

8.32.1 Removal
CAUTION
● Removing shattered or cracked window
glass may cause finger cuts.
● Wear proper PPEs when removing shat-

tered cab window glasses.
NOTE: To avoid finger cut during when remov-

ing a shattered or cracked glass, cover it with
a piece of adhesive film or tapes.
1. Removal of glass (3)

PD
Glass (3) is hold in place by sealing strips.
Pull it upward carefully to remove it.
ZX225-1006227
IO
2. Removal of glass (4) and (6)
1) Remove the sealing strip from the

frame of the cab door.
2) Push the glass outward carefully from

inside of the cab and remove glass (4)
and (6) together with the frame. 6
4
ZX225-1006228

3) Remove glass (4) and (6) from the

frame with a screw driver.
Frame
Sealing
ZX225-1006229
3. Removal of glass (8)

PD
1) Remove the retainer from the groove
on the rubber with an ordinary screw
driver.
8
2) Put a thin bamboo chip inside part A of

the retaining rubber and detach the re-
tainer along the edge.
IO
ZX225-1006230
3) Pat the glass from inside of the cab
and remove it. This job may require two
people.
Rubber retainer side
Rubber retainer Glass
Cab side
Retainer
A A
Cab
ZX225-1006231

4. Removal of glass (1), (2), (5), (7) and (9).

9
ZX225-1006232
1) Remove the resin board, decor strip

and retainer along the edge of the Cab
glass. PD
2) Punch a hole through the adhesive with
a drill (or a cutter) as illustrated.
Glass
Drill
Adhesive
ZX225-1006233
IO
3) Pull a piece of piano string (or steel
wire) through the hole as illustrated.
Piano string
(or steel wire)
ZX225-1006234

4) Fix both ends of the piano string onto (Outside)

Cab
two screw drivers. Pull the wire back
Glass
and forth in order to cut the adhesive
and detach the glass from the cab. This
job may require 2-3 people.
● Run the string along the center of the

adhesive. The string may break when
it becomes very hot. Use different sec- Adhesive
tions of the string while cutting the ad-
(Inside)
hesive. ZX225-1006235
PD
IO

8.32.2 Installation
● Reverse the disassembling sequence

when installing glasses (3), (4), (6) and
(8). Follow the procedures below to install
glasses (1), (2), (5), (7) and (9).
1. Clean the remaining adhesive and rubber

on cab frame (contact surface) with a knife
or scraper [5].
● Remove the remaining adhesive and [5]

rubber so that they will not affect the
ZXT225-1006236
application of new adhesive. Do not
scrape the original paint on the surface.
(Scraping of paint reduces the perfor-
mance of the adhesive.) PD
2. Clean the grease, dust and dirt on the cab
(8) and the glass (9) with unleaded gaso-
line.
● Contaminant on the contact surface re-

duces the performance of adhesive.
8
● Clean the black part on the back of the
IO
glass.
● After cleaning, dry the glass for at least

5 minutes. ZXT225-1006237
ZXT225-1006238

3. Priming coat (10)
● Priming paint expires 4 months after

production. Do not use expired paint.
Cab
● Use the paint within 2 hours after it is 11
unsealed.
10
● Use the paint within 24 hours even if it Old adhesive edge

on cab side
is sealed again immediately after un-
sealing. (Dispose the paint 24 hours
after it is unsealed) ZX225-1006239
1) Make sure the adhesive paint and glass

priming paint are well agitated before
application.
PD
● If the priming paint is stored in a refrig-
erator, keep it under ambient tempera-
ture for at least half a day before agita-
tion.
● (If the paint is unsealed immediately af-

ter it is taken out of a refrigerator, water
will condense on it.)
2) Always wash a used brush (11) with

IO
unleaded gasoline before using it.
● Check the brush for contaminants after

it has been washed.
● Prepare two brushes for priming paint,

one for painted surface and the other
for glass surface.

3) Apply priming paint (for painted sur-

face) evenly onto the surface where
sealing rubber is to be adhered and
where adhesive agent is to be applied 8
(on the cab (8)).
Priming paint (for painted

surface): Sunrise MSI Primer 24
● Do not apply primer more than twice;

otherwise, the performance of the prim-
er will be reduced. ZXT225-1006240
● Applying location: Cover the whole area

of (a). Dimension of (a): 25mm 8
PD a
6
ZX225-1006241
IO
● Besides the above locations, apply
primer also onto the right window glass
and the cab door lower window glass.
b
● Additional priming area on the right
window glass: (b)
ZX225-1006242b

● Additional priming area on the cab

door lower window glass: (c)
● Dry the primer for at least 5 minutes

(within 8 hours).
● Do not use wrong priming paint. c
If, for example, glass primer is mis-

takenly used, wash it with unleaded
gasoline. ZX225-1006242c
4) Apply priming paint (for glass surface)

onto the contact surface of window 9
glass (9). PD
Glass primer:
Sunrise MSI Primer 35
● Do not apply the primer more than

twice; otherwise, the performance of
the primer will be reduced. ZX225-1006243
IO
● Priming area: Apply the priming paint
8
on the contact surface of glass (9)
(rubber seal (6)adhering location) and
along cab frame (8).
6
● Leave a 5 mm margin uncoated along d

the black strip adjacent to the clear
area of the glass.
9
● When priming paint has been coated, ZX225-1006244
dry it for at least 5 minutes (within 8
hours).
● Do not use wrong primer.
If wrong glass primer is used, wash it

with unleaded gasoline.

4. Adhere rubber seal (6) (with adhesive tape

on both sides) along the inner edge of the
contact surface of the glass.
● Do not detach the waxed paper on the

rubber seal before the window glass is
installed.
● Do not touch the cleaned area on the

glass before rubber seal is adhered.
6
ZXT225-1006245
● Be careful not to allow the rubber seal
on the corners to peel off.
● When sticking rubber seal (6) along the
ed.
PD
window frame, do not overlap the two
ends of the seal. A 5 mm gap between
the two ends of the seal is recommend-
1) Stick rubber seal (6) onto the right cab

e 6
window frame as illustrated.
ZXT225-1006246
IO
● Adhere additional rubber seal (6a) onto f

the right cab window 6a
Position of the additional rubber seal:
(f): 50 mm h
(g): 90 mm
(h): 250 mm g
ZXT225-1006247

2) Adhere rubber seal (6) on the left cab

window as illustrated.
ZXT225-1006248
3) Adhere rubber seal (6) onto the lower

cab door window as illustrated.
PD 6
ZXT225-1006249
IO
● Adhere additional rubber seal (6b) onto
the lower cab door window frame as il- j
lustrated.
6b
Position of additional rubber seal:
m
(j): 110 mm
(k): 90 mm
(m): 200 mm k ZXT225-1006250

4) Adhere rubber seal (6) onto the front 6

window glass as illustrated.
ZX225-1006251
● Different from the rubber seal (6) on

other window, rubber seal (6c) on the
bottom of the front window shall be 6
adhered onto the external edge of the
PD 6c
lower part of the front window frame.
(If it is adhered along the inner edge,
the rubber seal will be seen through the
clear part of the glass.)
5. Positioning of new window glass

ZXT225-1006252
1) Check the clearance between the edge
of glass and the cab in 4 directions,
IO
and position the glass. Make sure the
clearance is even.
9
2) Put a tape [6] across the glass (9) and
cab (8) and draw a line (n) on it for
alignment. n
● Adhere tape [6] at 3 points as illustrated [6]

for precise alignment of right window
glass, left rear window glass and cab
door lower window glass.
8
3) Cut the tapes across the glass (9) and
ZXT225-1006253
the cab (8) and remove the glass.
● Do not remove the tape on the left side

of the glass until the glass is installed.

[6]
[6]
8 [6]
ZX225-1006254
● When positioning front window glass

(4), cover it across the width of the win-
PD
dow frame in the horizontal direction.
P
Set the clearance (p) between the top

edge of the glass and the upper frame
at 3 mm when positioning it in the verti-
cal direction. 4
ZX225-1006255
IO

6. Adhesive
13
● Store adhesion agent in dark places

where temperature is blow 25°C.
● Do not heat the adhesive to above 12

30°C.
● Before using adhesive that has been

unsealed, remove the hardened part at ZX225-1006256
the nozzle.
1) Open the aluminum seal (13) on the

head of the cylinder (12) and install the
nozzle (14).
Adhesive: PD
Sunrise MSI SR sealant U90 4463876
2) Cut the tip of nozzle (14) as illustrated.

Dimension of the cut:
14
r
(q): 10 mm
(r): 5 mm q
IO
ZX225-1006257
3) Set the cylinder (12) in the gun [7].

12 [7]
● An electrical caulking gun is more ef-

ficient.
ZX225-1006258

4) Remove the waxed paper of the rubber

seal on the surface where adhesive is
to be applied. 15
6
5) Apply adhesive (15) along the external

edge of the rubber seal (6).
ZX225-1006259
● Adhesive (15) for rubber seal (6) on

8
cab (8) shall be applied as illustrated: s
Dimension of (s): 10 mm PD 6
Dimension of (t): 15 mm t
15
● Adhesive (15) shall be thicker that the
rubber seal (6).
● Apply adhesive of the same thickness ZX225-1006260
evenly.
IO

● Apply adhesive (15) onto the additional

rubber seal of the right window (6a) and 6a
additional rubber seal of the cab door 15
lower window (6b).
ZX225-1006261
6b 15
PD
ZX225-1006262
7. Install window glass
1) Install window glass (9) and align it with

IO
the mark on the cab. (See step 5)
● Since the glass can not be remove

once installed, be very careful when
performing this task.
9
● Install the glass properly within 5 min-
utes after adhesive has been applied.
2) Press the perimeter of the glass (9)

after is has been put in place until it is ZXT225-1006263
securely stuck to the rubber seal.
● Press the corners of the glass hard.

● After the front window glass has been

installed, fill the clearance between the
glass on area (s) and the center adjust-
ing seal (16) to the dimension of (t) and
(u). Coat primer onto glass (4) on sec- A
tion A-A and apply the adhesive as fill-
ers.
A
S
Dimension of (t): 2 mm
Dimension of (u): 5 mm t
4
● Use a rubber spatula to cover the edge
of the glass and trim the adhesive.
● Remove surplus adhesive. u
Glass primer:
Adhesive:
PD
Sunrise MSI Primer 35
A-A
16
ZX225-1006264
Sunrise MSI SR Sealant U90 4463876

IO
8. Fix the glass
1) After the right window glass (1) has

been adhered to the cab, put position-
ing chips a (1 or 2 pcs) beneath the
glass in order to fix it.
a
ZXT225-1006265

2) Use foam polystyrene blocks [9] and

[10]
rubber band [10] to fix the glass and
the rubber seal as illustrated.
9. After the glass has been fixed, remove all

the remaining primer and adhesive on the
cab and on the glass.
● Clean the adhesive with unleaded gas- [9]

oline before it is hardened.
ZX225-1006266
● Do not apply impacting force onto the
glass when cleaning it.
10. Protection of fixed window glass
1) Remove the positioning chips, foam

PD
polystyrene blocks and the rubber band
after 10 hours.
(Condition: Temperature: 20; humidity:

60%)
2) Wait for another 14 hours after the re-

moval of positioning chips, foam poly-
styrene blocks and rubber band before
operating the machine.
IO

8.33 Front Window AS - Disassemble and Assemble
NOTICE
● Before removing the front window as-
sembly, lower the work equipment onto
the ground and shut down the engine.
The front window assembly must be removed

from the cab in order to replace the front win-
dow glass.
8.33.1 Disassemble
1. Raise the front window assembly to the

roof and secure it with the rear locks (at
both sides).
ner plate (2).

PD
2. Remove left corner plate (1) and right cor-
4
3
1
2
● Mounting bolt (4) and washer (3) of the

left corner plate will be used in Step 6
to hang the pull rod. ZX225-1006267
IO
3. Release the rear lock of the cab.
4. Lower the front window assembly carefully

a bit. Take out and hold the rollers (5) and
(6) at the bottom of the front window from
the removed parts in Step 2.
5. Remove roller (5) and (6) from both sides

of the bottom of the front window.
6 5
ZX225-1006268

6. Remove pin (7) at the lower left side.

9
● Plate (8) at the end of the pull rod (9)

8
will come out by removing of pin (7).
● Hang plate (8) onto the mounting bolt

of left corner plate (using the washer) 6
and fix it.
NOTICE 7
ZX225-1006269
● A return load of 58.8 N {6 kg} is applied
onto the rear of the cab. Be very care-
ful when removing pin (7) to disconnect
pull rod (9).
PD 9 8
ZX225-1006270
IO
7. Pull out the front window assembly (10)
10
from the opened part of the guide rail and
lower the assembly gradually.
ZX225-1006271

8. Lower the front window assembly (10)

completely.
10
● Be careful not to allow the front window
assembly to damage the machine mon-
itor.
ZX225-1006272
9. Move the front window assembly (10) to 12 11

the right and the left and remove the two
PD
upper rollers (11) and (12) from the guide
rail. Then, remove the front window as-
sembly (10).
IO
10
ZX225-1006274

8.33.2 Assemble
● Reverse the disassembling sequence.
● Adjust the opening and closing of the front

window assembly as per the following in-
struction.
1. Open and close the front window assembly

and check if it interferes with the guide rail.
Check if the roller is jammed.
2. If the front window can not be opened or

closed properly, loosen the mounting bolt
of the roller adjusting bracket (13) and
adjust the condition of the front window.
Tighten the mounting bolt after adjusting.
PD
Mounting bolt:
13
ZX225-1006275
34.3 N·m {3.5 kgf·m}
3. Raise the front window assemble and fix it

with rear locks (at both sides).
● Check if the locks at the rear of the cab

IO
are securely fixed. a
4. Install the right corner plate (2).

2
● After the "locked" position is adjusted in a
Step 6, tighten the corner plate. ZX225-1006276
● Install the right corner plate. Clearance

(a) between the guide rail and the right
corner plate (2) is 0 – 2.0 mm.
R
● Install the right corner plate. Keep the
surface (R) of the roller without a level
error.
ZX225-1006277

5. Install left corner plate (1)
● After the "locked" position is adjusted in b

Step 6, tighten the corner plate.
● Install left corner plate. Clearance (b)

between the guide rail and the left cor- b
ner plate (1) is 0 – 2.0 mm.
1
● Install left corner plate and keep the ZX225-1006278
surface (R) of the roller without a level
error. (See previous illustration).
6. Adjust the "locked" position of the lock of

front window assembly as per the following
instruction. PD
1) Tighten the left corner plate (1) and the
right corner plate (2) in a nearly correct 15
position so that front window glass (14)
is pressed closely against the adjusting
14
seal (15) on the cab.
ZX225-1006279
2) Open and close the front window as-

sembly and check the working condi-
IO
tion of left lock (16) and right lock (17).
● If left lock (16) and right lock (17) do

not work properly, Loosen the mounting 16 17
bolt (19) of the lock and move the lock
(16) forward. Tighten the bolt after that.
● Adjust the right lock with the same

method.
ZX225-1006280
3) Check again the adaptability between
the front window assembly (14) and
the adjusting seal (15) on the cab.
(Checked in Step 1)
● Tighten the mounting bolts of the left

and right corner plates when the left
and right locks (16, 17) are properly in
place.

7. After adjustment is finished, flush the front

window glass and check if any water leaks
into the cab.
16 19
ZX225-1006281
8. Adjust the "locked" position of the lock of

front window assembly
1) After the "locked" position of the lock of
to the roof.
PD
front window assembly is adjusted in
Step 6 and Step 7, raise the assembly
2) Set the locks of the front window as-

19 18
sembly at the rear of the cab at the ZX215-1006273

"locked" position, and check the follow-
ing items:
● Check the conditions of left lock (16)

IO
and right lock (17).
● The front window assembly must con- 18 20

tact the left and right rubber stopper
(18), and the rubber stoppers must be
pushed backward by 1.5 – 3.0 mm.
● The front window assembly shall push

the limit switch 4 – 7mm backward.
ZX225-1006283

3) Close the front window assembly (10).
4) Loosen the retaining nut (20) at the left

and right side of rubber stopper (18),
and pull the two rubber stoppers (18) 23
inward so that they can not contact the 21 22
"unlocked" front window assembly.
5) Adjust the position of latch bolt (21).

ZX215-1006275
● Latch bolt(21): M10, Inner diameter of
plate (23): ø14.5 mm
6) Adjustment of left and right rubber stop-

per (18) PD
● Allow front window assembly (10) to
contact the left and right rubber stopper
(18). (when the lock is "unlocked")
10 18
7) Lock front window assembly (10).
ZX225-1006285
IO
8) Turn the left/right rubber stopper (18) to
the left by one and a half round.
● Turning the rubber stopper (18) leftward

for one round is equivalent to pressing
it by 1.5 mm.
18
● When front window assembly is "un-
locked", it must move the left/right rub-
ber stopper (18) by 1.5 – 3.0 mm. ZX225-1006286
9) Tighten the retaining nuts (20) at both

sides of the rubber stopper (18).

9. Adjust the front window assembly retainer

(24).
● Adjust and lock both sides of the retain-

er (24) so that surface (d) of stopper
24
(D) of front window assembly contacts 10
surface (c) of retainer (24) when front
window assembly is raised.
D
ZX225-1006288
10. Check the locking ability of front window

assembly.
● After the adjustment from Step 6 to

PD 24
Step 9 is finished, check the locking D
force of left lock (16) and right lock (17). d
● Check the locking force at the "locked"

side (front of cab) and the "unlocked" c
side (rear of cab). ZX225-1006289
Left lower pin:
27 – 34 N·m {2.75 – 3.47 kgf·m}

IO
Mounting bolt:
16 17
Adhesive(LT-2)
ZX225-1006290

8.34 Monitor - Remove and Install
8.34.1 Removal
CAUTION
1. Unscrew the three bolts (4). Remove the 4

3
mounting plate and the monitor assembly
5
from the bracket (3).
2
2. Remove the nut (1) and the gasket (2) to

separate the monitor (5) from the mounting 1
plate.
PD ZX215-1006281
8.34.2 Installation

IO

8.35 Controller AS - Remove and Install
8.35.1 Removal
CAUTION

3
(2).
2. Remove rear covering (3).
3. Remove air conditioner cover (4). 4

1 2
SY195, SY205 ZXT225-1006292
PD
3
IO
2
1
SY215 4 ZXT335-1006800
4. Remove the controller wiring connectors

A1(5) and A2(6).
5. Remove the four bolts. Remove the con-

troller assembly (7).
7
8.35.2 Installation 6
5
ZX215-1006283

8-146
2. Wiring
8.36 Radio
1. Main structure
8.36.1 Structure
RED — L. SOUND TRACK INPUT
AUDIO INPUT
WHITE — R. SOUND TRACK INPUT

Disassembly and Assembly
RED — ACC IGNITION
YELLOW — BATT POWER SUPPLY
BLACK — GROUND
GRAY — R. SOUND TRACK OUTPUT +

IO
POWER, GROUND AND AUDIO OUTPUT

BACK PANEL
— R. SOUND TRACK OUTPUT –
WHITE — L. SOUND TRACK OUTPUT +

BLACK — L. SOUND TRACK OUTPUT –
RADIO ANTENNA
PD
ZX215-1006285
ZX215-1006284
8.36.2 Removal
NOTICE
● Disconnect the power supply prior to
removal.
1. Remove the console cover.
Arm rest cover
PD
2. Remove the radio connector CN-003F.
Radio
ZX215-1006286
IO
Connector CN-003F Cab harness

ZX215-1006287
3. Remove the four screws and the washers

in order to remove the radio and the radio
mounting brackets from the console cover.
Arm rest
4. Remove the four screws and the washers
in order to remove the radio from the radio
mounting brackets.
Radio
Mounting bracket Washer
Screw
ZX215-1006288

8.36.3 Installation

8.36.4 Connector model and wiring
1 2 3
1 2 3 20b R+ L+
4 5 6 7 0 20b R- L-
Raido wiring terminals

PD 4 5 6 7
Harness socket terminals

Type: Deutsch DJ7072-3-21
ZX215-1006289
IO

8.37 Battery
8.37.1 Structure
A
2 B
10 J
C
11
6 E
D
PD G
I
F
8 7 5 9 4 3 1
IO
ZX215-1006290
1) Spinning post 7) Paste (active material)

2) Charge densiometer 8) "Bag-type" screen
3) Heat-sealing cover 9) Polar group
4) PP casing 10) Liquid-gas separator
5) Central polar ear 11) Central busbar
6) Forged grid

8.37.2 Removal
NOTICE
● Turn the start switch to the OFF posi-
tion before removal.
● Do not remove the charge densimeter.

Tighten the densimeter clockwise, if it
is loosened, with a suitable tool.
1. Removal of battery grounding wire Bolt Terminal Grounding cable
● Open the tarpaulin, unscrew the bolt, and

remove the terminal from the battery wiring
post. VART
A
CAUTION
● Battery gas can cause explosion. No
sparks or flames are allowed near the
battery.
PD Battery
MAINTE
免维护
蓄电池
FREE BA
NANGE-
TTERY
ZX215-1006291
2. Disconnect the battery wiring cable and the Battery cable

battery breaker cable.
IO
VARTA
VARTA
Battery Breaker cable

ZX215-1006292
3. Remove the four bolts and washers. Re- Battery
move the battery assembly from the bot-

VAR
tom plate. Remove the battery.

TA
TA
VAR
Battery box
Bolt Wahser
ZX215-1006293

8.37.3 Installation

8.37.4 Replacement
There are two 12V batteries with ground-

ing negative (-) posts in the machine. If one
battery 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.
NOTICE
PD
● During installation, apply vaseline to
battery terminals in order to prevent
corrosion.
IO

8.38 Start Switch
8.38.1 Structure
23 22 20 18 17 15 13 12,11 28 6 10,9,8,7
PD
25,24 21 1 14 19 16 26 5 4,3,2
IO
27
4 5 6
1 2 3
ZX215-1006294
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

8.38.2 Removal
NOTICE
● Disconnect the power supply of the
start switch before removal.
X
T MA
STAR
ON
OFF
1. Remove the setscrew to remove the con-
CK
LO
MIN
sole cover.
Start swich Console cover Set screw

ZX215-1006295
PD
2. Remove both setscrews in order to remove Set screw Console cover
the mounting plate and the start switch
from the console cover.
IO
Mounting plate Start switch
ZX215-1006296
3. Remove the nut so as to remove the start

switch from its mounting plate.
Start switch Mounting plate Nut

ZX215-1006297

Working principle and wiring of start switch
1. Working principle
ON/OFF
Key Position Preheat Plug
Battery (B) Battery Relay (BR) Accessory Start Relay (C)
(R1) (R2)
HEAT
OFF
ON
START
2. Wiring
1 B BR ACC
PD
3 1 22 13 3
4 R1 R2 C 6 4 16 11 6
HARNESS PLUG TERMINALS

JACKET MODEL：YAZAKI 7123-7464-30
KEY SWITCH WIRING TERMINALS
IO
JACKET MODEL：YAZAKI 7222-7464-30
ZX215-1006299

8.39 Fuse Box
8.39.1 Removal
Cover
1. Remove the cover.
ZX215-1006300
2. Remove the bolts and take off the back Back cover Fuse box cover
cover along with the fuse box.
PD
Bolt
IO
ZX215-1006301
3. Remove the bolts so as to separate the

Fuse box harness
fuse box and harness assembly from the
back cover. Bolt
Back cover
ZX215-1006302

8.40 Wiper
8.40.1 Structure
Blade
Rotating mechanism
Arm
Wiper motor
Connector
PD Mounting bracket
ZX215-1006303
8.40.2 Working principle

IO
GREEN (LOW SPEED)
YELLOW (RESET)
M
BLUE (HIGH SPEED)
RED (POWER+)
BLACK (POWER-)
ZX215-1006304

8.40.3 Removal
1. Remove the decorative button in order to

remove the interior decoration.
Decoration
button
Inner decor
ZX215-1006305
2. Remove the moving mechanism and the

motor.
PD
● Unscrew the bolts to remove the wiper
motor and moving mechanism from the
cab.
Bolt
Moving
mechanism
Wiper motor
IO
Bolt
ZX215-1006306
3. Remove the arm and the blade.
● Unscrew the nut to remove the wiper

arm and blade from the cab.
Arm bracket
Cap
Locknut
Cab
ZX215-1006307

8.40.5 Installation

8.40.4 Angle adjustment of wiper arm
● The arm should stops moving when the Stopper

blade reaches the stopper.
● If the arm is still working when the blade

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
Arm
wiper. PD
● 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- Locknut
ment that the blade reaches the mechani-
cal stopper.
ZX215-1006308
IO

8.41 Relay
8.41.1 Engine relays

1. Starter relay - check S
● Check the conduction and action. Replace

the relay in case of any failure.
B
S
B 1 SW(-) SW L
AA2A
2 L(-)
ZX215-1006309
2. Mains relay - check PD

1(+)
2(-)
3 4
Batter (+) terminal
3 4
IO
1(+)
2(-)
ZX215-1006310
3. Heater relay
5(-)
1
5 1 2 3 4
(-) (+)
2 4(+)
Fuse 3
ZX215-1006311

4. Safety relay
Measure the resistance between terminal

2 and terminal 3.
Standard Value Approx. 200Ω

(P)6
3(R)
5
2(L)
the relay in case of any failure. (E)4
1(S) ZX215-1006312
8.41.2 Other relays
1. Function and location
Relay harness
Headlight relay
Starter control relay PD
Work lamp relay
IO
Parking relay Pilot control relay

Horn relay
Mounting plate
ZX215-1006313

2. Removal
1) Remove relay from its seat.

Relay harness Mounting plate
2) Remove the screw in order to remove the

relay seat and harness from the mounting
plate.
3. Installation

Relay seat Screw Relay
ZX215-1006314
PD
IO

4. Relay connector and wiring
1 4 2
RELAY WIRING TERMINALS

RELAY MODEL:HELLA 4RD 007 903-027
0
HORN
K5
32
31
WORK LAMP
0
K6
34
33 0
PD
PILOT CONTROL
K10
606 105
STARTER CONTROL
0
K3
12
105
PARKING
0
K7
65
63 13
HEADLIGHT
K8
0
70
72
23 24 27 11 64 71
HARNESS SOCKET TERMINAL

IO
SOCKET MODEL: JACKET 8JA003526-00
ZX215-1006315

8.42 Sensor
1. Water temperature sensor - check
● Put the sensor into a vessel containing en-

gine oil. 1
● Heat the oil to the specified temperature.

Stir the oil at the same time. Sensor body
● Measure the resistance value between the

terminal 1 and the sensor body at different
temperatures.
ZX215-1006316
50±0.2°C 80±10Ω
60°C 56.3Ω(ref.)
Standard
Value
80°C
100°C
106±0.3°C
120°C
PD
29.5Ω(ref.)
16.5Ω(ref.)
14.3±1.0Ω
10Ω(ref.)
● Replace the sensor if the measured value

exceeds the standard one.
2. Engine speed sensor - check

IO
● Measure the resistance between terminal
1 and terminal 2.
Std. Value(25°C) 2.3±0.2kΩ
● Replace the sensor if the measured value 2 1

exceeds the standard one. ZX215-1006317
NOTICE
● Insufficient tightening of the engine
speed sensor may cause signal output
failure. Tighten the sensor to specified
torque.

3. Pressure sensor - check

Coupler Body Connector
● Input volt: 4.75~5.25VDC
● Output volt: 0.5~4.5V
● Pressure range: 0~50BAR

Terminal C ZX215-1006318
4. Fuel level sensor - check
● Swing the float up and down in order Float

to measure the effective angle of radial
PD
swing, i.e. the line through the float and the
turning point will swing 105°.
Lever
● Swing the float up and down. The vertical
distance between the upper limit and the
lower limit of the float should be 500 mm.
Ternimal R
● Move the float to its upper limit. Measure Casing
the resistance between the sensor terminal
R and ground with a multimeter. The mea-
IO
Connector
sured resistance should be Ru ≦ 9.6Ω.
ZX215-1006319
● Move the float to its lower limit. Measure
the resistance between the sensor terminal
R and ground with a multimeter. The mea-
sured resistance should be Rd ≧ 86Ω.

8.43 Connector Terminals - Insert and Remove
8.43.1 Insertion
1. Hold tightly a wire terminal at a distance of

about 25 mm from its end.
ZX215-1006320
2. Hold the connector. Let the rear seal face

you. PD
ZX215-1006321
IO
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 en-
sure that the terminal is locked in place.
ZX215-1006322

8.43.2 Removal
1. Hold the connector, with its back end fac-

ing you. Select a suitable tool and clip on
the wire.
ZX215-1006323
2. Push the tool along the wire into the con-

PD
nector so that the tool can expand the ter-
minal lock shoulder and reach its flanged
part.
ZX215-1006324
IO
3. Pull out the tool to remove the wire with
terminal.
ZX215-1006325

E
G
PPDA
A IONK
BL

E
PPDAG
IOK
AN
BL

SY195-205-215C9 Crawler Hydraulic Excavator Engine
Engine
9 Engine
9.1 General .................................................................................................................... 9-3
9.2 Engine Assembly ..................................................................................................... 9-6
PD
9.3 Lubricating System ................................................................................................ 9-88
9.4 Fuel Supply and Engine Control ...........................................................................9-119
9.5 Cooling System.................................................................................................... 9-161
9.6 Air Intake and Exhaust System ............................................................................ 9-185
9.7 Electrical System ................................................................................................. 9-201
IO

Engine SY195-205-215C9 Crawler Hydraulic Excavator
PD
IO
WARNING
jury or death.

9 ENGINE
9.1 General
9.1.1 Terms and standard

1. Inspection and adjustment when the When the flywheel housing faces you, the
engine is loaded fan side is the Front.
● The procedures for inspection and adjust- ● Left and right

ment of parts and components list specific
testing and adjusting items. Always check When the flywheel housing faces you, the
for loosened parts, clearance, cracks and left-hand side is the Left side, and the right-
damages, whether specified or not. hand side is the Right side.
2. Inspection standard PD
● The inspection procedures of undercar-
riage parts and components focus primarily
on the removal, installation, disassembling,
assembling, inspection of parts and com-
6. Standard value
● Standard dimension in engine design

means: the specified size of each part, the
standard clearance between two adjoining
parts and the standard value of an assem-
ponents. bly.
3. Inspection 7. Limit
IO
● All items labeled "Acceptable” or “Unac- ● When a certain value of a part exceeds
ceptable" as per the inspection standard this limit, this part can not be used any
shall be specified. more in terms of performance and strength
and must be replaced or repaired.
● Some routine visual inspection and clean-
ing of repeatedly used parts may not be 8. Tightening torque
specified, but they shall be performed dur-
ing inspection. ● It specifies the standard tightening value of
bolts and nuts.
4. Caution
● Refer to the standard tightening torque
● Procedures which, if not observed, will table if not otherwise specified. (The stan-
result in major injury, or even death and dard tightening torque depends on the size
damage to the machine and inspection in- and material of the thread)
struments, are specified.
● "WET" shall be marked where wet type
5. Terms and units tightening is applicable. Otherwise, dry
type tightening is applicable and refer to
● Front and rear the specified tightening value.

9. Unit
● All tightening torques and other parameters

are given in SI units, and metric units is in
the curly brackets. Engine specifications,
performance curve and values in other
items cited from formally approved docu-
ments use only metric units.
*SI: International system of units
E.g. ： 390N·m {40kgf·m}
Original unit (Metric Unit)

SI unit (International system of units)
Item SI unit {Metric unit}

PD Conversion
Force N {kgf} 9.80665N {1kgf}
Torque N·m {kgf·m} 9.80665N·m {1kgf·m}
Positive pressure kPa {kgf/cm²} 98.0665kPa {1kgf/cm²}

Pressure
kPa {mmHg} 0.133322kPa {1mmHg}
Vacuum pressure
Pa {mmH2O} 9.80665Pa {1mmH2O}
Volume dm3 {L} 1dm3 {1L}
Heat J {kcal} 4186.05J {1kcal}
IO
Heat flux W {kcal/h} 1.16279W {1kcal/h}
Power kW {PS} 0.7355kW {1PS}

9.1.2 Engine serial No. and name plate
● Serial No. is an inherent part of the en-

gine, which indicates the manufacturing Engine serial No.
sequence of the engine. This number is

needed during vehicle registration and in-
spection.
FD215-1007001
● Information on the name plate includes:
● Engine type PD 6D34-TLU2E

ENGINE FAMILY:L05.8D3B
e4 97/68FA 2002/88 0076 04
FD215-1007002
IO

9.2 Engine Assembly
9.2.1 Specifications
Item Specification
Engine model 6D34TLE2A

Type In-line 6-cylinder; water-cooled, 4-cycle diesel engine
Combustion chamber type Direct injection
Valve mechanism OHV
Max. output power kW{PS}/rpm 114{155}/2050
Max. torque N·m{kgf·m}/rpm 590{60}/1400
Bore×Stroke mm φ104×115
Total displacement cm³{L} PD 5860{5.860}
Compression ratio 18.2
IO

9.2.2 Structure and operating principle
9.2.2.1 Structure layout

Cylinder bushing
Camshaft Cylinder head
Valve spring
Rocker arm
Flywheel
Rocker arm shaft
Plunger
Intake valve
Tappet
Camshaft gear
PD
Idle gear
Oil pump gear

IO
Crankshaft
Exhaust valve
Crankshaft gear Piston
Connecting rod
Injection pump gear FD215-1007035

9.2.2.2 Valve mechanism
Valve cap
Rocker arm Valve retainer lock
Stem Upper seat
seal
Adjusting screw External valve spring
Internal valve spring
Valve guide
Plunger Valve
PD
Tappet
Camshaft
FD215-1007036
IO
● A valve lever seal is placed inside the
valve, which controls the grease amount
on the sliding surface between the valve
and the valve guide.
● Both outer and inner valve spring use

springs of inconstant pitch. To avoid en-
gagement when the engine is running, the
winding directions of the two springs are
opposite.
● Adjustment of valve clearance is achieved

with the adjusting screw.

9.2.2.3 Cylinder head gasket
Size mark
1.3mm 1.35mm 1.4mm
“UP” Part No.
FD215-1007037
● Use cylinder head gasket of proper thick-

ness that matches the protrusion of the
PD
piston.
● The thickness of the gasket can be identi-

fied through the shape of the notch.
9.2.2.4 Water director

IO
Coolant
FD215-1007038
● Water director is installed beneath the cyl-

inder head. It directs the flow of water cool-
ant.

9.2.2.5 Connecting rod
Bushing
Connecting rod
Bolt
Upper bearing Weight mark

“A”-“E”
Match mark
Protrusion
Lower bearing
Cap
9.2.2.6 Piston
PD FD215-1007039
Part No.
Weight
IO
Oversize mark
Front mark
FD215-1007040

9.2.2.7 Timing gear
Idle gear
Oil orifice
Camshaft gear
Idle gear shaft
Idle gear bushing
Thrust plate
2
2
2
Injection pump gear
Idle gear
1
PD 3
3
1
3
1
Oil pump gear Crankshaft gear

FD215-1007041
● Match marks ("1", "2", "3") are imprinted on

IO
all the gears to ensure correct assembling.

9.2.3 Troubleshooting
Abnormal
Symptom Low output Reference
Cause noise
Incorrect valve clearance ○ ○
Defective cylinder head gasket ○ ○
Abrasion and carbon build-up on valve
○ ○
Cylinder head, and valve seat
valve mechanism Valve spring elastic fatigue ○ ○
Defective rocker arm and bracket ○
Rocker arm bracket greasing defect ○
Tappet abrasion ○
Gear engagement clearance defect ○
Timing gear Timing gear perimeter and idle gear
○
greasing defect PD
Excessive camshaft end play ○
Camshaft
Camshaft abrasion ○
Piston ring groove abrasion/damage ○ ○
Piston, connecting Piston ring abrasion, damage ○ ○
rod Abrasion of piston pin and connecting
○
rod small end
Excessive crankshaft end play ○
IO
Crankshaft defective assembling ○
Crankshaft Crankshaft pin and connecting rod bear-

○
ing abrasion, damage
Crankshaft journal and main bearing
○
abrasion, damage
Injection pump defect ○ ○
Fuel supply and
Fuel system Injector spray defect ○ ○
engine control
Fuel system parts air intake, clogging ○
Cooling system function defect ○
Cooling system Cooling system
Belt loose, damage ○
Air intake & ex- Air filter clogging ○ ○ Air intake and
haust system Muffler clogging ○ ○ exhaust system
Oil viscosity not meeting requirement ○ Lubricating system
Fuel not meeting requirement ○
Defective assembling of pipes/hoses ○
Alternator and other auxiliary equipment failures, defective
○
assembling

9.2.4 General inspection and adjustment
9.2.4.1 Compression pressure – measure
Inspection standard
Location Check item Standard value Limit Remedy
Each cylinder 2550kPa 1960kPa

Inspect
Compression (at 200rpm) {26kgf/cm2} {20kgf/cm2}
–
pressure Pressure difference be- 390kPa
– Inspect
tween cylinders {below 4kgf/cm2}
Special tools
Unit: mm
Location Tool name and shape Part No. Use
Compression gauge
A
connector
PD MH061460
Measuring compres-
sion pressure
M14×1.5 A
● The decrease of compression pressure

can serve as a guide to determine engine
IO
overhaul intervals.
● Measure the compression pressure on

a regular basis and note the pressure
change. This helps you to conduct fault
analysis. When the machine is new or
when machine parts are replaced, com-
pression pressure may increase since the
piston ring and valve seat are in the run-
ning-in state. Compression pressure will
become normal gradually with the abrasion
machine parts.
● Check if engine oil, starter and battery are

under normal condition prior to inspection.

● Set the machine to the following state:
a. Pre-heat the engine until coolant tem-

perature rises to 75 – 85°C.
b. Switch off all lights and auxiliary equip-

ment.
c. Adjust engine speed to minimum idle

speed.
● Remove the injector of the tested cylinder. Injector

Rag
mounting
● Cover the mounting hole of the injector hole
with rags.
● Start the engine with the starter. Check if

PD
any foreign matters are on the rags.
● If foreign matters (engine oil, coolant) are

FD215-1007043
found on the rags, the causes may be one
of the following:
● If only engine oil are observed, the pis-

ton ring may have caused the sealing
defect. In this case, inspect the piston
ring.
IO
● When both engine oil and coolant are
observed, the cylinder may have cracks
on it. Replace the crankcase if so.

CAUTION
● When coolant and engine oil are ad-
hered on the rag, they may spurt out of
the mounting hole under high tempera-
ture when the engine is running. Do not
touch or watch the injector mounting
hole when the engine is running.
● Install the gasket and tool onto the in-

jector mounting hole and fix them with the 10
20 30
40
50
injection nozzle cap. Install the compres-

0
60
Gasket
sion gauge.
● Start the engine and measure the com-

Injection
pression pressure of all cylinders and nozzle cap
calculate the pressure difference between
PD Injector mounting hole
them.
FD215-1007044
● When compression pressure and pres-
sure difference deviate from the limit, add
a small amount of engine oil through the
injector mounting hole and re-measure the
compression pressure.
● Increase of compression pressure may

IO
be caused by abrasion or damage of
the piston ring or the cylinder inside
surface.
● If compression pressure does not in-

crease, the valve may be engaged or
valve contact is defective, or the cylin-
der head gasket is defective.

9.2.4.2 Valve clearance – inspect and adjust
Inspection standard
– Valve clearance (When engine is cool) 0.4 – Adjust
Special tool
Adjusting valve
Grooved screw
MH060008 clearance
driver
(Loaded condition)
PD
Valve clearance shall be adjusted when the
engine is cool according to the following pro-
cedure:
[Inspection]
● Remove the rocker cover.

Pointer
IO
● Move piston No.1 or piston No.6 to the top
dead center of compression stroke as per FD215-1007046
the following procedure.
● Run the engine until the "1, 6" marks on

the flywheel aligns with the pointer on
the sight window of the flywheel hous-
ing.
● Move piston No.1 or No.6 to the top

dead center of compression stroke.
● When the rocker arm at the intake and

exhaust side can only be rotated by
hand the distance of valve clearance,
the pistons have been moved to the
TDC of compression stroke. Rotate the
engine further for 1 turn, the TDC of
compression stroke of piston No. 1 and
piston No. 6 will be switched.

● Measure the clearances of the valves

Valve clearance
marked with a "O" in the table below when
piston No.1 or No.6 are at the top dead
center of compression stroke.
● When a thickness gauge is used to mea-

sure the clearance, resistance shall be felt
when the gauge is moving in the clear-
ance.
FD215-1007047
Precise measurement can not be achieved if
the thickness gauge moves freely in the clear-
ance.
Cylinder No. 1 2 3 4 5 6
Valve sequence IN EX IN EX IN EX IN EX IN EX IN EX
No.1 Compression TDC ○ ○
PD ○ – – ○ ○ – – ○ – –
No.6 Compression TDC – – – ○ ○ – – ○ ○ – ○ ○
● If the measurement exceeds the specified

value, adjust the clearance as per the fol-
lowing method.
[Adjust] Adjusting screw
● When adjusting clearance, loosen the re-

IO
taining nut and turn the adjusting screw un- Retaining nut
til the thickness gauge can move slightly.
● When adjusting is finished, fix the adjusting

screw and fasten the retaining nut.
● Measure the clearance once again, if mea- Valve clearance FD215-1007048

sured value deviates from the standard
value, conduct further adjustment.
● When the engine is loaded, using to
turn the adjusting screw will make opera-
tion easier.
Adjusting
screw
FD215-1007049

9.2.5 Cylinder head & valve mechanism
Ta
3
1
4
7 Tb
Tb 7
6
PD 8
9
IO
10
*a
FD215-1007050

Disassembling sequence
1) Oiler cap 8) Cylinder head
2) Insulator 9) Cylinder head gasket
3) Rocker cover 10) Tappet
4) Rocker cover gasket *a: Crankcase
5) Rocker arm and bracket P : Position pin
6) Plunger : Non-reusable parts
7) Cylinder head bolt
NOTICE
● Heating plug and injector project un-
der the cylinder head. Be careful not
to damage these parts when placing
them.
Assembling sequence
PD
Reverse the disassembling sequence.
NOTICE
● Cylinder head bolt is fastened onto
plastic area. Replace the bolt if it has
IO
been tightened for 3 times.

Inspection standard
Unit: mm
6 Plunger runout – 0.4 Replace
Clearance between tappet and

10, *a 0.05 – 0.09 0.2 Replace
crankcase tappet hole
T Tightening torque
Unit: N·m{kgf·m}
Symbol Tightened parts Tightening torque Remark
Ta Bolt ( for installation of rocker cover) 4.9 – 6.9 {0.5 – 0.7} –
PD Wet type
Tb Cylinder head bolt 147{15}+90°
Reusable for 3 times
Special tools
Socket Installation of cylinder

IO
MH061560
wrench head
b Tappet puller MH063329 Removing of tappet

9.2.5.1 Pre-disassembling work
Preparation: Loosen valve spring

Adjusting screw
Rocker
● Before loosening cylinder head bolts, if the Cylinder head arm
rocker arm is pressed against the valve bolt
spring, loosen the adjusting screw of the
rocker arm to avoid damage to parts due to
the counter acting force of the valve spring.
Valve spring
9.2.5.2 Disassembling method FD215-1007053
Remove: Cylinder head
● Loosen cylinder head bolt slowly following

the sequence number, and remove the cyl-
PD
inder head.
Remove: Cylinder head gasket

1 9 17 25 20 10 2
5 13 23 22 14 6
NOTICE
● When removing cylinder head gasket, 3 7 11 15 19 21 24 18 16 12 8 4
do not leave scratches on the cylinder FD215-1007054
head and the crankcase.
IO
Remove: Tappet
Tappet
FD215-1007055

9.2.5.3 Inspecting method
Inspect: Plunger runout
● Replace the plunder if the measurement

exceeds the limit.
FD215-1007056
Inspect: Clearance between tappet and

crankcase tappet hole
● Replace the defective part if the measure-

ment exceeds the limit.
9.2.5.4 Assembling method

PD FD215-1007057
Install: Cylinder head gasket

Size mark
● Cylinder head gaskets of different sizes
A B C
are available. Choose proper gaskets ac-
IO
cording to the following procedure.
● Measure the piston projection of all cylin-

ders.
NOTICE
“UP”
● Piston projection may change when
changing pistons and connecting rods.
Piston projection must be measured.
● Choose from the table below cylinder head

gasket of proper thickness that suits the Notch
maximum piston projection. If the piston
projection of only one of the cylinders ex-
ceeds the average piston projection by 0.05 FD215-1007058
mm, gaskets of higher grade thickness
shall be used ((A→B, B→C).

Unit: mm
Piston projection Cylinder head gasket

Thickness (tight-
Average projection Size
ened)
0.546 – 0.610 A 1.3
0.610 – 0.674 B 1.35
0.674 – 0.738 C 1.4
● Size of cylinder head gasket is identified by

the notch on the gasket.
● Place the cylinder head gasket onto the

crankcase as per the illustration.
Install: Cylinder head
NOTICE
PD
● Before installing the cylinder head,
check the number of punch marks on
Punch mark
the bolt head. (Usable when no more
than 2 marks are available)
● The punch marks indicate the number

IO
of installations of the bolt in the plastic
area. If 3 marks have been punched (in-
dicating 3 installations), replace it with
a new bolt).
FD215-1007059
● Tighten the cylinder head bolts in the il-

lustrated sequence to half the specified
torque (75N·m {7.5kgf·m}).
25 17 9 1 6 16 24
23 13 3 4 12 20
● Then tighten the bolt to specified torque

(147N·m {15kgf·m}) in the same order. Fi- 22 18 15 10 8 2 5 7 11 14 19 23
nally, tighten the bolts according to the fol-

FD215-1007060
lowing procedure.
NOTE: Rocker arm and bracket shall be tight-

ened together.

● Turn the socket seat of tool leftward

and activate the internal spring.
Socket
Loop bar
Socket seat
Loop bar
(for connection)
FD215-1007061
● Allow the loop bar (for connection) to touch

the parts around the rocker arm bracket
and injection tube. Gauge mark
(Socket side) Loop bar
● Take the selected gauge mark as the

PD
● Choose a clear gauge mark on the socket
seat side.
benchmark, and turn the gauge mark on

Guage mark
(Socket seat side)
the socket by 90°(one mark is 5°) and FD215-1007062

tighten it.
● Cylinder head bolt can only be used for 3

IO
times. Punch a mark on the bolt head be-
fore installation.
NOTICE
● Cylinder head bolts are tightened in the
plastic area. No further tightening is re-
quired once the angle is fixed.

9.2.6 Rocker arm and bracket
4 5
7
1 10
9
8
6
2 FD215-1007063
1)
2)
Set bolt
Rocker shaft bracket
PD 6)
7)
Rocker shaft spring
Adjusting screw
3) Adjusting screw 8) Rocker arm bushing
4) Rocker arm bushing 9) Air outlet rocker arm
5) Air intake rocker arm 10) Rocker shaft
IO
: Non-reusable parts
Assembling sequence

Inspection standard
Unit: mm
Clearance between rocker

4, 8, 10 0.06 – 0.11 0.2 Replace
arm bushing and rocker shaft
Lubricant and/or sealant
Symbol Applicable location Type Quantity

Inside of rocker arm bush-
Engine oil As required
ing
Special tool PD Unit: mm

Rocker arm
Removing and installa-
bushing remover
A MH061378 tion of rocker arm bush-
A B
ing
φ19 φ21 B
IO
C
Inspect: Clearance between rocker arm

bushing and rocker shaft
Replace the bushing if the measurement ex-

ceeds the limit.
FD215-1007065

Replacement of rocker arm bushing
[Remove]
Bushing
FD215-1007066
[Install]
● Set the part as illustrated and align the oil

orifice on the rocker arm bushing with the
orifice on the rocker arm.
PD
● Install the bushing to the extend that it
meets the chamfer of the rocker arm.
Bushing notch
Rocker arm chamfer

Bushing
Bushing turning
(joint)
Bushing oil orifice

● Measure the clearance again after installa- Rocker arm oil orifice
FD215-1007067
tion.
● If measured value is below the standard

value, ream the bushing.
IO
9.2.6.2 Installation procedure
Set bolt holes
Install: Rocker shaft
● Install the rocker shaft as illustrated.
Front of engine Oil orifice

FD215-1007068

9.2.7 Cylinder head
Tc
13
1
10
2
Ta
3
11
Tb 14
4 9
12
5
6
PD
8
15
16
20
19
IO
21
18
17
FD215-1007069
1) Valve cap 9) Injection nozzle cap 17) Intake valve seat

2) Valve retainer lock 10) Injector 18) Exhaust valve seat
3) Upper seat 11) O-ring 19) Water director
4) Outer valve spring 12) Injection nozzle gasket 20) Stud bolt
5) Inner valve spring 13) Connecting plate 21) Cylinder head
6) Stem seal 14) Heating plug : Non-reusable parts
7) Intake valve 15) Intake valve guide
8) Exhaust valve 16) Exhaust valve guide

Assembling sequence
Reverse the disassembling sequence
NOTICE
● Replace the stem seal when replacing
the intake valve and exhaust valve.
Inspection standard
Unit: mm
Location Check item Standard value Limit valve Remedy
Free length 60.84 57.8
Outer valve Assembling load (assembling
4 24.5±1.2kg 20.8kg Replace
spring length 47.25)
5
Inner valve
spring
Verticality
Free length
length 40.3)
Verticality
PD
Assembling load (Assembling
–
55.07
9.5±0.45kg
–
2.5
52.1
8.1kg
2
Replace
Shaft outer diameter 8.96 – 8.97 8.85 Replace

Thickness of deflection on
1.0±0.25 – Inspect
7 Intake valve cylinder head bottom
IO
Valve perimeter thickness 1.5 1.2 Modify or replace
Valve seat surface angle 45°±1.5' –
Clearance between intake valve stem and
7, 15 0.04 – 0.06 0.15 Replace
intake valve guide
Exhaust valve Shaft outer diameter 8.93 – 8.94 9.85 Replace
Thickness of deflection on
1.2±0.25 1.7 Inspect
8 cylinder head bottom
Valve perimeter thickness 1.5 1.2 Modify or replace
Valve seat surface angle 45°±1.5' –
Clearance between exhaust valve rod and
8, 16 0.07 – 0.1 0.2 Replace
exhaust valve guide
17 Intake valve seat surface width 2±0.2 2.8 Modify or replace
18 Exhaust valve seat surface width 2±0.2 2.8 Modify or replace
Bottom deformation Below 0.05 0.2 Modify or replace

21 Cylinder head
Top-bottom height 95±0.1 94.6 Replace

T Tightening torque
Unit: N·m{kgf·m}
Ta Bolt (for installation of injection nozzle cap) 25{2.5} –
Tb Heating plug 15 – 20{1.5 – 2.0} –
Tc Nut(for installation of connecting plate) 1.0 – 1.5{0.1 – 0.15} –
Valve cap and rocker arm sliding portion
Lip of stem seal

PD Engine oil As required
Valve stem
O-ring
IO

Special tool
Unit: mm
Symbol Tool name and shape Part No. Use
Valve tappet
A MH061668
φ42
A
Removing and instal-
lation of valve retainer
lock
b Valve tappet hook MH061679
Stem seal installation
c
tool
A
φ28
B
φ9
PD
A B MH061293
Installation of stem
seal
Grinding of valve and

d Grinding tool 30091-07500
valve seat
A
IO
Valve guide remover
Removing of valve
e A B MH061066
guide
φ28 φ9
A
Valve guide installa-

tion tool A B
Installation of valve
f A B C MH061998
guide
φ28 φ9 18
C
Caulking tool
g A MH061067
φ9
Caulking ring Installation of valve

h MH061695 seat
A B A
B
<Air-in side>
h IN side φ47.6 i
EX side φ40.6 MH061069
<Air-out side>

9.2.7.1 Disassembling method
Remove: Valve retainer lock
Compress the retainer lock evenly and do not

allow it to tip. Remove the clamp.
NOTICE Retainer lock

FD215-1007077
● If the retainer lock is compressed ex-
cessively, the upper seat may contact
the stem seal and cause damages. Be
very careful in this regard.
1. Valve stem outer diameter

PD
Inspect: Intake valve and exhaust valve
● Replace the valve if measured value

is below the limit or one side of it is ex-
FD215-1007078
cessively worn.
● Grind the valve and the valve seat after

IO
valve replacement.
2. Valve seat surface angle and valve perim-
eter thickness
● Modify or replace the valve if measured

value exceeds the limit.
Valve seat
angle Valve edge thickness
FD215-1007079

Modification of valve
● Keep the grinding amount at minimum.
● If valve perimeter thickness still exceeds 30
the limit after grinding, replace the valve. 20
10
● After modification, grind the valve and the

FD215-1007080
valve seat.
Inspect: clearance between valve and valve

guide
● Replace defective parts if measured valve

is below the limit.
PD FD215-1007081
Valve guide – Replace
[Remove]
IO
Valve guide
FD215-1007082

[Install]
Install the valve guide so than it sits complete-

ly on the cylinder head.
Cylinder head
NOTICE 10mm
● The specified inserting depth of the
valve guide is 10 mm, so tool f must Valve guide
be used.
FD215-1007083
● Note that the exhaust valve guide is
longer than the intake valve guide.
Inspect: Contact condition of valve and

valve seat
PD
● Check if the valve and valve seat is normal
before inspection.
● Apply a coat of red lead evenly on the con-

Valve contact surface
tact surface of the valve seat.
● Tap the valve against the valve seat. Do

FD215-1007084
not rotate the valve when doing so.
IO
● If inadequate contact is detected through
observing the amount of red lead adhered
on the valve, modify the valve according to
the guide below.
Contact condition Remedy
Minor defect Grind the valve
Modify or replace valve and FD215-1007085

Major defect
valve seat

Valve – Grind
● Apply a thin coat of grinding paste on the

contact surface of the valve.
NOTICE
● Make sure no grinding paste is adhered
onto the valve rod. Valve rod
● Use grinding paste of medium size grit

Grinding paste
(120~150) at first, and then use grind-
ing paste of fine grid (above 200).
● A little engine oil can be added into

FD215-1007086
the grinding paste to make the coating
more even.
PD
● Tap the valve against the valve seat slight-
ly and rotate the valve bit by bit.
● Clean the grinding paste with light diesel

fuel.
● Apply a coat of engine oil on the contact

surface of the valve seat and rub them.
IO
● Re-inspect the contact condition between FD215-1007087
the valve and the valve seat.
● If the contact condition is still defective, re-

place the valve seat.
Inspect: valve seat
1. Valve seat surface width Valve seat
● Modify or replace the valve seat if mea- Valve seat

sured value exceeds the limit width

modification or replacement.
FD215-1007088

2. Thickness of the deflection on the cylinder

head bottom
Valve seat
● Press against the valve seat when

measuring this value.
● Replace defective parts if the measured

value is above the limit.
Dent depth
FD215-1007089
Valve seat – Modify
● Grind the valve seat with a valve seat cut- Dent depth Valve seat
ter or a wheel head. surface angle
● After grinding, place a sand paper of 400

PD
grit between the cutter and the valve seat
and grind the valve seat a bit. Valve seat
width
● Modify the valve using a 15° or 75° cutter Valve seat

until it meets the specified valve seat width.
FD215-1007090
NOTICE
● Make sure the thickness of the valve
deflection does not exceed the speci-
IO
fied limit during grinding operation.

modification.
Valve seat – Replace

Valve seat
[Remove]
● The installation of the valve seat is interfer-

ence fit. To remove the valve seat, grind
the surface to reduce its thickness,then re-
move the valve seat at room temperature.
0.5-1.0mm
Section to be ground FD215-1007091

[Install]
Check if aperture A and B of the cylinder head

valve seat meets the value in the table below.
Intake side valve seat aperture: A φ46+0.0250mm

Exhaust side valve seat aperture: B φ39+0.0250mm
A B
● Replace cylinder head in case of abnor-
mality. FD215-1007092
● Cool the valve seat by soaking it in liquid

nitrogen.
NOTICE
PD
● When working on a cool valve seat, be
careful with low temperature.
● Use tools g and h to install the valve

seat onto the cylinder head. At this time,
g
阀座seat
Valve
set the chamfer of tool h on the cylinder
head.
FD215-1007093
● Grind the valve after the valve seat has
IO
been installed.
Inspect: Deformation on cylinder head bot-

tom
● If the measured value is above the limit,

grind the valve seat bottom with a surface
grinder. Be careful not to allow the top-bot-
tom height of the cylinder head to deviate
from the limit.
NOTICE
● Make sure the valve deflection thick-
ness does not exceed the specific limit
during grinding operation.

Install: Water director
Install the water director onto the cylinder

Notch
head and the notch shall be driven in by 4mm
as illustrated.
FD215-1007095
Install: Stem seal
● Apply a coat of engine oil on the lip of the

PD
stem seal.
● When installing the stem seal, make sure it

is completely pressed against the cylinder Lip
head.
Valve stem seal
NOTICE
● After the seal is driven in, check if the Cylinder head
spring of the stem seal is deformed or
IO
FD215-1007096
damaged. Replace it with a new one in
case of abnormality.
Install: Retainer lock
● Install the retainer lock according to the

disassembling procedure.

9.2.8 Piston, connecting rod and cylinder bushing
5
3
2
P
PD Ta
FD215-1007097
1) Lower connecting rod bearing 4) Piston and connecting rod

IO
2) Connecting rod cover 5) Cylinder bushing
3) Upper connecting rod bearing P : Position pin
NOTICE
● The connecting rod is fastened in the
plastic area. Replace the bolt of con-
necting rod if it has been tightened for
3 times.
Assembling sequence

Inspection standard
Unit: mm

– Piston projection (Average) 0.43 – 0.69 – Inspect
– Connecting rod end play 0.15 – 0.45 0.6 Inspect
Connecting rod bear- Free span – 69.5
1, 3 Replace
ing Oil clearance 0.04 – 0.099 0.2
Clearance between piston, connecting rod
4, 5 0.07 – 0.11 – Replace
and the cylinder portion of cylinder bushing
Inner diameter φ104 – 104.03 φ104.25
Cylinder portion of Replace with
5 Circularity Less than 0.01 –
crankcase oversized ones
Cylindricity Less than 0.03 –
T Tightening torque
Symbol
Ta
PD
Tightened parts
Nut (for installation of connecting rod cover)

Tightening torque
29{3}+90°±5°
Unit: N·m{kgf·m}
Remark
Wet type
Reusable for 3 times

IO
Bolt thread
Inside surface of connecting rod bearing
Piston perimeter
Cylinder bushing perimeter

Special tools
Unit: mm
Piston guide clamp MH061890
b Piston guiding rod MH061658

Installation of piston
and connecting rod
Socket wrench
c MH061560
d
Cylinder bushing
installation tool
A
φ103
PD ME062228
Installation of cyliner
bushing

IO
Inspect: Piston projection above crankcase
top surface
NOTICE
● The projection of piston influences en-
gine performance. It must be inspected.
● Rotate the piston to the top dead center of

compression stroke.
● Take reference point A (7 in total) on the

crankcase as the O point and measure pis-
ton projection relative to this point. (Mea-
suring point B, reference point A).

● Calculation of piston projection take refer-

ence point A that is closest to measuring Crankcase
point B. One cylinder requires two mea-

surement (12 in total) and figure out the
average value.
● If the average is above the limit, inspect

the clearances.
● Select cylinder head gasket of proper

thickness according to the average piston
protrusion. (Refer to cylinder head section)
PD B
FD215-1007101
Inspect: Connecting rod end play
● Measure the end play of each of the con-

IO
necting rod.
● Replace defective parts if measured value

exceeds the limit.
9.2.8.2 Inspecting method FD215-1007102
Inspect: Free span of connecting rod bear-

ing
NOTICE
● Do not expand the bearing by hand.
● Replace both the upper and lower bearing

in pairs if the measured value is below the
limit.
FD215-1007103

Inspect: Clearance between connecting rod

bearing and crankshaft (Oil clearance)
Upper bearing
● Place the upper and lower bearing on the
connecting rod cover and the connect-
ing rod respectively and tighten the bolt to
29N·m {3kgf·m}.
● Measure the inner diameter of the connect-

ing rod bearing and the outer diameter of Lower bearing
crank pin.
Crank pin outer diameter
● If the clearance is above the limit, replace
the defective parts.
● When the bearings are replaced with

smaller ones, the outer diameter of the
PD
crank pin shall be modified to a smaller
size.
FD215-1007104
Inspect: Clearance between piston and cyl-

inder bushing on the cylinder portion
Crankcase Cylinder bushing
● Proceed with either of the following when
the measured value exceeds the limit. >20mm
80mm
IO
A: Measuring location at crankcase side A
(crank shaft axial direction) B
B: Measuring location at crankcase side >60mm

(Perpendicular to crankshaft axial direc-
tion)
C: Measuring location at piston side
(Perpendicular to piston hole)
72.15mm
● If the inner diameter of cylinder portion

of the cylinder bushing exceeds the limit, C
bore the cylinder portion to a larger size
and install piston and piston ring of a larger
size that match the cylinder.
NOTICE FD215-1007105
● Even if only one cylinder is defective,

all the cylinders shall be modified to
the same larger size.

Replace the piston and piston ring if the inner

diameter of cylinder bushing on the cylinder is
within the limit.
Piston size – Enlarge
● Expanded size: 0.50,1.00 mm (2 types)
● Measure the bores of all the cylinders. The

expanded size is determined by the cylin-
der with the largest bore.
● Measure the outer diameter of the piston

with expanded size.
● Take the clearance between the piston and

the cylinder as the standard and bore the
cylinders.
NOTICE
● To avoid cylinder deformation due to
PD
the heat generated by the boring, bore
the cylinders in the following order.
No.1→No.5→No.3→No.6→No.2→No.4
Boring size (tolerance: ±0.005) = Outer diam-

IO
eter of enlarged piston (measured value) +
Clearance between piston and cylinder (aver-
age modifying benchmark) – 0.02 mm (honing
margin)
Hone the cylinder after boring operation to get

the finish size (tolerance: ±0.005).
Finish size (tolerance ±0.005) = Outer diam-

eter of enlarged piston (measured value) +
clearance between piston and cylinder (aver-
age value of modifying benchmark)
● Roughness of honing surface: 2 – 4 mm
● Honing cross angle: 15 – 25 deg. (semi

angle)
● Cylinder bore squareness: 0.05 mm
● Confirm the clearance between piston and

cylinder

Cylinder liner – Replace
[Remove]
● Fix the boring machine on the crankcase

and align the machine. Alignment shall be
done on the lower part of the cylinder liner
with less nonuniform abrasion.
● Conduct boring operation until the thick- Cylinder bushing

FD215-1007106
ness of cylinder liner reaches 0.5 mm.
● Insert a tool (e.g. a screwdriver with the tip

specially treated) between the crankcase
and the cylinder liner. Hammer the screw
driver and remove the cylinder liner at the
same time. PD
NOTICE
● Press the round-edged portion of the
tool against the crankcase. Otherwise,
scratch may be left.
[Inspect]
183mm
IO
99mm Crankcase
● Check if the cylinder bushing mounting 15mm
hole of the crankcase if scratched.
B
D1 A
● Measure the inner diameter of the crank- D2
case, the outer diameter of the upper and
lower parts of the cylinder bushing and ra- D3
dial direction.
15mm
● Bore the crankcase to larger dimension Cylinder bushing

if the measured value deviates from the
standard value.
D1
99mm
183mm
B
D2 A
D3
FD215-1007107

Install
● Press the cylinder bushing into the crank-

Cylinder
case at the chamfer side with tool d . bushing
● When it is well placed, hone the cylinder Crankcase

bushing until the inner diameter meets the
standard value.
FD215-1007108
9.2.8.3 Assembling Method
Install: connecting rod bearing

Lower bearing Upper bearing
Protrusion
NOTICE
● If the lower bearing and upper bear-
ing (with oil orifice) are installed in a
reversed manner, the engine may seize
up. Be very careful when installing the
PD Oil orifice
bearings.
FD215-1007109
IO
Install: Piston and connecting rod
● Confirm that the end gap of the piston ring D A

is in the specified position.
“△”
A: End gap of the 1st compression ring
B: End gap of the 2nd compression ring
C: End gap of oil ring

B C
FD215-1007110
D: Joint of oil ring spring
"Δ" : Front mark of the piston

● Keep the piston front mark “Δ” in the front

“△”
of the engine.
● Place tool around the piston skirt and

adjust the piston with the adjusting bolt of
tool b so that the inner diameter match-
es the outer diameter.
Adjusting bolt
● When the adjusting is finished, remove it
from the piston and coat engine oil on the
following locations. Place it on the piston
ring again.
● Piston perimeter
● Inside of tool
crankcase
PD
● Inside of the cylinder portion of the
FD215-1007111
● Align the match marks on the connect-

ing rod and connecting rod cover after the
piston and the connecting rod have been Connecting rod cover
IO
installed. Tighten the bolt alternatively fol-
lowing the procedure below. Match mark
● Tighten the nut to torque 29N·m{3kgf·m}
● Further tighten the bolts according to the

procedure below. FD215-1007112

● Turn the socket of tool c to the left, and a

strain the spring inside the socket wrench. Socket
Loop bar
Socket seat
Loop bar
(for connection)
FD215-1007113
● Adjust the socket and transmit the spring

force to the crank shaft via the loop bar (for
Loop bar (for connection)
connection).
PD
● Align any of the gauge marks on the cylin-
der bushing with any of the gauge marks
on the socket. (Take this point as the 0 ref-
erence point. Gauge mark
Guage mark (Socket side)
● Take the aligned mark as the reference (Socket seat side)
FD215-1007114
point and tighten the socket as illustrated
by 90°±5°. (One mark is equivalent to 5°)
● When the connecting rod cover is in-

IO
stalled, check:
● End play of connecting rod
● Piston projection

9.2.9 Piston and connecting rod
8
4
7
6
PD
FD215-1007115
IO
1) 1st compression ring 6) Connecting rod bushing
2) 2nd compression ring 7) Connecting rod
3) Oil ring 8) Piston
4) Snap ring : Non-reusable parts
5) Piston pin
NOTICE
● Do not remove the connecting rod bolt
unless it is deemed abnormal.
Assembling sequence

Inspection standard
Unit: mm

1st compression ring 0.3 – 0.45
Piston ring end
1–3 2nd compression ring 0.4 – 0.55 1.5 Replace
gap clearance
Oil ring 0.25 – 0.45
Clearance be- 1st compression ring 0.09 – 0.13 0.2
1 – 3, 8 tween piston ring 2nd compression ring 0.06 – 0.1 Replace
0.15
and ring groove Oil ring 0.03 – 0.06
Clearance between piston pin and connecting
5, 6 0.03 – 0.05 0.1 Replace
rod bushing
5, 8 Clearance between piston pin and piston 0.007 – 0.021 0.05 Replace
Deflection – 0.05
7 Connecting rod Replace
Torsion PD – 0.1
Lubricant and/sealant

Piston pin perimeter
Connecting rod bushing
perimeter Engine oil As required
Mounting surface of con-
IO
necting rod bushing
Special tools
Unit: mm
Removal and installa-

Piston ring tools MH060014
tion of piston ring

Remover set of con-
b MH062225 tion of connecting rod
necting rod bushing
bushing

Remove: Piston ring
FD215-1007118
Remove: Piston pin
● Hammer out the piston pin. PD Piston pin
● If it does not come out, put the piston in hot

water and heat the piston and try removing
it again.
FD215-1007119

IO
Inspect: End gap clearance of piston ring
Cylinder portion
● Place piston ring horizontally into the cylin-
der section of the crankcase with the head
of the piston. Choose the less worn lower Piston
part of the cylinder.
● Be careful not to move the piston ring

when measuring the end gap clearance. Piston ring
FD215-1007120
● Replace full set of piston ring if measured


Inspect: Clearance between piston ring and

piston ring groove
● Clean the carbon build-up in the piston ring

groove before measuring.
● Measure the clearance along the piston

ring groove.
● Replace defective parts if measured value FD215-1007121

is above the limit. Full set of piston ring
shall be replaced.
Inspect: Clearance between piston pin and

piston

PD
is above the limit.
FD215-1007122
Inspect: Clearance between piston pin and

IO
connecting rod bushing
● Replace the bushing if measured value is

above the limit.
FD215-1007123

Connecting rod bushing – Replace

Remover
● Use tool b for the replacement.
Bracket Base plate
Spacer A
[Remove] Spacer B
● Remove the upper bearing (if equipped) at

the larger diameter end of the connecting
rod.
Nut Base
● Fix the connecting rod onto the base and Press
secure it properly with the bracket and
Remover
base plate.
● Place the spacer sleeve A on the remover Spacer A Bracket

Bushing
as illustrated, and apply a force of around
Base plate
49kN {5000kgf} onto it until the bushing is
PD
pushed out.
Base
FD215-1007124
[Install]
● Coat the mounting portion and the bushing Spacer B

Remover
IO
perimeter with engine oil.
Bushing
● Place spacer sleeve B onto the remover Oil orifice
as illustrated, and place the bushing and Connecting rod
Spacer A
spacer sleeve A. Fix all these parts with
the nut.
● Align the oil orifice of the bushing with that

Nut FD215-1007125
of the connecting rod and apply a force
of about 49kN {5000kgf} with a press ma-
chine until the bushing is pressed in place.
● Re-measure the clearance after installa-

tion.
● Bore the bushing if measured value is be-

low the standard value.

Inspect: Connecting deflection and torsion Deflection Aligner (measure instrument)
● Fix the connecting rod onto the aligner.

In order to create the same condition as 100mm
when the connecting rod is installed onto

the crankcase, the connecting rod bearing,
piston pin and connecting rod cover shall
also be installed. Tighten the bolt of the
connecting rod cover to 69N·m {7kgf·m}.
● Measure the deflection and torsion of the

connecting rod.
Torsion
● Replace the connecting rod if measured
9.2.9.3 Assembling method 100mm
Install: Piston and connecting rod
● Make sure all cylinders have the same

PD
weight when installing the connecting rod.
Aligner (measure instrument)
FD215-1007126
● Coat the piston pin with engine oil and in-

stall the piston and connecting rod as illus- “△”
trated. “Δ” : Front mark
IO
● If the piston pin is difficult to install, put the
piston in hot water or heat it with a piston
heater, and try once again.
Install: Piston ring Weight mark
FD215-1007127
● Set the piston ring in such a manner that
the mark near the ring end gap is facing
upward, and arrange the end gap of each
ring as illustrated.
A: 1st compression ring end gap “△”
B: 2nd compression ring end gap

C: Oil ring end gap
D: Oil ring spring joint
Producer mark
"Δ" : Front mark
FD215-1007128
Only the top and 2nd compression ring end
gaps are marked.

9.2.10 Flywheel
P
4
*a
Ta
1
PD 6
FD215-1007129
1) Lock piece 5) Engine speed sensor

IO
2) Bearing 6) Flywheel housing
3) Ring gear *a: Crankshaft
4) Flywheel P : Position pin
Assembling sequence

Inspection standard
Unit: mm

Rubbing surface runout
4 Flywheel – 0.2 Modify or replace
after installation
Eccentricity of the deflection when fly-
6 – 0.2 Modify or replace
wheel housing is installed
Tightening torque
Unit: N·m{kgf·m}
Ta Bolt (for flywheel installation) 39{4.0}+47° Wet type
Lubricant and/or sealant PD

Bolt thread Engine oil As required
Special tools

IO
Socket wrench MH062183
Flywheel installation
b Magnetic base MH062356

9.2.10.1 Pre-disassembling inspection
Inspect: Rubbing surface runout when the Flywheel

flywheel is installed
● If measured value exceeds the limit, check

if the bolt is properly tightened and check
the mounting surface between it and the
crank shaft. Modify or replace the flywheel
if necessary. FD215-1007131
Remove: Flywheel Flywheel
● Screw the bolt into the dismounting hole

and remove the flywheel.
Remove: Ring gear

PD
● Heat the ring gear with a gas burner etc. to
Bolt
Dismount hole
FD215-1007132
200°C and remove the ring gear from the

flywheel.
CAUTION
● Do not touch the heated area to avoid
IO
burns.

Dent
Inspect: Eccentricity of the deflection when
the flywheel housing is installed
● Rotate the crankshaft, inspect the eccen-

tricity at the illustrated area of the flywheel
housing.
● Re-install the assembly if the eccentricity FD215-1007133

exceeds the specified limit.
● Replace defective parts if the eccentricity

is still above the limit.

Install: Ring gear

Ring gear
● Heat the ring gear evenly with a gas burner
to 200°C.
CAUTION
● Do not touch the heated area.
Chamfered side
● Face the non-chamfered side of the ring

gear towards the flywheel. Flywheel FD215-1007134
Install: Flywheel a
Socket
● Tighten the bolt to 39N·m {4.0kgf·m}, and

tighten it further according to the procedure
PD Socket seat Loop bar
below.
Loop bar
(for connection)
● Turn the socket of tool to the left and
strain the spring inside the socket.
FD215-1007135
● Adjust the socket, transmit the force of the

IO
Gauge mark (socket side)
built-in spring to tool b via the loop bar
(for connection).
● Align any one of the gauge marks on the

socket seat with any one of the marks on
the socket. (Take this mark as the 0°refer-
Gauge mark
ence point) (socket seat side)
Loop bar (for connection)

● Turn the gauge mark on the socket to the FD215-1007136
right by 47°±3°in relation to the reference
point and fix it.
One gauge mark on the socket is equiva-

lent to 10°.

9.2.11 Timing gear
10
*c
4
*d
5 *b
*a
PD
Tb
8
11
2 *a
IO
9
3 13
12
1
Chamfer
Ta 10
FD215-1007137
1) Cone 7) Timing gear box 13) Pin

2) O-ring 8) Thrust plate *a: Crank shaft gear
3) Crankshaft belt roller 9) Idle gear bushing *b: Oil pump gear
4) Cap 10) Idle gear *c: Cam shaft gear
5) O-ring 11) Idle gear shaft *d: Injection pump gear
6) Front oil seal 12) F. oil seal oil catch ring : Non-reusable parts

NOTICE
● Do not remove the front oil seal unless
deemed abnormal.
Assembling sequence
Inspection standard
Unit: mm
Between crankshaft gear and oil pump gear 0.10 – 0.18 0.3
Clearance
Between idle gear and crankshaft gear 0.07 – 0.15 0.3
– between Replace
Between idle gear and camshaft gear
PD 0.07 – 0.17 0.3
the gears
Between idle gear and injection pump gear 0.07 – 0.17 0.3
– Idle gear axial clearance 0.05 – 0.15 0.3 Replace
9, 11 Clearance between idle gear bushing and idle gear shaft 0.03 – 0.06 0.1 Replace
Tightening torque
Unit: N·m{kgf·m}

IO
Ta Nut (for installation of crankshaft belt roller) 490{50} -
Tb Bolt (for installation of thrust plate) 78{8} -

O-ring
Lip of front oil seal Engine oil As required
Inside of idle gear bushing
b Mounting surface of timing gear box ThreeBond 1270C As required

Special tools
Unit: mm
C
Idle gear bushing
remover
B MH062224 tion of idle gear bush-
A B C
A ing
φ44.5 φ49 φ45
Cone remover
b A A MH062496 Removal of cone
M44×1.5
9.2.11.1 Disassembling procedure PD

Remove: Cone
Cone
● Set tool onto the shaft and rotate it as
illustrated so that it is engaged with the
cone. Remove the cone along with the
tool.
IO
FD215-1007140
Inspect: Clearances between gears
● Measure more than 3 spots on each pair of

gears.

exceeds the limit.
FD215-1007141

Inspect: Idle gear axial clearance

exceeds the limit.
FD215-1007142
Inspect: Clearance between idle gear bush-

ing and idle gear shaft
[Inspect]
ceeds the limit.

PD
● Replace the bushing if measured value ex-
FD215-1007143
Idle gear bushing – Replace

IO
[Remove]
Bushing
FD215-1007144
[Install]
● Set the idle gear in the direction as illus-

trated.
Chamfer
● Install the bushing so that it contacts the
chamfered part of the idle gear.
● Re-measure the clearance after installa- Bushing

tion.
FD215-1007145
● Bore the bushing if measured value is be-
low the standard value.

Install: Idle gear Idle gear

Injection pump gear
● Set piston No. 1 and No. 4 at the top dead Camshaft gear
center position.
● Align the idle gear with the match marks

on the gears "1", "2" and "3" and install the
idle gear.
Crankshaft gear FD215-1007146
Install: Timing gear box

Sealant
● Clean the sealant coating surface of the f1mm
timing gear box. Remove oil and grease on
the surface if any.
PD
● Coat the sealant continuously and evenly
on the timing gear box and install the front
cover within 3 minutes. Be careful not to
allow the sealant to deviate.
NOTICE
Front cover
● Do not start the engine within 1 hour
IO
after the timing gear box is installed.
● Re-coat the box with sealant if the

mounting bolt of the timing gear box is
loosened of removed. Timing gear box
FD215-1007147

9.2.12 Camshaft
“F”
PD
3
Ta 1 FD215-1007148
IO
1) Camshaft gear 4) Camshaft

2) Thrust plate : Non-reusable parts
3) Pin
NOTICE
● Do not disassemble the camshaft gear
unless confirmed abnormal.
Assembling sequence

Inspection standard
Unit: mm
– Camshaft end play 0.05 – 0.22 0.3 Replace

Interference between camshaft gear
1, 4 0.03 – 0.07 – Assembling 3 times (max.)
and camshaft
Major axis: 47.105
Air-in side 7.195±0.05 6.70
Major-minor Minor axis: 39.910
Replace
4 Camshaft axis difference Major axis: 46.979
Air-out side 7.321±0.05 6.82
Minor axis: 39.658
Deflection Below 0.02 0.05 Replace
Tightening torque
Symbol
Ta
PD
Tightened parts
Bolt (for camshaft gear installation)

Tightening torque
180{18}
Unit: N·m{kgf·m}
Remark

IO
Thrust surface of the thrust plate
Cam portion of camshaft and journal of camshaft

Inspect: Camshaft end play

exceeds the limit.
FD215-1007149

Bolt
Remove: Camshaft PD
● Loosen the bolt from the hole on the cam-
shaft gear. Then remove the camshaft.
NOTICE
● Be careful not to damage the camshaft
FD215-1007150
bushing when removing the camshaft.
IO
Remove: Camshaft gear
● Camshaft gear is pressed into the cam- Camshaft Camshaft gear

shaft. So use a press machine at the cam-
shaft side when removing the camshaft
gear.
NOTICE
● Do not strike the camshaft gear with a
hammer. Use a press machine.
FD215-1007151

Inspect: Interference between camshaft

gear and camshaft
● Replace damaged parts if measured value

exceeds the standard value.
FD215-1007152
Inspect: Camshaft
1. Difference between major axis and minor

axis of cam portion PD Engine front Major axis
● Replace the camshaft if measured val-

ue exceeds the limit.
NOTICE 6.5mm 6.5mm Minor axis
● Camshaft is cone-shaped in the cam Measuring position Measuring position

portion. Conduct the measurement at FD215-1007153
the location as illustrated.
IO
2. Deflection
● Support the journals at both sides and

measure at the intermediate portion
when measuring the deflection of the
camshaft.
● When the deflection of the camshaft

makes the camshaft turn for one round,
half the reading on the dial gauge. FD215-1007154
● Replace the camshaft if measured val-

ue exceeds the limit.

Install: Camshaft gear

Punch mark
● Check the punch mark in the center of the
gear before installing the camshaft gear.
The camshaft gear can only be installed for
3 times. If 3 punch marks are on the gear,
replace the camshaft gear and the cam-
shaft with new ones.
FD215-1007155
● Install the gear onto the camshaft as il- “2”

lustrated and use the retaining pin to stop Jig 2
rotation. PD 2
Camshaft gear
NOTICE Thrust plate

Retaining pin
● Apply the pressing force in the center
of the camshaft gear. If the force is ap-
plied onto the gear, the camshaft gear
may be damaged.
FD215-1007156
● Punch a mark in the center of the camshaft

IO
gear after installation.
Install: Camshaft
Camshaft gear
● Set piston No. 1 and No. 4 at the top dead
center position. Align the match marks on
the camshaft gear and idle gear "2".
FD215-1007157

9.2.13 Crankshaft and crankcase
16
15
P
Tb 14
13
PD12
1
11 b
IO
4
3 b
8
2
Ta 5
P
10 6
FD215-1007158

1) Rear oil seal 10) Crankshaft

2) Main fastening bolt 11) Front cover
3) Side oil seal 12) Gasket
4) Thrust plate 13) Upper main bearing
5) Lower main bearing 14) Check valve
6) Main bearing cap 15) Engine oil spray pipe
7) Crankshaft gear 16) Crankcase
8) Retaining pin P : Position pin
9) Rear oil seal oil-catch ring : Non-reusable parts
Assembling sequence
NOTICE
● The main fastening bolt is tightened
onto the plastic area. Replace the bolt
if it has been tightened for 3 times.
PD
● If the check valve is tightened to a
torque larger than specified, the engine
may seize up. Be very careful in this re-
IO
gard.

Inspection standard
Unit: mm
– Crankshaft end play 0.10 – 0.26 0.4 Replace thrust plate

5, 13 Main bear- Oil clearance 0.04 – 0.09 0.15
Replace
ing Span under free condition – Below 82.5
11 Deflection Below 0.025 0.05 Replace
Crankshaft Roundness Below 0.01 0.03
Pin and journal Modify or replace
Cylindricity Below 0.006 –
17 Deformation on crankcase top surface Below 0.07 0.2 Modify or replace
Tightening torque
Symbol
Ta
PD
Tightened parts
Main fastening bolt (for installation

of main bearing cap)
Tightening torque
59{6}+90°
Unit: N·m{kgf·m}
Remark
Wet type
Reusable 3 times (max.)
Tb Check valve 38{3.9} Wet type

IO
Lip of rear oil seal
Main fastening bolt thread
Inside of main bearing
Thread of check valve
Crankcase mounting surface of rear oil seal
b ThreeBond 1207C As required
Top and groove of side oil seal

Special tools
Unit: mm
Socket wrench Installation of main

MH061560
bearing cap
Bearing cap remover Removing of main

b A B MH061083 bearing cap (rear-
φ103 M8×1.25 B most)
PD A
Removing of crank-
c Gear remover MH061326
shaft gear
Tool for installation of

real oil seal oil-catch
IO
Installation of rear
d ring MH062677
C oil seal oil-catch ring
A B C AB
φ103 φ100 φ15
Inspect: Crankshaft end play
● Replace the thrust plate with a larger one

and adjust if measured value exceeds the
limit.
● Type of expanded sizes
+0.15, +0.30, +0.45mm

FD215-1007162
● Replace crankshaft if the end play can not

be adjusted.

Remove: Main bearing cap
● Since side oil seal is driven in between the

rear-most main bearing cap and crank-
case, remove the main bearing cover with
tool b .
Main bearing cap
FD215-1007163
Remove: Crankshaft gear
NOTICE
PD
● Do not strike the crankshaft gear in
order to remove it. Otherwise, the gear
may get damaged.
Remove: Rear oil seal oil-catch ring FD215-1007164
● Remove the real oil seal oil-catch ring with

a chisel or similar tools. Be very careful not
to damage the crankshaft.
IO
Inspect: Free span of the main bearing
NOTICE
● Do not expand the bearing by hand.
● Replace the full set of bearings of the main

bearing if measured value is below the
limit. FD215-1007165

Inspect: Clearance between main bearing Upper bearing

and crankshaft
● Install the upper and lower main bearing

into the crankcase and the main bearing
cap respectively.
● Tighten the main fastening bolt to 59N·m

{6kgf·m}.
● Measure the inner diameter of the main Lower bearing

bearing and the outer diameter of the
crankshaft journal.
● Modify the crankshaft journal to specified

smaller size if measured value exceeds the
limit. PD Journal outer diameter
Inspect: Crankshaft
FD215-1007166
1. Deflection
● Support journals No.1 and No.7 and

measure at the intermediate section
of journal No.4 when measuring crank-
shaft deflection.
IO
● Replace the crankshaft if measured
value exceeds the limit.
NOTICE
FD215-1007167
● When the deflection of the crankshaft
makes the crankshaft turn for one
round, half the reading on the dial
gauge.
Inspect: Crankshaft
2. Roundness and cylindricity of crankshaft

journal and crank pin.
● If measured value exceeds the limit,

grind the crankshaft to a smaller size or
replace the crankshaft.
FD215-1007168

Crankshaft – Modify
NOTICE
● If the crankshaft shall be modified by
grinding, replace the main bearing with
one of a smaller size.
● The center distance A between the journal

C B
and the pin shall not change. Pin portion D
Journal portion
A: 57.5±0.075 mm D
● Journal width B and crank pin width C shall A

not change.
B: 35mm(No.1 journal part 32mm)
C: 41+0.2 mm
● Make the round-cornered section D

smooth.
PD FD215-1007169
D: R4±0.2mm
● Conduct magnetic crack detection and

IO
check for grinding cracks. Also check
for surface hardness (no less than Hs75
Shore hardness).
● Replace the crankshaft in case of abnor-

mality.
Crankshaft downsizing specification

Unit: mm
Sub-size grade
0.25 0.50 0.75 1.00
Journal outer machining diameter 77.68 – 77.70 77.43 – 77.45 77.18 – 77.20 76.93 – 76.95
Pin portion outer machining diameter 64.69 – 64.71 64.44 – 64.46 64.19 – 64.21 63.94 – 63.96
Roundness Below 0.01
Cylindricity Below 0.006

● During grinding operation the crankshaft

Grinding Fine machining
and the grinding wheel shall be rotating to
the left when observed from the front of the
crankshaft.
● The crankshaft shall rotate to the right

when the crankshaft is being fine machined
Crankshaft
with oil stone or sand paper. Crankshaft
Grinding wheel Sand paper

FD215-1007170
Inspect: Deformation on crankcase top sur- Measuring position

face
● If measured value is above the limit, use a

PD
surface grinder to modify the crankcase.
● Keep the piston projection within the speci-

fied value during grinding operation.
FD215-1007171
IO

Install: Rear oil seal oil-catch ring Rear oil seal oil-catch ring
● If measured value is above the limit, use a

surface grinder for the modification.
● Install the rear oil seal oil-catch ring to the

extend that tool d touches the bearing.
Guide Installation tool

FD215-1007172
Install: Crankshaft gear

Notch Retaining pin
● Heat the crankshaft gear to 100°C with a
gas burner. PD
NOTICE
● The main bearing shall be replaced
with a downsized one if the crankshaft
shall be modified by grinding. Crankshaft gear Crankshaft
● Align the retaining pin on the crankshaft FD215-1007173
with the notch on the crankshaft gear, and

install the gear by tapping the surface of
IO
the gear with a plastic hammer.
Install: Main bearing Lower bearing Oil orifice Upper bearing
● Install the main bearing and set the protru-

sion into the corresponding groove.
Protrusion
When the crankshaft is downsized, main
Protrusion
bearing of a smaller size shall be used.
Type of smaller sizes: 0.25, 0.50, 0.75,

1.00mm FD215-1007174
NOTICE
● The main bearing shall be replaced
with one of a smaller size if the crank-
shaft shall be modified by grinding.

Install: Thrust plate Thrust plate Main bearing cap
● Install a thrust plate on the main bearing Oil slot

cap at the rear-most part of the engine so
that the oil slots are at the outside.
Oil slot
P : Position pin
Thrust plate
NOTICE
Oil slot FD215-1007175
● If the oil slots on the thrust plate are re-
versely installed, the engine may seize
up. Be careful in this regard.
● When adjusting crankshaft end play, install

a thrust plate of a larger size. It is accept-
able if the sizes in the left and right side
are different. But, thrust plates of the same
PD
size must be installed in the upper and
lower part.
Install: Main bearing cap
Punch mark
NOTICE
● Check the punch marks on the bolt
head before installing the main fasten-
IO
ing bolt. (If no more than 2 marks are
available, the bolt is usable. )
● The punch marks record the number

of tightening in the past. If 3 marks are FD215-1007176
available, replace the bolt with a new
one.
● Set the numbers "1" ~ "7" , mark "R" and

front mark “ ” in an order as illustrated
and tighten the main bearing cap from the
engine front in the numbered order.
Engine front
F F F F F F F
FD215-1007177

● Coat the main fastening bolt thread and a

the seat surface with engine oil and tighten Socket
the bolt to 59N·m{6kgf·m}. Further tighten
Loop bar
the bolt according to the procedure below. Socket seat
Loop bar
● Turn the socket seat of tool leftward
(for connection)
and activate the internal spring.
FD215-1007178
● Adjust the socket so that the force of the Cranshaft

built-in spring is applied onto the crank-
shaft via the loop bar (for connection). Loop bar
(for connection)
● Align any of the gauge marks on the socket
PD
seat with a mark on the socket. (Take this
point as the 0°reference point)
● Take the 0°position as the reference point Gauge mark

(Socket seat)
and tighten the socket in the illustrated di- Gauge mark (Socket side)
rection to the extend that the gauge mark FD215-1007179
on the socket is at 90°.
● One mark on the socket seat is equivalent

to 5°.
IO
● When the main fastening bolt is tightened
in the plastic area, punch a mark on the
bolt head to record the number of bolt
tightening.
NOTICE
● Since the bolt is tightened in the plastic
area, no further tightening is required
after angle tightening.
● When installation is finished, check that the

crankshaft can be rotated by hand. Check
the installation of the main bearing cap if
abnormality is observed.

Install: Side oil seal

Main bearing cap
● Inject sealant into the mounting groove of
the side oil seal of the main bearing cap. Sealant
FD215-1007180
● Apply sealant on the top and install the

side oil seal between the main bearing cap
A B
and the crankcase as illustrated.
A: Crankshaft side PD Top of side oil seal

B: Crankcase side
● When installation is finished, apply sealant

to the illustrated location. Be careful that
no engine oil shall leak in all the locations. Sealant FD215-1007181
Install: Rear oil seal
● Coat engine oil on the lip of the rear oil

IO
seal.
● Clean the surface of the oil seal. Lip
● Apply sealant evenly and continuously

along the line on the rear oil seal.
● Install the oil seal within 3 minutes after

sealant is applied. Do not allow the sealant
to deviate.
Sealant
NOTICE
● Do not start the engine within 1 hour φ 2mm
after the installation of rear oil seal.
● Re-apply sealant on the seal if the bolt

is loosened or removed.
Line
FD215-1007182

9.2.14 Camshaft bushing
4
*a 5
3
1
PD FD215-1007183
1) No.1 camshaft bushing 5) No.5 camshaft bushing

2) No.3 camshaft bushing *a: Camshaft
3) No.4 camshaft bushing : Non-reusable parts
IO
4) Seal cover
NOTICE
● Do not remove the camshaft unless
confirmed abnormal.
Assembling sequence

Inspection standard
Unit: mm
Clearance between cam- No.1, 5 0.03 – 0.08 0.15 Repair or replace

1-3, 5, *a
shaft bushing and camshaft No.3, 4 0.06 – 0.11 0.17 Repair or replace
Inside of camshaft bushing Engine oil As required
Special tools
Symbol
PD
Tool name and shape Part No. Use
Unit: mm
Loop bar
Camshaft bushing as- Removing and
sembling and removing MH061276 installation of cam-
Guide
tools shaft bushing
IO
Connector

9.2.14.2 Inspecting procedure
Inspect: Clearance between camshaft

bushing and camshaft
● Replace the bushing if measured value ex-

ceeds the limit.
FD215-1007185
9.2.14.1 Camshaft bushing – replace
● Use tool for the replacement of the

bushing. Loop bar
For bushing No.4, prepare and use a jig to

PD Connector
extend the loop bar.
Guide
Jig
f30mm
IO
f17.5mm 50mm
200mm
FD215-1007186
Disassembling
● Remove the bushing along with the corre-

sponding connector on the loop bar.
Loop bar
Unit: mm
Corresponding connector
Bushing
A B C A C
No.1 φ54.5 41.5 φ58.5
No.3 φ54.5 26.5 φ58 Connector
B
No.4 φ54.5 26.5 φ57.5
FD215-1007187
No.5 φ53 30.5 φ57

1. No.1 and No. 3 camshaft bushing Connector
● Remove camshaft bushing No. 1 and

No. 3 from the engine front by striking.
Loop bar
Bushing
No.3 Bushing
No.1 Bushing
FD215-1007188
2. No.4 camshaft bushing

PD
● When removing bushing No. 4, use the
Loop bar
jig to extend the loop bar, and remove

the bushing from the engine front by
striking. Connector
Jig
No.4 Bushing
IO
FD215-1007189

3. No.5 camshaft bushing Connector
● When removing bushing No.5, remove

the seal cover first. Remove the bush-
ing from the rear of engine by striking. Loop bar
No.5 Bushing
Seal cover
FD215-1007190
[Install] PD
● Install the bushing in combination with the
corresponding connector and guide on the
loop bar.
Loop bar
Unit: mm
Guide
Correspond- Correspond- Connector
Bushing
ing connector ing guide
IO
O.D. A B C D
A C
Bushing
No.1 φ58.5 φ54.5 41.5 φ58.5 φ58.5
No.3 φ58 φ54.5 26.5 φ58 φ58 B
No.4 φ57.75 φ54.5 26.5 φ57.5 φ57.5
D
No.5 φ57 φ53 30.5 φ57 φ57 FD215-1007191


Connector
● Align the oil orifice on the bushing and

the oil orifice on the crankcase.
Loop bar Guide
● Install bushing No. 4 onto the crank- Jig
case from the engine front by striking No.4 Bushing
as illustrated.
Oil orifice
FD215-1007192

PD
● Align the oil orifice on bushing No.5
with the orifice on the crankcase.
Connector
Loop bar
● Install bushing No.5 onto the crankcase
from the engine rear by striking as illus- No.5 Bushing
trated.
IO
Seal cover
FD215-1007193

3. No.3 camshaft bushing Loop bar

● Install bushing No.3 onto the crankcase Guide

from the engine front by striking as il- Connector
lustrated
Bushing A C
D
FD215-1007194

PD
Connector
Loop bar
Guide
● Install bushing No. 1 onto the crank- Jig No.4 Bushing
case from the engine front by striking
as illustrated
IO
Oil orifice
FD215-1007195
Install: Seal cover

Engine front
● Set the seal cover into the crankcase to Seal cover
the specified depth.
2.5mm
FD215-1007196

9.3 Lubricating System
Item Specification
Lubricating method Oil pump type
Engine oil filter type Paper core, spiral type
Engine oil cooler type Shell type (multi-plate type)
Type API rating CD, CD/SF, CE, CE/SF, CF-4
Engine oil Oil pan 18{18}
Volume dm³{L}
Engine oil filter 1{1}
Pressure regulating valve opening valve kPa{kgf/cm²} 440±29{4.5±0.3}
Bypass valve opening pressure kPa{kgf/cm²} 390±29{4.0±0.3}
Reducing valve opening pressure MPa{kgf/cm²} 1.1±0.1{11±1.0}
PD
IO

9.3.2.1 Lubricating system layout
2 3
14 19 25
4
5 6 7
15 17
26 27
8
23
11
9 10
12
PD 16 18
20
21
24
A
22
13
IO
28
FD215-1007197
1) Main oil duct 11) Reducing valve 22) Tappet

2) Reducing valve 12) Oil pump 23) Check valve
3) Engine oil pressure switch 13) Primary oil filter 24) Piston
4) Engine oil bypass alarm s/ 14) Main bearing 25) Injection pump
w 15) Connecting rod bearing 26) Automatic advance unit
5) Bypass valve 16) Connecting rod bushing 27) Turbocharger
6) Full flow filter element 17) Idle gear bushing 28) Engine oil pan
7) Part flow filter element 18) Timing gear bushing
8) Pressure regulating valve 19) Camshaft bushing A: Oil-measuring plate
9) Bypass valve 20) Rocker arm bushing
10) Engine oil cooler 21) Plunger

9.3.2.2 Engine oil pump
Oil pump gear

Crankshaft gear
Oil pump
To oil cooler
From primary oil filter

PD Reducing valve
To engine oil pan

FD215-1007198
IO
● The oil pump is a gear-type pump. It is
driven via the engagement between crank-
shaft gear and oil pump gear, and the rota-
tion of the crankshaft.
● A reducing valve is installed on the oil

pump. When the output pressure of the oil
pump rises above the specified range, the
reducing valve will conduct some of the oil
back to the engine oil pan to prevent over-
pressure in the lubricating system.

9.3.2.3 Oil cooler and oil filter
Bolt Connector
Gasket
Gasket
Connector
PD
Oil filter element
Gasket
Seal
Oil cooler
FD215-1007199
IO
(a) Bypass valve
To oil cooler
● High oil viscosity due to low temperature or
clogged oil cooler may increase the resis-
Bypass valve
tance of oil flow. Under this circumstance,
the bypass valve on the oil cooler will open
so that engine oil flows directly back to the
oil filter without flowing into the oil cooler.
Oil filter
FD215-1007200

(b) Pressure regulating valve

To main
● When oil pressure in the main oil duct rises oil duct Pressure regulating valve
above the specified value, the pressure To engine
regulating valve will open. Part of the oil re- oil pan
turns to the oil pan to regulate oil pressure.
Oil filter
FD215-1007201
(c) Engine oil pressure switch
● If the pressure of the oil conducted to the

main oil duct is below the specified value,
sure switch will close.

PD
internal electrical terminal in the oil pres-
● Alarm lamp on the monitor will light up in-

forming the operator of abnormal oil pres-
Engine oil
pressure s/w
To main oil duct
sure.
FD215-1007202
IO
(d) Engine oil bypass alarm switch
● If the oil filter element is clogged, the Main oil duct

amount of engine oil will decrease and the
engine will seize up. To avoid that, a by-
pass alarm switch is installed.
● When the oil filer is clogged, the oil by-

pass alarm switch conducts engine oil di-
rectly into the main oil duct without flowing
through the full flow filter element. When Engine oil bypass alarm s/w
the engine oil bypass switch is activated, FD215-1007203
the alarm lamp lights up to inform the op-

erator of clogged filter element.

(e) Oil filter
To main oil duct
To oil pan
Part flow filter elememt
PD Bypass valve
Full flow filter element
FD215-1007204
● The oil filter is part-flow and full flow paper

spiral type.
IO
● A bypass valve is installed under the filter.
When the filter element is clogged, the by-
pass valve will open and conduct oil into
the main oil duct without passing the filter
element so that the engine will not seize
up.

9.3.2.4 Lubrication of parts
● Engine oil conducted to the main oil duct

lubricates the following parts.
(a) Main bearing and connecting rod bearing
Main oil duct

Connecting rod oil orifice
Connecting rod bearing

PD Main bearing
Crankshaft Crankshaft oil orifice

FD215-1007205
● Lubricate the large end of the connecting

IO
rod (connecting rod bearing) via the oil
orifice inside the crankshaft. At the same
time, lubricate the small end of the con-
necting rod (connecting rod bushing) via
the oil orifice inside the connecting rod.

(b) Timing gear
Camshaft Main oil duct

Idle gear bushing
Retaining plate
Oil pipe
Injection pump gear
Idle gear
Camshaft gear
Bearing Timing gear box
Vacuum pump Idle gear shaft Oil injection tube
FD215-1007206
PD
● Engine oil lubricates all the gears via the
inside of camshaft and idle gear shaft.
Beside, an oil spray tube for the forced lu-
brication of oil pump gear is installed in the
timing gear box. This oil spray tube lubri-
cates the injection pump gear continuously.
IO

(c) Valve mechanism
Rocker arm oil orifice

Rocker arm
Rocker arm bushing
Rocker arm bracket
Rocker arm shaft
Cylinder head
Oil circuit
PD Plunger
Crankcase Piston rod

IO
To oil pan
Camshaft
No.1 camshaft bushing
From main oil duct
FD215-1007207

● After lubricating camshaft bushing No. 1,

engine oil is conducted to rocker shaft via
the oil circuit between the crankcase and
the cylinder head.
● Engine oil in the rocker shaft lubricates the

rocker arm bushing via the bracket and
spurt out via the oil orifice on the rocker
arm.
● Engine oil flows back to oil pan from the oil

orifice on the tappet from the plunger after
lubrication.
(d) Check valve and oil spray tube
● An oil spray tube is installed beneath the

PD
oil duct of each cylinder.
Piston
Main oil duct
● The oil spray tube sprays oil towards the
inside of piston to cool it down.
● Oil spray tube is installed with a check

Oil spray tube
valve which opens and shuts within the
Check valve
specified oil pressure. The check valve FD215-1007208
shuts when the engine is running at a low

speed to provide adequate oil for the parts
IO
in the engine lubricating system and pre-
vent oil pressure decrease.

(e) Turbocharger
Bearing bushing
Snap ring
From main
oil duct
To oil
Piston ring
PD pan
Bearing
Piston ring
FD215-1007209
● Engine oil from the main oil duct is con-

ducted to bearing bushing via oil pipe to
lubricate the inside of bearing bushing.
IO
● Piston ring installed on both sides of the
turbine wheel shaft functions as oil seals.
(f) Injection pump

Speed adjustor
● Oil from the main oil duct passes the oil
pipe and lubricates the pump, and lubri-
cates the speed regulator via the automatic
advance unit.
Oil pipe
Automatic advance
Injection pump
FD215-1007210

Symptom
Excessive eng. oil con-

Eng. oil pressure low
sumption (oil leak)

Startup difficulty
Reference
Cause
Overheating
Defective installation of oil cooler filter element ○ ○ ○
Damaged gasket ○ ○ ○
Damaged o-ring ○ ○ ○
Oil cooler PD
Oil cooler filter element clogged
Oil cooler filter element damaged
Bypass valve sprig low elasticity
Pressure regulating spring low elasticity
○
○
○
○
○
○
○
Oil pump failure ○ ○

Interference between oil pump gear and oil
Oil pump ○ ○
pump case or cover
Reducing valve spring low elasticity ○
IO
Defective installation ○
Oil filter Clogged oil filter element ○ ○
Damaged gasket ○
Primary filter defective installation, clogged ○ ○
Crankshaft front oil seal defective ○
Crankshaft rear oil seal defective ○ Engine
Timing gear box installation defect ○
Piston cooling oil spray tube defect ○ ○
Oil entering combustion chamber ○
Oil dipped in combustion chamber ○
Oil viscosity too high ○
Oil quality low ○
Deterioration of oil ○
Oil mixed with fuel ○

9.3.4.1 Oil filter element – replace
Engine oil (API rating CD, CD/SF, CE,

– Oil filter About 1dm³{1L}
CE/SF, CF-4)
Special tools
Unit: mm
Oil filter wrench

PD MH061537 Removal of oil filter
NOTICE
IO
● Spilled engine oil may pose a fire haz-
ard. Wipe off spilled oil if observed.
● When adding oil into the engine, make

sure no oil is spilled on the belt. Belt
contaminated with oil may slip and re-
duce the cooling effect.

[Remove]
● Loosen the drain plug on the oil filter and

drain the engine oil in the filter. Air vent
Oil filter
Drain plug
FD215-1007212
PD FD215-1007213
[Install]
● Clean the mounting surface on the oil filter Filter seat

seat.
IO
● Apply a thin coat of oil on the gasket of oil
filter. Gaske
● Tighten the oil filter manually to the extend

Engine oil filter
that the filter seat contacts the gasket. Fur-
ther tighten the filter by 11/8~3/8 round. Drain plug
● Start the engine after installation is fin- FD215-1007214

ished. Check if oil leaks from the gasket.
● Re-install the filter if abnormality is detect-

ed.
● Stop the engine and check if oil level is

within the specified range.
● Replenish if oil level is too low.

9.3.4.2 Engine oil – replace
Tightening torque
Unit: N·m{kgf·m}
– Drain plug (oil filter) 9.8±1.96{1.0±0.2} –

– Drain plug (oil pan) 34-39{3.5-4.0} –
– Oil filter Engine oil(API rating CD, CD/SF, 1dm³{1L}

– Oil pan CE, CE/SF, CF-4) 18dm³{18L}
CAUTION
● Spilled engine oil may pose a fire haz-
ard. Wipe off spilled oil if observed.
PD
● When adding oil into the engine, make
sure no oil is spilled on the belt. Belt
contaminated with oil may slip and re-
duce the cooling effect.
IO
[Drain]
Air vent pipe plug

● Remove the oil filler cap.
● Remove the drain plug and drain the oil. Oil filter
[Fill]
Drain plug
● Tighten the drain plug to the specified
Filler cap
torque. Add new engine oil to specified
level.
● Check if oil level is within specified range.
● Add oil if oil amount if less than specified.
Drain plug
FD215-1007215

9.3.4.3 Oil pressure – measure
Inspection standard
Unit: mm
49kPa
At min. unloaded speed 145kPa{1.5kgf/cm²}
Oil pressure (at {0.5kgf/cm²}
– Inspect
70-90°C)
295~490kPa 195kPa
At max. unloaded peed
{3~5kgf/cm²} {2kgf/cm²}
Tightening torque
Unit: N·m{kgf·m}
Symbol
–
Tightened part
PD
Engine oil pressure switch
Tightening torque
7.8~12{0.8~1.2}
Remark
Sealant
When engine is cool

IO
– Thread of oil pressure switch ThreeBond 1215 As required

● Remove the oil pressure switch.
FD215-1007216
● Install the transition connector onto the oil

pressure switch, and install the oil pressure Pressure gauge
gauge onto the transition connector.
● Preheat the engine until oil temperature

rises to 70 – 90°C.
PD
● Measure the oil pressure when the engine
is running at min. unloaded speed and
max. unloaded speed respectively.
Connector
FD215-1007217
● Inspect the lubricating system thoroughly

if measured value is below the standard
value.
● Apply sealant on the thread of the oil pres-

IO
sure switch after measurement, and tighten
the switch to specified torque.
NOTICE
● Engine oil pressure switch must be in-
stalled while the engine is cool.

9.3.5 Oil pan, primary oil filter and injection pipe
1 Ta
Tb
PD 5
3
4
IO
FD215-1007218
1) Drain plug 5) Check valve

2) Oil pan 6) Oil injection pipe
3) Primary oil filter : Non-reusable parts
4) O-ring
Assembling sequence
NOTICE
● Over-tightening of the check valve may
cause engine failure. Tighten the check
valve to specified torque.

Tightening torque
Unit: N·m{kgf·m}
Ta Drain plug 69{7.0} –

Tb Check valve 38{3.9} Wet type

Mounting surface of oil pan ThreeBond 1207C As required
O-ring
b Engine oil As required
Threaded part of check valve
Install: Oil pan

PD
● Clean the sealing surfaces of all parts.
Sealant φ2mm
● Apply sealant evenly and continuously

onto the mounting surface of the oil pan as
illustrated.
IO
● Install the oil pan within 3 minutes after
sealant is applied. Be careful that the seal-
ant does not come off.
NOTICE
● Do not start the engine within one hour
after the oil pan is installed. Apply new
sealant when the mounting bolt of the
oil pan is loosened or removed again
after installation.
FD215-1007219

9.3.6 Oil pump
*b
4
PD *a
6
3
IO
1 7
FD215-1007220
1) Pin 7) Gear housing

2) Valve seat 8) O-ring
3) Reducing valve spring *a: Drive gear
4) Reducing valve *b: Crankshaft gear
5) Oil pump over : Non-reusable parts
6) Driven gear
Assembling sequence

Inspection standard
Unit: mm

Mounting load of reducing valve spring
3 225N{23.15kgf} – Replace
(Mounting length 33.4)
1.1±0.1MPa
4 Opening pressure of reducing valve -– -–
{11±0.1kgf/cm²}
5, 6 Clearance between pump cover and driven gear shaft 0.04 – 0.07 0.15 Replace
5, *a Clearance between pump cover and drive gear shaft 0.04 – 0.07 0.15 Replace
6, 7 Clearance between driven gear shaft and gear housing 0.04 – 0.07 0.15 Replace
Deflection between gears and gear housing 0.01 – 0.07 0.18 Replace
6, 7, *a
Clearance between gear teeth and gear housing 0.10 – 0.19 0.2 Replace

Sliding portions of oil pump
O-ring

Drive gear
Inspect: Driven gear, drive gear and gear Driven gear
IO
housing
● Inspect the following items. Replace oil

pump in case of abnormality.
1. Deflection on the housing surfaces of all

gears. Gear housing
FD215-1007221
2. Clearance between teeth of all gears and

gear housing Gear housing Drive gear
Driven gear
FD215-1007222

Inspect: Oil pump cover, driven gear and

gear housing
● Measure the clearance between the gear

shafts and the pump cover and gear hous-
ing.

FD215-1007223
Install: Oil pump cover

Pump cover
● Place two 9 mm pins into the bolt mount-
ing holes (diagonally), and align the gear
PD Pin
housing with the pump cover.
Gear housing
FD215-1007224
IO
● Insert bolts in the remaining mounting Oil pump gear
holes and tighten the bolts to specified
torque. Pin
● Remove the position pins and tighten the

remaining bolts.
● After installation is finished, rotate the oil

pump gear and make sure it rotates freely.
Bolt
Pin
● Dismantle and re-install the assembly in FD215-1007225

9.3.7 Engine oil filter
4 1
a 5
Ta 13 6
7
14
a
15
12
10
a
9
Tb
PD
11
FD215-1007226
IO
1) Hose 9) Bypass alarm switch
2) Connector 10) O-ring
3) Cap 11) Plug
4) Hose 12) Oil filter seat
6) Plug 14) O-ring
7) Drain plug 15) Filter attachment
8) Oil filter : Non-reusable parts
Assembling sequence

CAUTION
● Spilled oil may pose a fire hazard. Wipe
off spilled oil once observed.
● Do not touch the engine while it is hot

to avoid burns.
NOTICE
● Do not spill engine oil on the belt. Oil
can make the belt slippery and reduce
cooling effect.
Tightening torque
Symbol
Ta
Tb
PD
Tightened parts
Drain plug
Engine oil pressure switch
Tightening torque
7.8±2.0{0.8±0.2}
49±4.9{5.0±0.5}
Unit: N·m{kgf·m}
Remark
–
–

IO
Sliding parts of oil pump Engine oil As required

9.3.8 Engine oil cooler
26
b
Tc 18
22 17 Tb
21
24
25 23
Tb 19 Ta
PD 20 13 Ta
15 14
4 16
2
12
3
Ta 1
6
10
Tb 5 11
9
8
IO
7 Ta
FD215-1007227
NOTICE

cooling effect.

1) Plug 15) Pressure regulating valve spring

2) O-ring 16) Pressure regulating valve
3) Bypass valve spring 17) Plug
4) Bypass valve 18) O-ring
5) Plug 19) Plug
6) O-ring 20) O-ring
7) Plug 21) Engine oil pressure switch
8) O-ring 22) Oil cooler filter element
9) Pressure regulating spring 23) O-ring
10) Pressure regulating valve 24) Oil cooler
11) Plug 25) O-ring
12) Connector 26) Gasket
13) Plug PD : Non-reusable parts
14) O-ring
Assembling sequence

Inspection standard
Unit: mm
IO
Mounting load of bypass valve spring
3 49N {5kgf} – Replace
(Mounting length: 64)
Mounting load of pressure regulating
9, 15 49N {5kgf} – Replace
valve spring(Mounting length: 64)
Air leak in oil cooler filter
21 (at air pressure of 980kPa{10kgf/cm²} 0cm³{ 0mL} – Replace
and hold for 15 seconds)

Tightening torque
Unit: N·m{kgf·m}
Nut (for installation of engine oil cooler filter element)
Ta Plug (for installation of pressure regulating valve spring) 19.5±5{2.0±0.5} –
Plug (for installation of bypass valve spring)
Tb Plug 34.5±5{3.5±0.5} –
Tc Engine oil pressure switch 7.8-12{0.8-1.2} Sealant

O-ring Engine oil As required
b Threaded part of engine oil pressure switch
PD ThreeBond 1215 As required
Inspect: Engine oil cooler filter element
● Plug the outlet of the cooler filter element

and attach a hose to the engine oil inlet.
Place the engine oil cooler filter element in
Plug
a water tank.
IO
● Apply a pressure of 980kPa {10kgf/cm²}
onto the hose for 15 seconds and check if
air leaks from the filter element. FD215-1007228
● If air leak is observed, replace the oil cool-

er filter element.

9.3.9 Engine oil cooler, oil filter
5 Ta
17
6
Tb
3 13 7
4
11 12
10 Ta
Te 1
PD 9
Ta 14
Tc
16 15
Td
FD215-1007229
IO
1) Drain plug 10) O-ring

2) Oil filter 11) Bypass valve spring
3) Oil cooler filter element 12) Bypass valve
4) Gasket 13) Engine oil pressure switch
5) Plug 14) Engine oil bypass alarm switch
6) O-ring 15) Drain plug
7) Pressure regulating valve spring 16) Oil cooler
8) Pressure regulating valve 17) Gasket
9) Plug : Non-reusable parts
Assembling sequence

CAUTION

cooling effect.
Inspection standard
Unit: mm

Air leak of oil cooler filter element (at air pressure of
3 0cm³{0mL} – Replace
980kPa{10kgf/cm²} and hold for 15 seconds)
Mounting load of pressure regulating valve spring
PD
7 49N{5kgf} – Replace
Mounting load of bypass valve spring
11 49N{5kgf} – Replace
Tightening torque
Unit: N·m{kgf·m}

IO
Nut (for installation of oil cooler filter element)
Plug (for installation of pressure regulating
Ta 19.5±5{2.0±0.5} –
valve spring)
Plug (for installation of bypass valve spring)
Tb Engine oil pressure switch 7.8 – 12{0.8 – 1.2} Sealant (When engine is cool)
Tc Engine oil bypass alarm switch 12 – 18{1.2 – 1.9}
Td Drain plug (oil cooler side) 25±4.9{2.5±0.5}
Te Drain plug (engine oil filter side) 9.8±1.96{1.0±0.2} Sealant

Oil filter gasket
O-ring
b Threaded portion of engine oil pressure switch ThreeBond 1215 As required

Special tools
Unit: mm
Oil filter wrench MH061590 Removal of oil filter
Remove: Engine oil filter

PD
FD215-1007231
IO
Inspect: Engine oil cooler filter element
● Plug the outlet of the cooler filter element

and attach a hose to the engine oil inlet.
Place the engine oil cooler filter element in
Plug
a water tank.
● Apply a pressure of 980kPa {10kgf/cm²}

onto the hose for 15 seconds and check if
air leaks from the filter element. FD215-1007232
● If air leak is observed, replace the oil cool-

er filter element.

Install: Engine oil cooler
● Clean the mounting surface of the oil cool-

er filter.
● Apply a thin coat of oil on the gasket of oil

filter.
Gasket
● Tighten the oil filter by hand until the gas-
ket contacts the oil cooler. Further tighten
the filter by 3/4 round. FD215-1007233
● Start the engine after the filter is installed

and check if oil leaks from the gasket.
ity.
PD
● Re-install the oil filter in case of abnormal-
● Stop the engine and check if oil level

meets the specification.
● If oil amount is less than specified, add oil.

IO

9.4 Fuel Supply and Engine Control
Item Specification
Producer Bosch
Type A
Type RSV
Injection pump Governor
Form Mechanical variable speed governor
Advance unit type SCDM
Feed pump type KS
Producer Bosch
Fuel injector
Type Hole-type spring
Fuel filter TypePD Filter paper
IO

9.4.2.1 Fuel system (fuel flow diagram)
Fuel return hose Fuel filter Injection pipe
Fuel injector
Injection pump
Relief valve
Fuel feed pump

PD Fuel suction pipe Fuel return pipe
Fuel tank
FD215-1007234
IO
● Fuel in the tank is primed by the fuel feed ● Residual fuel in the injector enters the re-
pump which is driven by the shaft of the turn hose and returns to the tank via the
injection pump. Impurities in the fuel is fil- fuel return pipe.
tered by the fuel filter.
● If fuel in the injection pump is over-pressur-
● Filtered fuel becomes pressurized when it ized, the relief valve opens and fuel returns
passes the injection pump and is sprayed to the tank.
into the combustion chamber by the fuel
injector.

9.4.2.2 Fuel tank
5
11
10
13
12
PD
7
6
9
IO
8
20
16
转台
2
19
17
18 3 15
4 14
FD215-1007235

1) Fuel tank 8) Bolt 15) Pipe

2) Seat 9) Gasket 16) Seal
3) Hose 10) Guide 17) Bolt
4) Plug 11) Cap 18) Bolt
5) Cap 12) Float 19) Gasket
6) Sensor 13) Primary filter element 20) 1.0mm washer
7) O-ring 14) Elbow
CAUTION
● Keep the fuel tank away from fire
sources to avoid fire and explosion.
● Keep all removed parts clean. Wash

contaminated parts with diesel oil.
PD
IO

9.4.2.3 Fuel tank attachment circuit
8
9 7
10
Primary filter
To Engine
12
FuelTank Secondary filter To Engine
12 10
PD 6
11 2
5 1
3 31
13
34
27 5
27 26
4
26
25 5
15
33 2
20
32 28
21
18 16
IO
5 23
19 17
3 24 14 30
29
22
6
5 22
1
4
FD215-1007236

1) Hose 10) Connector 19) Socket 28) Bracket

2) Hose 11) Bolt 20) Bolt 29) Bolt
3) Hose 12) Seal 21) Washer 30) Washer
4) Hose 13) Band 22) Clamp 31) Clamp
5) Pipe strap 14) Bracket 23) Bolt 32) Bolt
6) Clamp 15) Clamp 24) Washer 33) Washer
7) Connector 16) Bolt 25) Clamp 34) Pipe clamp
8) Bolt 17) Washer 26) Bolt
9) Seal 18) Clamp 27) Washer
NOTICE
● Check the hoses for damages and cor-
rosion after disassembling. Make nec-
essary replacements. PD
● Pay attention to leak-proofness when
re-installing the assembly to prevent oil
leakage.
IO

9.4.2.4 Fuel filter
Fuel filter cover

To injection pump
From tank
Fuel filter
PD FD215-1007237
● The fuel filter element filters the impurities

in the fuel.
● A manual pump is installed on the fuel filter

IO
cover intended as the air vent of the fuel
system.

9.4.2.5 Injection pump
Delivery valve seat
Delivery valve spring
Delivery valve
Piston bushing
Control pinion
Control rod
Control socket
Piston spring
PD Piston rod
Camshaft
FD215-1007238
● The injection pump is equipped with a de-

vice which conducts pressurized fuel to the
fuel injector and increases or decreases
IO
fuel amount.

1. Fuel feeding
When the piston rises, the spiral chute Fuel suction hole
meets the fuel at the fuel suction hole and Spiral chute
Piston sleeve
fuel flows out via the inlet/outlet hole at the
Piston
center of the piston. Surplus fuel cannot
be conducted via the rising of the piston.
Tappet
Besides, the piston stroke which is used to
feed fuel is called the effective stroke. Camshaft
Pressure Pressure
Suction feed ends
feed starts
FD215-1007239
Fuel suction hole

PD Spiral chute
Control rod
Piston FD215-1007240
IO
2. Injection adjusting structure
Increase and decrease of fuel injection Fuel suction

amount according to the engine load is hole
Stroke
achieved by rotating the piston to a certain Sprial chute

angle and changing the meeting position
of the fuel inlet/outlet hole and the spiral
chute when the piston is rising and chang-
Piston
ing the effective stroke. All the pistons are
engaged with a control rod and rotate for
FD215-1007241
the same amount.

3. Delivery valve
Fuel pressurized via the piston sprays at Suction stroke

the upper delivery valve and pump feed
Spring
finishes. The delivery valve returns to its
original position through the action of the
delivery valve spring. Fuel path is cut off
Delivery
in this way to prevent fuel counterflow.
valve
Besides, during this downward suction
stroke, the delivery valve sucks fuel and Pressure feed Injection Pressure feed Suction
starts ends ends
the residual fuel pressure between the (Suction starts)
delivery valve and fuel injector drops FD215-1007242
instantly. This suction effect helps to clean

the fuel in the injector and prevent oil drib-
bling after spray.
4. Relief valve
PD
When fuel pressure in the injection pump
rises to a certain level, the steel ball is
pushed upward, and fuel flows back to the
Steel ball
tank via the injection pump. This function

contributes to the stability of fuel tempera-
ture and the distribution of fuel temperature
so that fuel amount injected into each
cylinder is constant.
IO
FD215-1007243

9.4.2.6 Governor
Supporting rod shaft

Housing Guide
Tension rod
Starting spring
Control rod
Shackle
Rotating rod
Cover
Camshaft
Floating rod
Governor spring
PD Idle speed auxiliary spring
Control spring
Regulating lever
Position lever
Fly block
Retaining bolt
FD215-1007244
IO
● Using the centrifugal force of the fly block,
the governor not only controls the maxi-
mum and minimum rotation speed of the
full speed regulator, but automatically
controls the rotation of the random speed
area.

9.4.2.7 Fuel feed pump
Priming pump
To fuel filter
Inlet check valve

Outlet check valve
Pump housing
PD Mesh filter
From fuel tank
FD215-1007245
● The fuel feed pump is driven by the cam-

shaft of the injection pump. When the injec-
IO
tion pump stops working, the priming pump
can feed the fuel manually, especially dur-
ing air venting.
● Mesh-type filter removes the impurities

from the fuel pumped from the tank to pre-
vent clogging inside the pump. Mesh-type
filter must be washed with light oil.

Suction
The camshaft of injection pump drives the

plunger, and pressurized fuel inside the oil
suction chamber opens the outlet check valve. Fuel suction
Outlet check valve chamber
The majority of the squeezed fuel is sucked
Pressure
into the pressure chamber via the bottom of chamber
Push rod
the piston. Camshaft
FD215-1007246
Pressure feed
Fuel suction chamber Inlet check valve
When the camshaft cannot push the cam up
after rotation, the force of the piston spring
can be applied to push the piston back. Fuel is Piston spring
conducted to the filter via the pressure cham-
PD Outlet check valve Piston
ber. Camshaft
Pressure chamber
At the same time, outlet check valve shuts and
inlet check valve opens. Fuel is sucked into
FD215-1007247
the suction chamber.
When stopped
When the pressure inside the pressure cham-

ber rises beyond the specified range, the
IO
piston cannot return via the force of the pis-
Piston spring
ton spring. The function of the pump stops to
prevent the pressure inside the fuel filter from Piston
rising beyond specified range. Pressure chamber
FD215-1007248

9.4.2.8 Automatic advance unit
● The automatic advance unit is a mechanic

timing device. It changes automatically the
injection interval in accordance with the
speed of the engine.
● Automatic advance unit is mounted onto

the camshaft of the injection pump with a
round bolt and driven by the air compres-
sor via the driving plate.
Spring Adjusting gasket
Housing
PD Fly block seat
Fly block
IO
Flange
FD215-1007249

9.4.2.9 Fuel injector
● When the pressure of the fuel from the

From injection pump
injection pump (injection tube internal
pressure) exceeds the elastic force of the
To fuel tank
spring, the needle valve only rises in the
space of the lift range and fuel ejects from
the injector.
Injection nozzle seal
Spring
PD Injection nozzle
Needle valve
FD215-1007250
IO

Engine does not start easily
Engine output - inadequate

Engine does not start at all
Engine stops after startup

Max. speed -not achieved
Accelerator pedal operat-

Max eng speed very high
Engine output - unstable
Engine idling - unstable
Fuel supply inadequate

Symptom
Engine does not stop
ing force too large
Alarm lamp blinks

Reference
Engine - knock
Cause
Injection pump body - defect ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ *

Injection
Installation - defect ○ ○ ○ ○
pump
Relief valve function - defect ○ ○ ○ ○ ○ *
Fuel
Needle valve - fixation
Opening pressure - low
Fuel orifice - clogged
Air-proofness - defect
PD ○
○
○
○
○
○
○
○
○
○
○
○
○
Opening pressure - high ○
injector
Spring - broken ○ ○
Needle valve slide - defect ○
Opening pressure - defect ○
IO
Spring elasticity- low ○
Fuel filter - clogged ○ ○ ○ ○
Fuel tank - no fuel ○
Fuel hose - clogged or joint leaks ○
Fuel system -air/water inside ○ ○ ○ ○
Fuel quality - low ○ ○ ○ ○
Accelerator pedal check bolt
○ ○
adjustment defect
Accelerator control bracing
○
Engine cable installation defect
control Accelerator control bracing
○
cable sliding defect
Accelerator position sensor
○
defect
Fuel pipe/hose - crack ○
Lubricating
Oil viscosity -unqualified ○ ○
system

Engine does not start easily
Engine output - inadequate

Engine does not start at all
Engine stops after startup

Max. speed -not achieved
Accelerator pedal operat-

Max eng speed very high
Engine output - unstable
Symptom
Engine idling - unstable
Fuel supply inadequate

ing force too large
Alarm lamp blinks

Reference
Engine - knock
Cause
Wrong valve clearance ○ ○

Cylinder head gasket - damage ○ ○
Valve & valve seat - abrasion, carbon ○ ○
Valve spring - low elasticity ○ ○ Engine
Piston ring - abrasion, damage PD ○ ○
Piston ring groove - abrasion, damage ○
Piston/crankcase cylinder part - abrasion ○ ○
Cooling sys-
Cooling device function defect ○ ○
tem
Starter switch fault ○ Electrical
Fuse blown ○ ○ ○ system
IO

9.4.4.1 Injection timing – inspect and adjust
Inspection standard
– Injection timing (BTDC) 14° – Adjust
T Tightening torque
Unit: N·m{kgf·m}

– Connecting nut 24{2.5} –
–
–
–
Lock plate
PD
Delivery valve seat
Nut (for installation of injection pump)
3.4 – 4.9{0.35 – 0.5}
39 – 44{4.0 – 4.5}
29 – 39{3.0 – 4.0}
–
–
–
Special tools
Unit: mm

IO
Universal extension
bar Inspection and adjust-
MH061099
A ment of injection timing
14 A

[Inspect]
Injection pipe
● Remove injection pipe, lock plate, delivery

valve seat, spacing collar, delivery valve Valve seat
spring and delivery valve from the cylinder
No.1 of injection pump. Spacing collar Lock plate
● After all the parts are removed, install the Spring
delivery valve seat. Delivery valve
NOTICE
● Put removed parts in light oil to prevent
dust buildup on the parts.
PD FD215-1007252
● Install the prepared injection pipe onto cyl- Injection pipe

inder No.1. Face the other end of the pipe
downward so that the condition of the fuel
flowing out can be clearly observed.
IO
● Rotate the crankshaft manually by more
than 180° and set cylinder No.1 at 30° of
the top dead center of compression stroke.
FD215-1007253
● Use the priming pump to deliver fuel. Allow Injection pipe

fuel to flow out from injection pipe, and at
the same time, rotate the engine in a posi-
tive direction by hand.
NOTICE
● The engine position lever on the gov-
Engine position lever
ernor must be set at the engine start Priming pump
position. FD215-1007254

● When fuel discharge in the injection pipe

is about to stop, further rotate the engine
slowly by hand. Stop the rotating when fuel Pointer
discharge is finished.
● Check if the gauge mark on the flywheel

points to 1° before the injection timing.
FD215-1007255
● If injection timing deviates from standard

value, adjust it according to the procedure
below.
[Adjust]
PD
● Loosen the mounting bolts of the injection
pump A
B
A: 4 locations (flange portion)

FD215-1007256
B: 1 location
IO
● Take the pointer as the target and activate
the pump to adjust injection timing. Injection pump
● Tighten the nut to specified torque and

measure the injection timing again.
Pointer FD215-1007257

● When injection timing is slow, tip the injec-

tion pump towards the crankcase side C.
C
D
● When injection timing is fast, tip the injec-
tion pump towards the opposite direction of
Injection pump
the crankcase.
FD215-1007258
● After injection timing is the same as the

standard value, install delivery valve, de- Injection pipe Delivery valve
livery valve spring, spacing collar, delivery seat
valve seat, lock plate and injection pipe.
PD
● Tighten all the parts to specified torque.
Lock plate
FD215-1007259
IO

9.4.4.2 Air in fuel system – release
T Tightening torque
Unit: N·m{kgf·m}

– Plug 9.8±2.0{1.0±0.2} –
● Loosen the plug of the fuel filter. Plug
● Rotate the handle of the priming pump

PD FD215-1007260
counterclockwise and remove the handle.
● Pump the handle of the priming pump to

feed fuel. Priming pump
IO
● When no foam is observed in the fuel drain
from the fuel filter, tighten the plug to speci-
fied torque.
FD215-1007261
● Pump the priming pump 5~6 times. Then,

press the handle and turn it clockwise to fix
it.
Priming pump
● When air is completely released, clean the

spilled fuel and re-start the engine. Check
for fuel leaks.
FD215-1007262

9.4.4.3 Fuel filter – replace

– Gasket of the fuel filter Engine oil As required
CAUTION
● Use of improper fuel filter may cause
fuel leakage and fire. Use genuine
parts.
● To avoid engine failure due to abnormal

injection, be extremely careful not to al-
low impurities to enter the fuel filter or
PD
fuel pipes.
● Clean the mounting surface of the fuel fil-

ter.
● Apply a thin coat of engine oil evenly onto

the contact surface of the fuel filter cover. Contact surface
of fuel filter cover
● Tighten the fuel filter manually so that the

IO
filter cover meets the contact surface of
the filter. Further tighten the filter by 3/4~1
circle.
FD215-1007263
● Start the engine and check the connecting

area for fuel leakage.
● Re-install the fuel filter in case of abnor-

mality.

Engine FuelCrawler
SY195-205-215C9 SupplyHydraulic
and Engine Control
Excavator
9.4.5 Fuel filter
<Revolving type>
4 Tb
Ta
1
2
PD 2
3
1 Ta
FD215-1007264
IO
1) Connecting bolt 5) O-ring

2) Fuel hose 6) Fuel filter cover
3) Fuel filter element : Non-reusable parts
4) Plug
Assembling sequence

T Tightening torque
Unit: N·m{kgf·m}
Symbol Tightened part Tightening torque Remark

Ta Connecting bolt 34{3.5) –
Tb Plug 9.8±2.0{1.0±0.2} –
Gasket of fuel filter

O-ring
Special tools
Symbol
Filter wrench
PD
Tool name and shape
A
Part No. Use
Unit: mm
A MH061509 Removal of fuel filter

90.2
IO
Remove: Fuel filter
FD215-1007266

Install: Fuel filter
CAUTION
Contact surface
● Use of improper fuel filter may cause of fuel filter cover
fuel leakage and fire. Use genuine parts
● To avoid engine failure due to abnormal

injection, be extremely careful not to al-
low impurities to enter the fuel filter or FD215-1007267
fuel pipes.
● Clean the mounting surface of the fuel fil-

PD
ter.
● Apply a thin coat of engine oil evenly onto

the contact surface of the fuel filter cover.
● Tighten the fuel filter manually so that the

filter cover meets the contact surface. Fur-
ther tighten the filter by 3/4~1 circle.
● Start the engine and check the connecting

IO
area for fuel leakage.
● Re-install the fuel filter in case of abnor-

mality.

9.4.6 Primary fuel filter (revolving type)
4
PD
2
3
1
FD215-1007268
IO
1) Drain valve 5) Filter element
2) Vent plug 6) Seal
3) Bowl assembly 7) Filter base
4) Seal
Assembling sequence
CAUTION
● Spilled fuel may cause a fire. Wipe off
spilled fuel once observed.
● Fuel is extremely flammable. Keep fuel

away from naked fire and heat sources.

Tightening torque
Unit: N·m{kgf·m}
Tightened parts Tightening torque

Filter base 10.2±1.1{90±10}
Bowl assembly 10.2±1.1{90±10}
Vent plug 0.3±0.1{3±1}
Drain valve 1.1±0.2{10±2}
PD
IO

9.4.7 Secondary fuel filter (revolving type)
10
8
9
PD 5
1
FD215-1007269
IO
1) Drain valve screw 6) Seal cover assembly

2) Seal 7) Seal
3) Connecting screw 8) Oil screw
4) Casing 9) Washer
5) Filter element 10) Filter base
Assembling sequence

CAUTION

Tightening torque
Unit: N·m{kgf·m}
Tightened parts Tightening torque

Filter base 10.2±1.1{90±10}
Drain valve 1.1±0.2{10±2}

IO

9.4.8 Injection pump
Te
7
16
Td 8
14
10 9 Ta
11
15
13
12 Ta
17 1 Ta
PD 4
6 Tc
5
*a
3 Tb
IO
FD215-1007270
1) Connecting bolt 8) Air pipe 15) Pump bracket

2) Fuel feed pipe 9) Connection bolt 16) Injection pump
3) Connecting bolt 10) Fuel feed pipe 17) O-ring
4) Fuel feed pipe 11) Fuel return hose
5) Connection bolt 12) Relief valve *a: Front shell
6) Engine oil pipe 13) Connector : Non-reusable parts
7) Connection bolt 14) Injection pipe
Assembling sequence

CAUTION

NOTICE
● Particulate matters entering the injec-
tion pump may decrease the perfor-
mance of the engine. Always cover the
mounting portions once pipes or hoses
are removed. Clean bolts, gasket and
other parts with light oil. Be very care-
ful not to let foreign matters entering
PD
the assembly.
Contact BOSCH service station for the inspec-

tion and repair of the injection pump.
IO

Inspection standard
Unit: mm

12 Relief valve 255kPa {2.6kgf/cm²} – Replace
T Tightening torque
Unit: N·m{kgf·m}

Connecting bolt (for installation of fuel feed pipe)
Ta 20 – 29 {2.1 – 3.0} –
Relief valve
Tb Connecting bolt(for installation of fuel feed pipe) 20 – 25 {2.1 – 2.6} –
Tc Connecting bolt (for installation of oil pipes)
PD 10 – 13 {1.0 – 1.3} –
Td Injection pipe 24 {2.5} –
Te Connecting bolt (for installation of air pipes) 12 – 15 {1.2 – 1.5} –

IO
Special tools
Unit: mm
Socket wrench
Removal and installation
A A 31391-14100
of injection pump
12

Remove: Injection pump
9.4.8.2 Assembling method FD215-1007272
Install: Injection pump
● Move piston No.1 of cylinder to the top

dead center of compression stroke. Align 1 6
Pointer
the gauge mark of the engine flywheel with
pointer 1.6. PD
● At this time, the plunger of the intake/ex-
haust valve of cylinder No. 1 shall not proj-
ect, i.e. the TDC of compression stroke of
cylinder No. 1. To raise the intake/exhaust
valve with the plunger, rotate the crank- FD215-1007273
shaft by 360°.
● Align the match mark on the advance unit

IO
with the gear notch of the injection pump.
Notch
Match mark
FD215-1007274

● Insert the position pin of the advance unit

into the position hole of the front shell.
Align the injection pump gear with the slid-
ing gear and push it forward.
Position pin
Position hole FD215-1007275
● Check if the notch of the injection pump

is aligned with the match mark on the ad-
Notch
vance unit and insert the injection pump.
Turn the gear in the marked direction so
that the notch is well engaged.
PD Match mark
FD215-1007276
Install: Injection tube
● Check the tube and the seat surface of the

IO
connector for damages and ruggedness.
Tube
● Press the tube evenly against the seat
Seat surface
surface of the connector. Do not use rough Seat surface
force to fix the tube.
● Tighten the tube to specified torque after Connector
fixing.
FD215-1007277

9.4.9 Fuel injector
12
1 Ta
11
13
10
14 Ta
9
5
3 6
7
8
PD 4 Tb
FD215-1007278
1) Injection pipe 9) Pressure pin

2) Fuel drain pipe 10) Spring
3) Spray nozzle cap 11) Adjusting gasket
IO
4) Holding bolt 12) Spray nozzle seat
5) Spray nozzle seal 13) O-ring
6) Cylindrical pin 14) Spray nozzle gasket
7) Needle valve : Non-reusable parts
8) Spray nozzle
Assembling sequence
CAUTION


NOTICE
● The injector shall be disassembled,
assembled and adjusted when carbon
buildup on it has been removed. Check
the spray pressure, spray condition
and check for fuel leakage before dis-
assembling. Do not disassemble the
injector in case of abnormality.
● Never change the position of the needle

valves of the injectors and the mount-
ing position of the spray nozzle.
Inspection standard
PD Unit: mm
– Spray pressure 21.6MPa{220kgf/cm²} – Adjust

– Valve lift 0.29 – Adjust
T Tightening torque
Unit: N·m{kgf·m}
IO
Injection pipe connecting nut
Ta 25{2.5} –
Bolt (for installation of spray nozzle cap)
Tb Holding nut 34±5{3.5±0.5} –
Special tools
Unit: mm
Injector cleaning tool 105789-0010* Cleaning of the injector
*:Bosch Part No.

Inspect: Fuel injector
● Fix the injector onto the tester and proceed

with the following inspection.
NOTICE
● Operate the lever of the tester before
inspection. Spray 2~3 times and re-
move the air tap.
1. Inspection of opening pressure
● Press the lever of the tester at 1~2 sec-

onds per stroke. When the pointer on the Injector tester
gauge rises, measure the pressure when

PD
vibration is at the strongest.
● If measured value exceeds the standard

value, disassemble the injector, clean and
re-install it.
FD215-1007279
● Replace the injector if necessary.
CAUTION
IO
● Do not contact the spray the injector.
2. Inspection of spray
● Rotate the tester lever at 1~2 seconds per

stroke so that the injector sprays continu-
ously.
A: 5 orifices evenly spray (OK)

B: Symmetrical (OK)
C: Asymmetrical (N/G)
D: Divergence of spray(N/G)
E: Poor spray(N/G)
A B C D E F
F: Ladder spray(N/G)
FD215-1007280
CAUTION
● Never contact the spray from the injec-
tor.

● Make sure there is no dribbling after spray.
● In case of abnormality, disassemble the in-

jector, clean and re-install it, and inspect it
again.
● Replace the injector in case of abnormality

after re-inspection.
3. Oil seal, leakage
● Set the pressure in the injector 1960kPa

(20kgf/cm²) lower than the specified needle
valve opening pressure and hold the pres-
sure. Make sure no fuel dribbles from the
nozzle within 10 seconds.
PD
● In case of abnormality, disassemble the in-
jector, clean and re-inspect it.
● Replace the injector in case of abnormality

after re-inspection. FD215-1007281
IO

Disassemble: Fuel injector

Sliding part
NOTICE
● Do not touch the sliding part of the nee-
dle valve. In case of it being touched,
wash it with cleaning fluid (e.g. light
oil).
● Never mismatch the removed needle FD215-1007282

valve and spray nozzle pairs.
9.4.9.3 Cleaning method
Clean: Injector PD
● After washing the needle valve and spray
nozzle with cleaning fluid (light oil), remove
the carbon buildup on them with tool as
Cleaning bar
per the following instruction.
● Remove carbon buildup on top of the nee-

dle valve with tool .
FD215-1007283
IO
NOTICE
● Do not clean the valve with a wire
brush or hard metal tools.
● Remove carbon buildup on the orifices Needle cleaner

of the spray nozzle by turning the needle
cleaner along the orifices.
● Diameter of the needle cleaner: ≤φ0.23mm
FD215-1007284

● Clean the seat surface of the spray nozzle Scraper

with tool .
● Remove the hard carbon on the nozzle

with a carbon remover.
FD215-1007285
Inspect: Injector
● Assemble the needle valve and the spray

nozzle after washing them with cleaning
fluids. PD Needle valve
● Pull the needle valve by 1/3 of its length
and check if it can fall under its own
Spray nozzle
weight. (turn the valve and check again for
several times)
FD215-1007286
● If the needle valve can not fall under its

own weight, wash it and conduct more in-
spections. Re-assemble the needle valve
IO
and the spray nozzle in case of abnormal-
ity.
NOTICE
● When replacing the spray nozzle, use a
full set of spare parts including spray
nozzle, cylindrical pin, needle valve and
seals.
● After the spray nozzle is replaced, be

sure to adjust the lift and fix the open-
ing pressure same as the standard
value.

Adjust: Injector
● Before adjustment, wash all the part with

cleaning fluid (light oil) and remove the
dusts etc. on these parts.
NOTICE
● Never touch the sliding part of the nee-
dle valve.
● Assemble all the parts of the spray nozzle Adjusting gasket

as illustrated.
Spring
● Tighten the holding nut to specified torque.

Needle valve
● Set the injector on the tester and measure Spray nozzle
the opening pressure.
CAUTION
PD
● Never contact the spray out of the in-
jector.
FD215-1007287
● Replace the adjusting gaskets if measured

valve exceeds the standard value.
IO
Install: Injection pipe
● Check the tube and the seat surface of

Tube
the connector part for damages or rugged-
Seat surface
ness. Seat surface
● Press the tube evenly on the seat surface

of the connector part. Do not apply rough Connector part
force to fix it.
FD215-1007288
● Tighten the tube to specified torque after

fixing.

9.5 Cooling System
Item Specification
Cooling method Forced water circulation cooling type
Pump type Belt driven, spiral type
Thermostat type Paraffin core, bottom bypass type(with jump valve)
Cooler capacity (Engine body) dm³{L} 9.5 {9.5}
9.5.2.1 Cooling system (coolant flow diagram)
Radiator
PD
Cylinder head
Thermostat module High temp

Low temp
IO
Cylinder
Water pump
FD215-1007289

9.5.2.2 Thermostat
To radiator
Cover
Thermostat
Casing
PD From cylinder head
To water pump
FD215-1007290
● The thermostat is a bottom bypass type

IO
with paraffin stuffed in the core. It applies
the volume change of the paraffin when
it changes from solid to liquid when tem-
perature rises. The opening of the valve
changes with the temperature, and the
valve displacement regulates the amount
of coolant flowing to the radiator and the
water pump (bypass side), and controls the
temperature of the coolant.

9.5.2.3 Water pump
Casing
Bearing
Flange
Group seal
Pump shaft
Snap ring
PD
Spacer ring
Drain hole
Vane wheel
FD215-1007291
● The water pump has a drain hole, prevent-

IO
ing the coolant from entering the bearing
due to group seal abnormality.

Inadequate engine
adequate cooling)
Over heating (in-
Abnormal noise
Symptom
output power
consumption
Over-cooling
Fast coolant
Reference
Cause
Loose or rupture ○ ○
Belt Over-tight ○
Oil/grease on belt ○
Defective installation ○ ○
Defective gasket ○ ○
Defective bearing ○ ○
Water pump Defective impeller
Defective group seals
PD
Loose contact between pump shaft
and flange or impeller
Housing installation defect
○
○
○
○
○
○
Opening temperature too high, valve
○
Thermostat always closes.
IO
Opening temperature too low, valve
○
always opens
Coolant temp sensor water leakage ○ ○
Core clogged ○
Radiator
Core broken or weld comes loose ○ ○
Defective installation of engine oil
○ ○ Lubricating
Oil cooler cooler
system
Defective installation of cylinder head ○ ○
Cylinder head Engine
Defective pressure cap ○
Coolant insufficient or contaminated ○
Coolant circuit contaminated or clogged. ○
Defective installation of hoses ○ ○
Low ambient temperature ○
Inter-cooler Foreign matters built up on the core ○

9.5.4.1 Belt tension – inspect and adjust
NOTICE
● Keep the belt free of grease or oil.
Grease or oil may cause the belt to slip
and reduce the cooling effect.
Inspection standard
Unit: mm

– Belt tension PD 10~15 – Adjust
Special tools
Measurement of belt
Belt tensiometer MH062345
tension
IO
[Inspect]
● Apply a pressing force of about 98N {10kgf}

onto the intermediate part of belt and mea- A
sure the deflection of the belt.
C
Deflection
A: Alternator belt roller
Belt
B: Crankshaft belt roller
B
C: Water pump belt roller FD215-1007292

● Set the o-ring (small) of tool at the

O-ring (small)
98N{10kgf} mark (press load) on the
gauge.
Gauge mark
● Set the o-ring (large) at the the mark of
specified maximum deflection.
O-ring (large)
Gauge mark FD215-1007293
● Position tool on the intermediate part

of the belt as illustrated. Press it until the O-ring
arrowed part meet the o-ring. Flange
PD
FD215-1007294
● Measure belt deflection.

IO
Deflection
● Adjust the belt as per the following proce-
dure if the measurement exceeds the stan-
dard value.
FD215-1007295

[Adjust]
Adjusting bolt
● Loosen the nut of the alternator and adjust

belt tension with the adjusting bolt. Belt
● Tighten the nut after adjustment.
Nut FD215-1007296
9.5.4.2 Inspect: Belt crack and damage
● Check the belt visually for cracks and dam-

ages.
PD
● Replace the belt if abnormality is observed.
Belt
FD215-1007297
IO

Belt condition Remaining service life (for reference)
New machine or the travel distance from displacement

to inspection or more
Wrinkle
New machine or 1/2 travel distance from displacement

to inspection
Surface crack
PD 1/4 New machine or 1/4 travel distance from displace-

ment to inspection
Crack to the bottom

IO
Crack to the core wire
Service life

9.5.4.3 Replace coolant and clean cooling system
T Tightening torque
Unit: N·m{kgf·m}

– Crankcase drain valve 98{10} –
● Failure to clean the radiator after long ser-

vice hours may cause the cooling system
to overheat due to scaling buildup. Clean
the cooling system on a regular basis.
Drain coolant
PD
● Loosen the pressure cap to relieve the
pressure in the cooling system before
draining the coolant. Also drain the coolant
in the reservoir.
CAUTION
● Drain the coolant after it has complete-
ly cooled down to avoid burns.
IO
Crankcase drain valve
Pressure cap
● Loosening the pressure cap while the
coolant is still hot may cause the cool-
ant to spurt out. When loosening the
pressure cap, put a rag on it and turn
slowly to relieve the internal pressure.
FD215-1007298

Cleaning procedure
NOTICE
● Do not use hard water for the cleaning.
Use soft water with the following nature
to prevent scaling and rusting.
Total hardness: < 300ppm

Sulphate SO4-: < 100ppm
Chloride Cl-: < 100ppm
Insoluble solid concentration: < 500ppm
pH value: 6~8
● Allow the coolant to circulate inside the
radiator and keep coolant temperature
PD
around 90°C. Open the thermostat.
● To increase coolant temperature quickly,

cover the front part of the radiator with a
cardboard or similar material.
● If too much scaling exists inside the radia-

tor, leaks may be observed after cleaning.
Conduct leak tests carefully when the cool-
ing system has been cleaned.
IO
● Cleaning method may vary depending on
the following conditions.

gNormal condition gWhen coolant contaminated gWhen radiator clogged
Clean with radiator cleaning liquid(Radipet 7)

Clean with water
Drain coolant
Make cleaning solvent by mixing 5-10 cleaning

liquid (Radipet 7) with 100water.
(Operation sequence)
Fill the mixture into the reservoir
Run the engine at idle under 90° for 30 min.
NOTICE

•When cleaning liquid is added, if the engine
keeps running for more than 1 hour, cooling
system may be damaged.
Observe the cleaning procedure.
Drain coolant
PD
Add tap water (hot) into the reservoir
Run the engine at low idle under 90 deg.

for 10 minutes
Drain tap water

IO
If drained water is clear, cleaning work is finished.
If drained water is dirty, repeat the steps above.
NOTICE
•When the cooling system has been cleaned,
add coolant as soon as possible.
•To prevent freezing of coolant and corrosion
in the cooling system,add long-acting coolant
properly. (refer to the instruction manual)
CAUTION
● Diesel engine long-acting coolant is
flammable. Keep it away from heat
sources and naked fire.

CAUTION
● In case long-acting coolant contacts
your eyes, flush with plenty of water
and seek medical attention immediate-
ly.
9.5.4.4 Release air in the cooling system
● Remove the pressure cap, and run the en-

gine at low idle when coolant temperature
is 90°C until air inside the cooling system
has been released. Foam
● After air inside the cooling system has

been released, add coolant into the reser-
voir as required. PD
9.5.4.5 Leak inspection FD215-1007299
● Air and waste gas in the coolant may ac-

celerate rusting in the cooling system.
Conduct the following inspection.
● Remove the pressure cap
CAUTION
IO
● Make sure the coolant has cooled down
before loosening the pressure cap. Hot
coolant may spurt out.
● Start the engine until coolant temperature

rises to 90°C.
● If foams are observed in the coolant under

this condition, this shows air or wasted gas
exists in the coolant.
● Existence of air in the coolant shows signs

of loosening of cylinder head bolts, pump
holding bolts, hose connection or hose
damage.
● Waste gas in the coolant shows damage in

the cylinder head gasket or broken cylinder
head.

9.5.5 Radiator, engine oil cooler and intercooler
10
11
7
6
5
3
PD 9 4
IO
FD215-1007300
1) Pressure cap 7) Upper bracket

2) Fan hood 8) Engine oil cooler
3) Intercooler 9) Lower bracket
4) Bracket 10) Radiator
5) Guard plate 11) Frame
6) Gasket
Assembling sequence

Inspection standard

49±9.8kPa
1 Opening pressure of pressure cap – Replace
{0.5±0.1kgf/cm²}
Intercooler air leak (Air pressure:
150kPa{1.5kgf/cm²})
Engine oil cooler air leak
(Air pressure: 1.5MPa{15kgf/cm²})
Radiator air leak
(Air pressure:100kPa{1.0kgf/cm²})
Inspect: Intercooler air leak

PD
● Immerse the intercooler in water and plug
one of the air openings. Apply specified air
pressure onto the other end.
Cap
● Replace the intercooler if air leak is ob-

served.
IO
FD215-1007301
Inspect: Engine oil cooler air leak
● Immerse the oil cooler in water and plug

one end of it. Apply specified air pressure
onto the other end.
Cap
● Replace the engine oil cooler if air leak is
observed.
FD215-1007302

Inspect: Radiator air leak
● Install hoses, radiator cap tester, and plugs Radiator cap tester
onto the reservoir of the radiator.
Plug Hose
● Tighten the reservoir plug and put it in a

water tank.
● Use the radiator cap tester to apply speci-

fied air pressure and check for air leaks.
Plug FD215-1007303
● Replace the radiator assembly if air leak is
observed.
Inspect: Pressure cap
● Opening pressure PD
● Replace the pressure cap if measured
value exceeds the standard value.
Pressure cap
FD215-1007304
IO

9.5.6 Fan and belt
*a
5
2
1
PD 4
FD215-1007305
IO
1) Fan 4) Fan coupling

2) Fan spacer ring 5) Pump belt roller
3) Belt *a: Water pump
Assembling sequence
NOTICE
● Always replace the belt in pairs to
avoid belt tension difference.
● Keep the belt free of grease or oil.

Grease or oil may cause the belt to slip
and reduce the cooling effect.

9.5.7 Water pump
8
7
6
5
4 Tb
1
10
11
3 9
2 12
PD FD215-1007306
1) Impeller 8) Pump shaft

IO
2) Flange 9) Group seal
3) Snap ring 10) Grease fitting
4) Bearing 11) Pump housing
5) Spacer ring 12) O-ring
6) Bearing : Non-reusable parts
7) Gasket
Assembling sequence
Reverse the disassembling sequence,

except the following parts.
12→8→7→6→5→4→11→3→9→10

Inspection standard
Unit: mm
Interference between impeller Re-install no more than

1, 8 0.03 – 0.06 –
and water pump shaft 2 times
Interference between flange Re-install no more than

2, 8 0.03 – 0.08 –
and water pump shaft 2 times
T Tightening torque
Unit: N·m{kgf·m}
Ta Bolt (for installation of water pump) 24{2.4} –

Tb
Symbol
Grease fitting
Applicable location
PD 12.3±2.4{1.3±0.25}
Type
–
Quantity
Bearing stuffing MoS2 grease As required
Grease fitting [NLGI No.2(hectorite)] 60g
b Group seal perimeter ThreeBond 1102 As required
IO
Special tools
Unit: mm
Socket wrench
Removal of impeller
A B MH061417
clamp
φ48 φ10 A

Remove: Impeller
FD215-1007307
Remove: Flange
Gear clamp
PD
FD215-1007308

IO
Inspect: Interference between impeller and
pump shaft
Flange

NOTICE
● Even if the measurement meets the Water pump shaft
standard value, do no install more than
FD215-1007309
twice.

Inspect: Interference between flange and

Shaft
pump shaft
● Replace defective parts if measurement

NOTICE Flange
Above Φ20mm Clamp
● Even if the measurement meets the
standard value, do not install more Φ40mm
FD215-1007310
than twice.
Install: Flange
NOTICE PD
● Before installing the flange, check the
punch marks on the flange, as illus-
trated. One mark shows the flange is
usable. Punch a mark to record the cur-
rent disassembling and installation.
● The punch marks on the flange record FD215-1007311

the past disassembling and installation.
If two marks are available, (showing
IO
two disassembling and installations),
the flange must be replaced.
● Apply a load onto the pump shaft using a

press machine.
● Install the flange until it meets the bearing.
NOTICE
● The pump housing may be damaged if
no jigs are used during installation. Punch mark
FD215-1007312

Install: Impeller
NOTICE
● Before installing the impeller, check
the punch marks on the impeller as il-
lustrated. One mark shows the wheel
is still usable. Punch a new mark to
record the current disassembling and
installation.
Punch mark
● The punch marks on the wheel record
FD215-1007313
the past disassembling and installation.
If two marks are available, (showing
two disassembling and installations),
the impeller must be replaced.
PD
● Use the flange side surface of the pump
shaft as the load bearing surface.
● Apply a load onto the end surface of the

impeller with the press machine and install
the impeller. The dimension of the pump
housing end surface and the impeller end
surface is shown in the illustration.
IO
Flange
FD215-1007314
9.5.7.4 Post-installation inspection
Inspect: Rotation of flange

Clamp
● Rotate the flange by hand to check if the Vane wheel

21.34mm
rotation is flexible and free of block.
● If the rotation is not flexible, disassemble

Casing end surface
the pump and inspect it again.
Shaft
FD215-1007315

9.5.8 Thermostat
密封胶
Ta 4
10
7
PD 11
8
5 Ta
6 Ta
FD215-1007316
1) Thermostat cover 8) Gasket
IO
2) Gasket 9) O-ring
3) Thermostat 10) Bypass pipe
4) Coolant temperature sensor 11) O-ring
5) Coolant temperature sensor P : Position pin
6) Screw plug : Non-reusable parts
7) Thermostat housing
Assembling sequence
NOTICE
● Keep the o-ring free of engine oil. Oil
on the o-ring may cause it to expand
and result in water leak.

Inspection standard
Unit: mm

Valve opening temperature 76.5±2°C – Replace
3 Thermostat
Valve lift /temperature Above 10/95°C – Replace
T Tightening torque
Unit: N·m{kgf·m}

Coolant temperature sensor
Ta 20 – 26{2.1 – 2.7} Locking agent
Screw plug
Symbol
b
PD
Applicable location
O-ring
Coolant temperature sensor
Type
Soap water
Loctite 575
Quantity
As required
As required
Screw plug
IO

Inspect: Thermostat Agitator

Thermometer
● Agitate the water so that water tempera- Wire rope
ture in the container is even. Conduct the
following inspection.
● If measured value exceeds the standard

value, replace the thermostat.
Heat source
1. Valve opening temperature Valve lift FD215-1007317
● Fix the thermostat with a wire rope and

keep it away from heat sources.
● Add hot water gradually until valve

PD
opening temperature is reached.
● Keep this condition for 5 minutes and

check if the valve has opened.
● When water temperature drops to

65°C, check if the valve has shut.
2. Valve lift
IO
● Keep water temperature a bit higher than
the valve opening temperature. Hold on for
5 minutes when the valve has been com-
pletely open and measure the valve lift.

9.6 Air Intake and Exhaust System
Item Specification
Air filter element type Paper filter element
Dust indicator type Electrical
Type TE06
Turbocharger
Producer MITSUBISHI
9.6.2.1 Air filter

PD
IO
Vacuum pump
Air filter
FD215-1007318
● The air filter uses two elements.
● A vacuum pump is installed on the air filter.
● When engine speed is below the specified speed, the vacuum pump vibrates due to load
change and drain the internal water and dust automatically.

9.6.2.2 Turbocharger
Bearing bushing
Liner Thrust bearing Thrust ring Piston ring
Rear plate
Air compressor Turbine housing

casing
Shaft and turbine

Air compressor
wheel
PD
IO
Thrust lining Oil retainer Bearing
FD215-1007319

Inadequate engine output power
in air intake/exhaust system

Abnormal noise or vibration
Excessive oil consumption
Symptom
Engine startup difficulty
White exhaust gas

Black exhaust gas
Reference
Cause
Air filter Air filter element clogged ○ ○ ○ ○

Bearing damaged ○ ○ ○
Turbine wheel carbon buildup ○ ○
Turbo-
and housing
Shaft deflection
charger Turbine wheel damaged

PD
Interference between turbine wheel
Turbo- assem- Interference between air compressor

○
○
○
○
○
○
○
○
○
○ ○ ○
charger bly wheel and housing
Air compressor wheel damaged ○ ○ ○
Part sliding failure due to clogged
○ ○ ○
greasing pipe and connecting bolt
IO
Oil seal damaged due to clogged oil
○ ○
return hose
Defective installation of air compressor casing ○ ○ ○ ○
Defective installation turbine housing ○ ○
Deformation of exhaust pipe and muffler ○ ○
Defective installation of exhaust pipe and muffler ○ ○
Wrong valve clearance ○
Damaged cylinder head gasket ○
Abrasion and carbon buildup on valve and valve seat ○
Engine
Decreased valve spring elasticity ○
Abrasion or damage of piston ring ○ ○
Abrasion or damage of piston ring groove ○ ○
Function defection of cooling assembly ○ Cooling system
Excessive engine oil ○ Lubricating system
Main mobile parts seized ○ ○ Engine
Nonuniform or excessive spray ○ Fuel system

9.6.4 Air filter
1 7
6
2
1) Dust indicator
PD 6) Inner filter element
3
FD215-1007320
3) Vacuum valve 8) Body
4) Cover : Non-reusable parts
5) Outer filter element
IO
NOTICE
● Do not disassemble the inner filter ele-
ment unless it needs to be replaced.
● Do not clean the inner filter element.
Assembling sequence
Inspection standard
Unit: mm
Dust indicator operating vacu-

1 6.23±0.57kPa{47±4.3mmHg} – Replace
um negative pressure

9.6.4.1 Cleaning procedure
Clean: Outer filter element
● Blow the filter element from the inside with

compressed air less than 685kPa{7kgf/
cm²}.
● Blow the filter pleats up and down until the

filter is clean.
NOTICE
● Read the instruction manual when air- FD215-1007321
blowing the filter element. Frequent
cleaning may cause damage to the
filter element and cause dusts and for-
eign objects to enter the engine.
PD
● Do not remove dusts by tapping the fil-
ter element or striking it against other
objects.
● Do not air-blow the filter element from

the outside to the inside.
IO

Inspect: Outer filter element
● Put a light bulb inside the filter element.
● Replace the element if the pleats are dam-

aged or become thinner, or if the seal of
the contact surface is damaged.
● Besides, if damp soot or carbon buildup is

observed on the filter element, replace the FD215-1007322
filter element regardless of its replacement
interval.
Inspect: Dust indicator operating vacuum 2 1

negative pressure PD
● Apply negative pressure onto the dust in-
dicator slowly, and measure the negative
pressure between terminal 1 and 2 when
connected.
● Replace the dust indicator if measured

value exceeds the standard value. FD215-1007323
IO

9.6.5 Turbocharger
Ta
Tb
11 5
3
1
*a
13
PD 6
7
9
Tc
14
Ta
15
12 8
IO
Tb
10
FD215-1007324
1) Air hose 10) O-ring
2) Intake pipe 11) Connecting bolt
3) Air hose 12) Connecting bolt
4) Turbocharger cover 13) Oil duct pipe
5) Spacer ring 14) Turbocharger
6) Exhaust pipe 15) Gasket
7) Gasket *a: Air suction pipe
8) Oil return pipe : Non-reusable parts
9) Gasket
Assembling sequence

T Tightening torque
Unit: N·m{kgf·m}

Ta Clamp 4.9{0.5} –
Tb Connecting bolt (for installation of oil duct pipe) 21{2.2} –
Tc Nut(for installation of turbocharger) 41{4.2} –

Apply to turbocharger
O-ring
Install: Turbocharger
PD
● Before installing the turbocharger, apply
Orifice Turbocharger
suitable amount of engine oil into the ori-

fice to ensure smooth operation of the in-
ternal parts .
IO
FD215-1007325

Turbocharger
Ta
1
PD 5
FD215-1007326
1) Shaft coupling 5) O-ring

2) Turbine housing 6) Turbocharger assembly
3) Snap ring : Non-reusable parts
IO
4) Air compressor casing
Assembling sequence
NOTICE
● The turbocharger can not be disassem-
bled. Replace it when the turbine wheel
and the air compressor wheel is dam-
aged, or when rotation is not smooth.

Inspection standard
Unit: mm
Axial clearance 0.05 – 0.09 0.1 Replace
Turbocharger Clearance in the Turbine wheel side 0.40 – 0.53 0.58 Replace
6 direction per-
assembly
pendicular to the Air compressor
0.55 – 0.66 0.72 Replace
rotation axis wheel side
T Tightening torque
Unit: N·m{kgf·m}
Ta Bolt (for installation of shaft coupling)

PD 8 – 9{0.8 – 0.9} Wet type

MoS2 grease
Bolt thread As required
[NLGI No.2(hectorite)]
b O-ring Engine oil As required
IO
Match mark
Match mark
● Imprint match marks on shaft coupling, tur-
bine housing, air compressor casing and Air compressor casing
turbocharger assembly. Turbocharger
assembly
Turbine housing
Shaft coupling FD215-1007327

Remove: Turbine housing
● Strike the outside of the turbine housing

with a rubber hammer. Be careful not to
damage it.
NOTICE
● The blades of the turbocharger assem-
bly bend easily. Be careful not to strike FD215-1007328
the turbine housing.
Remove: Air compressor casing
PD
● Strike the outside of the air compressor
casing with a rubber hammer. Be careful
not to damage it.
NOTICE
● The blades of the turbocharger assem-
bly bend easily. Be careful not to strike
FD215-1007329
the air compressor casing.
IO
9.6.5.4 Post-disassembling work
Clean
● Before cleaning, visually inspect the condi-

tion of the disassembled parts for ablation,
scratches and other signs that are difficult
to be observed after cleaning. Replace de-
fective part if abnormality is observed. Solvent
● Put disassembled parts into inflammable

fluid. Dry them with compressed air. (Dilute
the cleaning fluid produced by NEW HOPE
with 5~10 times of water) FD215-1007330
● Remove foreign objects on the parts with a

plastic scrapper or a bristle brush.

NOTICE
● Do not immerse the turbocharger as-
sembly into the fluid. Otherwise, o-rings
in the assembly will expand and cause
damage to the turbocharger.
● Immerse the parts in the cleaning fluid

again.
● Dry the parts with compressed air.
Inspect: Turbocharger assembly
● Measure the following items. Replace the

PD
turbocharger assembly if measured value
exceeds the specified limit.
1. Axial clearance between shaft and turbine

wheel
FD215-1007331
2. Clearance in the direction perpendicular to

<Turbine wheel side>
the rotation axis
IO
FD215-1007332
<Air compressor wheel side>
FD215-1007333

Install: Snap Conical surface
● Insert the snap ring into the air compressor

casing with the conical surface facing up-
ward.
Snap ring
CAUTION
● Press the snap ring with you hand in
case it ejects. Air compressor casing FD215-1007334
9.6.5.7 Post-assembling work
Inspect: Rotating condition of the turbo-

charger assembly
PD
● Rotate the wheel of the turbocharger as-
sembly and check if it rotates freely.
● Disassemble the assembly and repair it in

FD215-1007335
IO

9.6.6 Intake manifold
Ta
4 2
PD Ta
FD215-1007336
IO
1) Intake pipe 4) Gasket

2) Intake hose : Non-reusable parts
3) Intake manifold
Assembling sequence
T Tightening torque
Unit: N·m{kgf·m}
Symbol Tightened part Tightening torque Remark

Ta Clamp 4.9{0.5} –

9.6.7 Exhaust manifold
Ta
PD
Folded portion
FD215-1007337
IO
1) Exhaust manifold : Non-reusable parts
2) Gasket
Assembling sequence
T Tightening torque
Unit: N·m{kgf·m}

Ta Nut (for installation of exhaust manifold) 41 – 54{4.2-5.5} –

9.6.8 Exhaust pipe and muffler
5
6
1
4
3
*a
2
PD 7
FD215-1007338
IO
1) Insulator 6) Muffler
2) Exhaust pipe 7) Muffler bracket
3) Gasket *a: Turbocharger
4) Clamp : Non-reusable parts
5) Muffler clamp
Assembling sequence

9.7 Electrical System
Alternator
Item Specification
Producer MITSUBISHI
Type Built-in regulator type alternator
Model A4TU7686
Output V-A 24-50
Start motor, preheating
Start motor
Producer
Model
Output
PD
Item
V-kW
Specification
MITSUBISHI
M008T87171
24 – 5.0
Reduction gear mechanism Planetary gear
Solenoid switch operating voltage V 16 or below
Model U001T37072
Exciting current V-A 24 – 2.3
IO
Starter relay Connecting voltage V 16 or below
Disconnecting voltage V 4 or below
Admissible interrupting current A 200
Model Sheath type
Heating plug
Rated voltage/current V-A 11-130
Model U001T31383
Exciting current V-A 24-2.3
Heating plug Connecting voltage V 16 or below
relay Disconnecting voltage V 4 or below
Admissible interrupting current A 200
Temperature fuse capacity A 127

9.7.2.1 Start motor
Solenoid switch
Steel ball Lever
Terminal S Starter relay Brush spring
Terminal B Front bracket
Brush
Terminal M Brush seat Spring
Rear bracket
Pinion stopper
Rear bearing
Terminal SW
PD Armature
Yoke
Cap
E-ring
Gasket
Pinion
Front bearing
Overdrive clutch
Rubber seal
Gear shaft
Terminal L Planetary gear
Internal gear
FD215-1007339
IO
● This starter uses planetary gears as the re-
duction gear mechanism.
Planetary gear
FD215-1007340

9.7.2.2 Alternator
Terminal E
Terminal P
Terminal B
Neutral diode
PD
Terminal R Terminal L
Rectifier
Rotor
Stator
Fan
Belt roller
Rear bearing
IO
Front bearing
Regulator
Rear bracket Field coil Front bracket
FD215-1007341

9.7.3 Circuit diagram
9.7.3.1 Alternator with a neutral diode
Terminal P
Terminal B
Neutral diode
Neutral point
Stator coil
Terminal L
Terminal R
Field coil
Terminal E
Neutral diode
PD IC Regulator
FD215-1007342
1. Features
● This alternator is the same as general alternators except that neutral diodes are installed.
IO
● These neutral diodes helps to generate more DC output when the alternator is rotating at a
high speed than a alternator without neutral diodes.
Wave form at neutral point during high speed rotation

(V) Wave form at neutral point during low speed rotation
28 Output voltage
14 Neutral point (1/2 output voltage)

average voltage
0 Ground potential
Voltage
Rotating angle
FD215-1007343

2. Voltage change at neutral point and neutral diode operating principle
● The potential at the neutral point changes with the DC voltage (half of output voltage) at the
neutral point.
● When the alternator is rotating at high speed, voltage at the neutral point can rise above out-
put voltage (28V) and drops to below grounding voltage (0V). To regulate the over-voltage
and under-voltage (dashed area), over-voltage is taken out by the neutral diode and added
into the DC output.
Operation of the potential and voltage of the neutral diode:
● When the voltage at the neutral point is between 0~28 V, 6 of the diodes are working. The
neutral diodes do not work.
PD
Positive diode (+)
Terminal P
Terminal B
Terminal L
Terminal R
Field coil
Terminal E
IO
IC Regulator
FD215-1007344

3. When voltage at neutral point rises above 28 V
● The positive diode (+) increases the extra DC output to all electrical equipment.
Terminal P
Terminal B
Terminal L
Terminal R
Field coil
Terminal E
PD
Negative diode(-)
IC Regulator
FD215-1007345
IO

4. When voltage at neutral point drops below 0 V
● The negative diode (-) supplies output from the neutral point via the rest 3 diodes.
Gauge group Thermostat s/w
Coolant temp sensor
Starter
Oil press s/w
M Alternator
M
B E B P
L R Oil bypass alarm s/w
S
S
B
Starter relay
L
SW
PD Indicator
Relay Start switch

OFF
S E L R P R1
AC
START
IO
Safety relay B R1ACBR C
Indicator
Heating plug relay
Main power source relay
Indicator
+
-
Battery
+
-
Heating plug
FD215-1007346

9.7.4.1 Power source and charging
and start switch is turned to the

ON position, the battery charg-
Symptom
When engine is not running
ing alarm does not light up.

Alternator normal, but dis-
Fast electrolyte decrease
Battery normal, but dis-

Reference
charge excessive
charge excessive
Cause
Battery overheat
Connecting defect, wiring damage, ground-

ing fault
Fuse blown
Belt loosened
PD ○
○
○
○
○
○
○
Cooling system
Belt damaged ○ ○
Battery fault ○ ○
Disconnection in stator coil ○
Stator coil and core short circuit ○
IO
Disconnection in field coil ○
Alternator
Rectifier fault ○
Regulator fault ○ ○ ○
Wiring error ○
Gauge combination fault ○

9.7.4.2 Engine startup, preheating and shutdown
Starter works
but engine does
not start
Engine working condition poor

Symptom
Pinion engages with ring

gear but does not rotate
Flywheel rotates but en-
Pre-heating not working

Starter does not work

Reference
Pinion does not en-

gage with ring gear
gine does not start

Cause
Connecting defect, wiring damage, grounding

PD
fault
Fuse blown ○ ○ ○
Battery undercharged ○ ○
Solenoid switch contact seizure or
○ ○
melted
Start motor Solenoid switch coil open circuit ○ ○
Overdrive clutch fault ○
Pinion abrasion or damage ○
IO
Starter relay fault ○
Starter switch fault ○
Flywheel ring gear abrasion or damage ○ ○ ○ Engine
Coolant temp sensor fault ○
Heating plug defect ○
Heating plug relay defect
Connecting piece defect

9.7.5 Switches
9.7.5.1 Thermostat switch
● Put the switch into a oil container. 2

1
● Raise oil temperature to specified value
and agitate the oil.
● Measure the temperature between 1 and 2.
Standard value 105±2°C
FD215-1007347
● Replace the switch if measured value ex-
ceeds the standard value.
PD
9.7.5.2 Inspection of engine oil pressure switch
● Inspect the switch according to the follow-

ing procedure. Replace the switch if neces-
sary.
Body
1
1. Inspection when no pressure is applied
● Check if terminal 1 and the body is con-

nected.
IO
Operating pressure imprint No.
2. Inspection when pressure is applied FD215-1007348
● Apply air pressure gradually onto the

switch from 0kPa{0kgf/cm²}.
● If air pressure is measured at the mo-

ment when the connection between
terminal 1 and the body has not be
detected, check if the measured value
complies with the standard value.
Standard value
50±10kPa{0.5±0.1kgf/cm²}
(work pressure)

9.7.6 Dust indicator and heating plug
9.7.6.1 Inspection of dust indicator
● Follow the procedure below. Replace the

dust indicator if any fault is observed.
● When no air pressure is applied onto the

dust indicator, check if terminal 1 is discon-
nected with terminal 2.
● Check if terminal 1 is disconnected with (+)2 1(-)

FD215-1007349
terminal 2 when applying a negative pres-
sure of 6.23±0.57kPa{635±58mm H 2O}
onto the dust indicator.
9.7.6.2 Inspection of heating plug

PD
● Measure the heating plug as illustrated.
Standard value (at room

Approx. 3.8Ω(ref.)
temperature)
● Replace the heating plug if measured val-

ue exceeds the standard value.
IO
FD215-1007350

9.7.7 Start motor
Starter
Terminal B
PD Terminal S
Starter relay
IO
FD215-1007351
CAUTION
● Before removing the start motor, dis-
connect the cable with the negative
terminal of the battery and insulate the
cable and the negative terminal.
● It is dangerous not to disconnect the

negative terminal, because terminal B
is always with battery voltage.

b 24
b 25
26 21
22
28
23
27 18
d 19
20 7
b
8
29
30 5
31 10
6
11
1
2
3
4
PD 17
b
15
14
9
12
b 16 13
5
Terminal S
IO
28
27
28 d
FD215-1007352

1) Stopper 12) Brush (+) 23) E-ring

2) Pinion gear stopper ring 13) Yoke 24) Gear shaft
3) Pinion 14) Rear bearing 25) Washer
4) Spring 15) Gasket 26) Inner gear
5) Solenoid switch 16) Armature 27) Overdrive clutch
6) Adjusting gasket 17) Steel ball 28) Lever
7) Rear bracket 18) Cover 29) Front bearing
8) Conical gasket 19) Rubber gasket 30) Oil seal
9) Brush spring 20) Planetary gear 31) Front bracket
10) Brush (-) 21) Rubber gasket
11) Brush seat 22) Steel disc
● Do not remove the bearing if no evident

PD
damage is available.
● When the armature is being removed, the

steel ball may come out. Be careful not to
lose the ball.
● If only the starter is to be disassembled

for the inspection, do not remove the pin-
ion when inspecting the brush and related
IO
parts.
● When any other parts are to be removed,

be sure to remove the pinion.
Assembling sequence
● Be sure to adjust the clearance of the pin-

ion when replacing the solenoid switch.
● The rubber gaskets can be reused if they

are normal.

Inspection standard
Unit: mm

– Pinion clearance 0.5 – 2.0 – Adjust
No load perfor- Current Below 85A –
– Apply 23V Modify or replace
mance Speed Above 3750rpm –
29.2 – 39.4N
9 Brush spring pressure 20N{2kgf} Replace
{3 – 4kgf}
10, 12 Brush length 18 11 Replace
Commutator outer diameter 32 31.4
Replace
Commutator radial runout – 0.1 or above
16
Depression depth of the mica plate
0.5 – 0.8 0.2 or below Modify or replace
between sector blocks

Contact surface of solenoid switch lever
Conical gasket
General grease
Sliding surface of gear shaft assembly and As required
[NLGI No.2(hectorite)]
overdrive clutch
Sliding surface of lever and overdrive clutch
Sliding surface of armature assembly and
IO
gear shaft assembly
b Steel ball Molykote AG650 As required
Planetary gear teeth and inner gear teeth
Gasket
General grease[NLGI
c Oil seal As required
No.2(hectorite)] or oil seal grease
Spline part of overdrive clutch Multemp OA-171
d As required
(Kyodo Yushi Co.,Ltd.)
Special tools
Unit: mm
Bearing removing and installing A B

MH063596 Removal and
tool
A: MH063614 installation of
A: Removing and installing tool
B: MH063619 front bearing
B: Installing tool

Match mark: Rear bracket and yoke Rear bracket
Match mark
Yoke
9.7.7.2 Disassembling method FD215-1007353
Disassemble: Pinion gear
● To remove the pinion, energize the start Pinion

Front bracket Lever
motor for the pinion to pop out.
Stopper ring
PD Solenoid s/w
CAUTION
● When the starter is energized, the
pinion will pop out and rotate. Do not
touch it with your hand.
● The solenoid switch may become very

hot. Be careful when touching it.
S
P H
CAUTION B
IO
M
● Do not energize the driving coil P and
the retaining coil H for more than 10
and 30 seconds respectively. Other-
wise, the two coils may become over-
heated or burned.
FD215-1007354
● Make sure the starter is energized and
the parts are in proper place for the
pinion to pop out. If the starter is not
energized and the pinion is removed by
the lever, the front bracket and the le-
ver may get damaged when the stopper
is removed.
● When the starter is energized, high cur-

rent (100 A or more) will come through.
Use strengthened cable or similar thick
cable during inspection. Make sure all
connections are reliable.

● Connect the starter as illustrated. Terminal S

Terminal M
Pinion
Cable
FD215-1007355
● The following operation is to be conducted DC power

with the starter energized. Remove the pin-
ion within 30 seconds.
S/W1
S
● Set S/W 1 and 2 to the ON position and
PD S/W2 B P H
energize the starter, and the pinion will M
pop out and rotate.
FD215-1007356
● After the pinion starts rotating, set S/W 2

IO
DC power
to the OFF position within 5 seconds and
+ -
stop the rotation of the pinion.
S/W1
S
B P H
S/W2
CAUTION M
● When S/W 1 and 2 are set to the ON po-

sition, both driving coil P and retaining
coil H are energized. The circuit is con-
nected in such a matter that terminal B
FD215-1007357
of the starter is de-energized. Current
flows to the driving coil and the pinion
starts rotating. To prevent the driving
coil from getting burned, set S/W 2 to
the OFF position within 5 seconds after
the pinion starts rotating.

● Put the tube tool on the pinion stopper. Pinion stopper

Pinion
● Strike the tube tool with a hand hammer
Stopper ring
and remove the stopper from the groove.
● Remove the stopper and the pinion.
● Set S/W 1 to the OFF position and cut off

the power. Ring groove Tube tool
Tube tool
FD215-1007358
NOTICE
● When the starter is de-energized, the
mechanism will try to pull the pinion
in and the stopper may slide into the
groove. In this case, re-energize the
starter and repeat the removal process.
Disassemble: Yoke and brush seat

PD
● Follow the procedure below to remove the
yoke and the brush seat so that the brush
Yoke and brush seat
Commutator
Brush spring
Brush
will not damage the commutator of the ar-

mature assembly.
● Raise the brush so that it parts from

IO
the commutator. Press the brush spring
and hold the brush. Armature
FD215-1007359
● Hold the part A of all the brushes and raise

the brush. Brush Brush(+)
● Support the brush with the spring as illus- A

trated.
● Remove the yoke and the brush seat as- Brush(-)

sembly.
Brush spring Yoke and brush seat
FD215-1007360

Disassembly: Gear shaft and inner gear

Gear shaft and inner gear
● Remove the E-ring, and then remove the

gear shaft and the inner gear from the
overdrive clutch.
Overdrive clutch
● If the gear shaft and the inner gear can not

be removed because the spline that con-
nects the internal parts of the gear shaft
E-ring
and the overdrive clutch is too tight, follow
the procedure below.
Overdrive clutch Gear shaft
● Press the gear shaft towards the over-
drive clutch.
● Rotate the gear shaft by about 1/8

round and change the position of the
PD
spline. Spline
FD215-1007360
Remove: Front bearing Static load 1 ton
-A
IO
Front bearing
FD215-1007362
Inspect: Solenoid switch
● Follow the procedure below. Replace the

Terminal S
switch when abnormal condition is ob-
served.
1. Coil opening test
Terminal M
● Check if terminal S and terminal M are in-
terconnected.
FD215-1007363

● Check if terminal M and the body are inter-

connected.
Body
Terminal M
FD215-1007364
2. Contact fusion test
● Check if terminal B and terminal M are

disconnected. Terminal B
PD Terminal M
FD215-1007365
3. Contact connection test

IO
● Insert the plug of the solenoid switch Terminal B
and close the internal contact point.

Then, check if terminal B and terminal
M are interconnected.
Terminal M
FD215-1007366

Inspect: Brush spring pressure
● Use a new brush and measure the force to

disengage the brush spring and the brush.
● Replace the brush spring if measured val-

ue is below the specified limit.
Brush spring
Brush FD215-1007367
Inspect: Brush (-)
1. Brush length
● If the length of brush (-) is less than the

Brush length
limit, replace the brush. PD
NOTICE
● Replace the brush seat together with
the brush.
FD215-1007368
2. Contact surface between the armature

commutator and the brush
● If the contact surface between any of

IO
the brush and commutator is rough or
unevenly worn, modify the surface with
(#300-500)sand paper.
Inspect: Brush seat
● Clean the (+) brush seat and the (-) seat

plate, and check if they are disconnected.
● Interconnection indicates a short circuit.

Replace the brush seat in this case.
Brush seat Seat plate

FD215-1007369

Inspect: Yoke
Brush (+)
1. Coil opening test
● Check if cable (+) and the brush are in- Yoke

terconnected.
● Non-interconnection indicates an open Cable

circuit. Replace the yoke or the (+)
brush in this case. FD215-1007370
2. Earth test
● Check if the yoke and the (+) brush are Brush (+)
disconnected.
● Interconnection indicates the coil is Yoke
tion can not be repaired.
NOTICE
PD
earthed. Inspect the insulation. Replace
the yoke and the (+) brush if the insula-
FD215-1007371
● Metal particle buildup due to brush or
armature abrasion may interconnect
the coil with the yoke and become
earthed.
IO
Inspect: Brush (+)
1. Brush length
● Replace the brush if its length is below

the limit.
Brush length
2. Contact surface between the armature

commutator and the brush
● If the contact surface between any of

the brush and commutator is rough or FD215-1007372
unevenly worn, modify the surface with
(#300-#500) sand paper.

Inspect: Armature
1. Coil short circuit test Iron bar
● Hold the iron bar and keep it parallel to Armature tester

the armature.
● Rotate the armature slowly by hand.
● If the iron bar vibrates or if it is pulled FD215-1007373

towards the armature, a short circuit is
available. Replace the armature in this
case.
2. Earth test
● Check if the commutator and the arma-
case.
PD
ture (or shaft) are disconnected.
● If they are interconnected, the coil is

earthed. Replace the armature in this
Commutator Armature core Shaft
FD215-1007374
3. Armature outer diameter

IO
● If the measured value is below the
specified value, replace the armature.
FD215-1007375

4. Commutator run out
● If the gauge reading exceeds the limit,

modify the commutator of the armature.
Make sure the outer diameter is within
the specified range.
5. Commutator surface condition
● If roughness or abrasion is evident,

modify the surface with (#300-#500) Commutator
FD215-1007376
sand paper.
● After modification, check the run-out

range of the commutator.
6. Depression depth between the sectors

PD
● Modify or replace the armature if the
measurement is below the limit.
● Grind the depression to modify the ar-

mature.
Illustrated part
Dent depth
FD215-1007377
IO
● Modify or replace the armature accord-
ing to the abrasion condition of the de-
pression section.
○: OK
×: N/G
FD215-1007378

Inspect: Overdrive clutch
● Replace the overdrive clutch if abnormal

condition is observed.
● Rotate the shaft in direction B and

check if the rotation is smooth.
● Rotate the shaft in direction A and A

check if it is locked.
B Shaft
FD215-1007379
Install: Front bearing

Static load 1 ton
● Use tool -A and tool -B to press the

front bearing.
PD Front bearing
-A
-B
FD215-1007380
IO
● Use the claw on tool -A to rivet the
front bearing after pressing. Dynamic load 3 ton
-A
NOTICE
● Do not rivet the bearing on the old rivet
Claw Claw
seam.
Front bearing
FD215-1007381

Install: Yoke and brush seat

Rear bracket
Conical gasket
● Reverse the disassembling sequence
when assembling the yoke and the brush
seat.
Install: Conical gasket
● Install the conical gasket onto the bracket

as illustrated.
FD215-1007382
Install: Solenoid switch Solenoid switch

Terminal S
● Align the switch with terminal S and install
the switch onto the lever as illustrated.
PD Lever
FD215-1007383
Install: Pinion
Overdrive clutch
● Do not energize the starter when installing
Pinion
the pinion.
IO
Pinion stopper
● Install the stopper ring and the pinion Stopper ring

onto the overdrive clutch as illustrated.
● Put the stopper into the groove of the

overdrive clutch. Ring groove
FD215-1007384

● Pull the pinion and fix the stopper onto the Stopper
groove of the pinion check ring. Check ring Pinion
Groove
FD215-1007385
9.7.7.5 Post-assembling inspection
Inspect: Performance and pinion clearance

Solenoid s/w Pinion
● When the starter has been assembled, en-
ergize it and check.
not to touch it.

CAUTION
PD
● Once the starter is energized, the pin-
ion will pop out and rotate. Be careful
S
B P H
M
hot during inspection. Be careful when
touching it.
IO
NOTICE FD215-1007386
● Do not energize the driving coil P and

the retaining coil H for more than 10
and 30 seconds respectively. Other-
wise, the two coils may become over-
heated or burned.
● When the starter is energized, high cur-

rent (100 A or more) will come through.
Use strengthened cable or similar thick
cable during inspection. Make sure all
connections are reliable.

1. Performance test
Terminal
● Connect the starter as illustrated. Terminal Pinion
● Fix the voltage at DC 23V Terminal
CAUTION
● Do not apply a voltage more than 24 V.
Ammeter Voltmeter DC power

● The following operation is to be conducted
A V + -
with the starter energized. All the testing
s/w
procedures (measuring the starter current S
P H
and speed )must be finished within 30 sec- B
M
onds.
● Set the switch of the starter to the ON
CAUTION
PD
position and energize the starter, and
the pinion will pop out and rotate.
DC power
FD215-1007387
● When the switches are set to the On + -

position, both driving coil P and retain-
s/w1
ing coil H are energized. When high
P H
current from the DC source flows from s/w2
terminal B to terminal M, the current to
IO
driving coil P is cut off. Only the retain-
ing coil H is energized. To prevent the
driving coil from getting burned, finish
all the operation within 5 seconds.
FD215-1007388
● Measure the current and speed of the

starter. Measure the speed of the pin-
ion with a stroboscope.
● Set the switch to the OFF position and

de-energize the starter.
● If measured value exceeds the specified

value, disassemble and inspect the starter
again.

2. Pinion clearance
Terminal S
● Connect the starter as illustrated. Terminal M
Pinion
● The following operation shall be conducted Cable

with the starter energized. All the measur- FD215-1007389
ing process must be finished within 30 sec-
onds.
● Set S/W 1 and 2 to the ON position and DC power

energize the starter. The pinion will pop
out and rotate. S/W1
PD
● When the pinion starts rotating, set S/
W 2 to the OFF position within 5 sec-
onds and stop the pinion.
S/W2
S
B
M
P H
CAUTION FD215-1007390
● When S/W 1 and 2 are set to the ON

position, driving coil P and retaining
IO
coil H are both energized. The circuit is
connected in such a manner that termi-
nal B of the starter is de-energized, so
the current flows to the driving coil and
the pinion starts rotating. To avoid the
driving coil from being burned, set S/W
2 to the OFF position within 5 seconds
after the pinion starts rotating.
● Pull out the top of the overdrive clutch

and push it in slightly. Measure the ra- Pinion clearance
dial displacement, i.e. pinion clearance.
● Set switch 1 to the OFF position and

de-energize the starter.
● If measured value exceeds the specified Overdrive clutch

value, replace the lever.
FD215-1007391

9.7.8 Alternator
View A
Terminal E 2
4
Terminal P
Terminal B A
5
Terminal L
4 Terminal R
PD 1
3
FD215-1007392
1) Adjusting bolt 4) Alternator

IO
2) Adjusting shaft 5) Adjusting plate
3) Belt *a: Bracket
CAUTION
● When the starter is energized, the pin-
ion will pop out and start rotating. Be
careful not to touch it.

hot during inspection. Be careful when
touching it.
Assembling sequence
Adjust the tension of the belt.

Inspection standard
Output current at 1500rpm Above 24A – Modify or replace

(*In hot state; output 27 at 2500rpm Above 38A –
4
V) at 5000rpm Above 45A –
Regulator voltage(at 5000rpm; load 5A) 28.5±0.5V – Replace
*Hot state: the state after the alternator has

been running under normal ambient tempera-
ture at 5000 rpm and maximum output load for
30 minutes.
Inspect: Alternator
PD
● The inspection includes: simple inspec-
tion when the alternator is loaded; and
thorough inspection when the alternator is
removed and set on the testing table.
● When abnormality is observed during sim-

ple inspection, conduct a thorough inspec-
tion, disassemble and repair the alternator.
IO
1. Output current
Ammeter Voltmeter
a. Simple inspection A
● Connect the gauges onto the alternator

as illustrated. S/W
Terminal Terminal B
FD215-1007393

CAUTION
● To avoid personal injury, disconnect
the negative terminal of the battery
and insulate it before wiring operation.
When the negative terminal (-) is con-
nected, the battery voltage is always
applied on terminal B.
● When connecting the switches, the

diameter of the cable to be used shall
be the same or larger than the chassis
cable connected to terminal B.
● Connect the switches, and make sure

the voltmeter indicates the voltage of
the battery.
● Start the engine.

PD
● Connect all the light switches on the
machine immediately.
● Increase the engine speed to the value

below and measure the output current
of the alternator.
IO
● Approx. 2500rpm
● The alternator is considered normal

when the measured value is 70% or
above the rated output current.
Rated output
Alternator Voltage Output current

50A 24V 50A

b. Thorough inspection (table testing)

● Connect the alternator as illustrated.
+ -
(+)
(-)
NOTICE
● Use cables with adequate thickness
S/W A
and fix all the connectors securely.
S/W B
B: Terminal B E
E: Terminal E
Load resistance
L: Terminal L (Variable resistance)
B
R: Terminal R
L
Drive motor
● Increase the load resistance to maxi-
mum (nearly no load current)PD R Alternator
FD215-1007394
● Turn switch A and B to the ON position.
● Adjust load resistance and run the al-

ternator at 5000 rpm for 30 minutes in
order to reach the current below.
Rated current
IO
Current
About 45A
● Measure the current of the alternator at

each of the specified speed.
● Disassemble and inspect the alternator

if measured value exceeds the stan-
dard value.

2. Regulating voltage
a. Simple inspection
Ammeter DC power Voltmeter
● Connect the gauges onto the alternator A

as illustrated.
Terminal B
CAUTION
S/W
● To avoid personal injury, disconnect
the negative terminal of the battery
and insulate it before wiring operation. Terminal FD215-1007395
When the negative terminal (-) is con-
nected, the battery voltage is always
applied on terminal B.
● When connecting the switches, the

diameter of the cable to be used shall
be the same or larger than the chassis
cable connected to terminal B.
PD
● Turn off the switches of the lights and
heater so that no electrical load is ap-
plied during inspection.
● Connect the switch and start the en-

gine.
IO
● If the output current is below 5 A when
the engine is running at 2500 rpm,
measure the voltage at terminal B.
When output current is above 5A and

the battery is being charged, measured
value will be a little lower.
At this time, the charging may last for a

little while. Wait for the current to drop
below 5A or replace the battery with a
fully charged one.
● If measured value exceeds the stan-

dard value, conduct an inspection again
on the testing table.

3. Thorough inspection (table testing)

● Connect the alternator as illustrated.
+ -
(+) (-)
B: Terminal B
S/W
E: Terminal E
L: Terminal L
R: Terminal R E Alternator
Alternator drive motor

● Fix the DC power source at 24V
B
● Turn the switch to the ON position.

L
● Run the alternator at a low speed.
R
● Raise the alternator speed to 5000
PD FD215-1007396
rpm and measure the voltage (adjust-
ing voltage) at this speed. At the same
time, keep the current at 5000 rpm at or
below 10A.
● If measured value exceeds the stan-

dard value, proceed with the following:
● Higher than standard value: replace

IO
the regulator.
● Lower than standard value: check

related alternator parts before re-
placing the regulator.

3
4
5
6
7
2
1
Ta
PD 8
11
10
12
9
FD215-1007397
IO
1) Belt roller and fan 7) Front bracket
2) Spacer ring 8) Field coil
3) Rear bearing 9) Stator
4) Rotor 10) Regulator
5) Cover 11) Commutator
6) Front bearing 12) Rear bracket
● Do not remove the front/rear bearings and

the stator unless they are damaged.
Assembling sequence

Inspection standard

8 Field coil resistance (at 20 deg) 6.1 – 7.1Ω – Replace
T Tightening torque
Unit: N·m{kgf·m}

Ta Nut (for installation of belt roller) 132 – 162{13 – 17} –
Rear bracket
Disassemble: Rotor and front bracket PD Front bracket
Stator
● Remove the mounting bolt of the front and
rear brackets. Flat head screw driver
● Insert the screw driver between the front

bracket and the stator.
Bolt
● Pry the rotor and front bracket assembly

with the screw driver so that it parts with
IO
the stator and the rear bracket.
NOTICE
● Be careful not to insert the screw driver
too deep to avoid damage to the stator
coil and a possible short circuit. Coil FD215-1007398

Disassemble: Belt roller

Nut
● Fix the rotor onto the vice, remove the nut Belt roller Claw
and dismantle the belt roller.
NOTICE Vice
Rotor
● When the rotor is hold in the vice, hold
the supporting part of the claw. Dam-
age may result if the claw is hold. Support Support
FD215-1007399
Disassemble: Field coil

Screw B
● Remove screw A (2).
NOTICE PD
● If screw B is removed first, the weight
of the field coil may be applied onto the
connecting part with the regulator. The
regulator is fixed with screw A, so the Screw A
connecting part may get damaged. To
avoid this, remove screw A first.
Field coil
IO
● Remove screw B (3).
FD215-1007400
NOTICE
● When screw B is removed, the field coil
may fall under its own weight. Hold the
coil with your hand.
● Remove the field coil.
NOTICE
● Do not remove the field coil with force.
Otherwise, the connecting part with the
regulator may get hooked by the stator
coil.

Remove: Stator
Cable
● Remove the stator cable from the commu-

tator. The cable is welded onto the commu-
tator diode at 4 points.
NOTICE
● Melt the weld within 5 seconds; other-
Diode
wise, the diode may get damaged. Commutator Stator
FD215-1007401
Inspect: Field coil
nals of the field coil.

PD
● Measure the resistance between the termi-
● Replace the field coil if measured value ex-

ceeds the standard value.
FD215-1007402
Inspect: Stator
IO
● Conduct the following inspection. Replace
the stator in case of any abnormality.
1. Connecting condition between the cables.
● Check if the cables of the stator are in-

terconnected.
FD215-1007403
● If they are not interconnected, it shows
the cable is broken.

2. Connecting condition between the cable

and the core
● Check if the cable and the core are un-

connected.
● If they are connected, the cable is

short-circuited.
FD215-1007404
Inspect: Commutator
● Check if the diode of the commutator is

working normally. Replace the commutator E
if any fault is observed.
PD A
● If the resistance is infinite under two condi- B
tions, the diode is open. C F
D
● If the resistance is near 0W under two con-
ditions, the diode is short-circuited.
G
A, B, C, D: The connecting area of the

stator coil F
E B
E, G: Radiating area
IO
F: Connecting area of the regulator
● Alternate the positive pin and the negative

pin of the gauge twice during inspection.
A D
C G
● When testing with the instrument, the cur- FD215-1007405
rent flowing through the commutator is

lower than normal current. So, the resis-
tance reading on the instrument may be
incorrect.
Besides, when the measuring range is re-

duced, the incorrect reading may increase.
Adjust the instrument to maximum measur-

ing range.

Install: Stator
● Reverse the disassembling sequence of

the stator.
9.7.10 Pre-heating system
● Set the engine start switch to the OFF po-

sition.
Test light
● Connect the testing light onto the heating

plug.
● Check the heating plug if the testing light

PD Heating plug
does not light up.
FD215-1007406
● Replace the heating plug in case of any
abnormality.
9.7.9 Safety relay
● Measure the output voltage between the

terminals of the safety relay.
IO
Safety relay
Terminal P
Terminal R
Terminal E Terminal L
Terminal S
FD215-1007407

Inspection standard
Replace alternator or
When engine stops Below 1V –
wiring
Output voltage
When engine is running
at terminal P
(Idling speed above 12 – 16V – Inspect or replace wiring
600rpm)
Output voltage
When engine is running Approx. 24V – Inspect or replace wiring
at terminal R
Replace safety relay

- when the voltage reach-
Output voltage When engine starts
Below 1V – es the battery voltage
at terminal S (Starting moment)
Inspect and replace all
Output voltage
at terminal L
PD
When engine is running
Below 5V
(but not 0V)
–
parts at 0 V
Replace
Inspect or replace al-
ternator or wiring when
the voltage reaches the
battery voltage
IO

Alternator
E B P
L R
To heating plug relay
To starter relay
terminal L Start switch
Voltmeter OFF
S E L R P (+) R1
AC
(-) START
Ground
+
-
Battery
+
-
PD Main power supply relay
FD215-1007408
3. Inspection of terminal P output voltage ● Start the engine and measure the voltage
when it is running at idle speed (above 600
● Measure the voltage between terminal P of rpm). If the measurement is 0 V, because
safety relay and earth. If measured value the wiring to terminal P is short-circuited,
exceeds the standard value, inspect the the wiring and the connecting part of the
IO
alternator or the wiring. Replace defective connector shall be checked. Replace de-
parts in case of abnormality. fective parts in case of abnormality.

Alternator
E B P
L R
To starter relay
Voltmeter OFF
S E L R P (+) R1
AC
(-) START
Ground
+
-
Battery
+
-
PD Main power supply relay
FD215-1007409
4. Inspection of terminal R output voltage sured value deviates from the standard
value, inspect the wiring. Replace defec-
● Measure the voltage when the start switch tive parts in case of abnormality.
is moved to the ON position. When mea-
IO

Alternator
E B P
L R
To starter relay
Voltmeter OFF
S E L R P (+) R1
AC
(-) START
Ground
+
-
Battery
+ PD
-
Main power supply relay
FD215-1007410
5. Inspection of terminal S output voltage ● Start the engine, and run it at low idle
(above 600 rpm)
● Turn the start switch to the START position
IO
and measure the voltage between terminal ● Measure the voltage at terminal P. Replace
S and the earth when the engine is run- the alternator if measured value exceeds
ning. the standard value.
● Inspect all parts if measured value ex- ● Check that the indicator does not light up
ceeds the standard value. Replace defec- when the engine is idling. Replace the
tive parts in case of abnormality. safety relay when the voltage at terminal P
is normal but the indicator is on.

Alternator
E B P
L R
To starter relay
terminal L Engine start switch
OFF
Voltmeter
(+) S E L R P (+) R1
Voltmeter AC
(-) (-) START
Earth Earth
Indicator
+
-
+ PD
-
Main power supply relay

Battery
FD215-1007411
6. Inspection of terminal L output voltage ● If the measured value is close to the bat-
tery voltage, inspect the alternator or the
● Measure the voltage when the start switch wiring. Replace the defective parts in case
is moved to the ON position. Replace the of abnormality.
IO
safety relay when measured value exceeds
the standard value.

E
G
PPDA
A IONK
BL

E
PPDAG
IOK
AN
BL

SY195-205-215C9 Crawler Hydraulic Excavator System Schematics
System Schematics
10 System Schematics
10.1 Hydraulic System Diagram .................................................................................. 10-3
10.2 Air-Conditioning Electrical Circuit Diagram .......................................................... 10-4
PD
10.3 Fuse Box Relay ................................................................................................... 10-5
10.4 Control Switches and Monitor Electrical Diagram ............................................... 10-6
10.5 Operator Cab Electrical Circuit Diagram.............................................................. 10-7
10.6 Chassis Electrical Circuit Diagram....................................................................... 10-8
IO

System Schematics SY195-205-215C9 Crawler Hydraulic Excavator
PD
IO
WARNING
jury or death.

10.1 Hydraulic System Diagram

P2
A8
A7 PPC LOCK VALVE

TO PnA2
A6 BOOM TO ARM PRIORITY
TO MAIN VALVE Xbp2
A5 BKT CONFLUENCE
TO MAIN VALVE PsP

SWING MECHANISM
A4 SWING PRIORITY
TRANSITION BLOCK ARM

A3
TO MAIN VALVE PbL (P5) (P4)
TO SWIVEL JOINT SIGNAL PORT BOOM DOWN TO MAIN VALVE XBb1
A2 TRAVEL SPEED
A1
XBp2
P1 T SH R2
BKT DUMP TO MAIN VALVE XBk
PaL
BYPASS CUT
(XBp1)
HVa
CCO
PG (ROD) Aa
接(ROD) Aa
TO MAIN VALVE XAb1 CCk
T P BOOM UP TO MAIN VALVE XAb2

P4
BaR
AaR Ba
(HEAD)
ARM2 XAa2
XBa2
XBa1
XAa1 ARM1
BUCKET
LCa
BUCKET Dr7 LCAT2 LCAP2 4-φ1.0

Dr3
BKT DIG TO MAIN VALVE XAk A6 PnA2
P3 (HEAD) Ak AkR
BoR AR
(Bo)
M (ROD) Bk
P2 BOOM BkR AoR (Ao)
R TRAVEL BUCKET XAk
XAb2
XBk
PCK
(XAo) OPTION
(XBo)
BOOM L TRAVEL LCK
LCo
PbL
P1 HVb
(HEAD)
Ab CCb
TO MAIN VALVE XBa1

ARM IN
TO MAIN VALVE XBa2
(XAb2)
Pck BOOM2
PD
AbR BbR
T P P2
(ROD)
Bb
A B XAb1
TO MAIN VALVE XAs BOOM1 PsP PRIORITY
L SWING XBb1 A4
ARM
Dr1 C2
LCb
Pns
SWING
接As
P1 TO MAIN VALVE XAa1 接Bs Atl
Bs
As
ARM OUT TO MAIN VALVE XAa2
P3 Btl
XAs
SWING
TO MAIN VALVE PaL XBs
LEFT
4-φ2.0
XAtl
LCs
SWING TRAVEL XBtl
Py
Dr6
Dr2
P4 CP1
BTR
TO MAIN VALVE XBs Px CPG
R SWING ATR
STRAIGHT
XATR
TRAVEL (PTa)
XBTR
RIGHT
T P
P3 Pz CMR2 TRAVEL
TO MAIN VALVE R TRAVEL XATR MR CMR1
φ0.7 φ0.7
φ0.7 d2 d1
d3
R TRAVEL
L TRAVEL
TRAVEL PPC VALVE

P4
P1
P2
TO MAIN VALVE R TRAVEL XBTR
TO MAIN VALVE L TRAVEL XATL
TO MAIN VALVE L TRAVEL XBTL

IO PG P1 (P0) R1 P3
Psv1
PH1
P2
A1
a1 a2
A2
PH2 Psv2
D1 D2 D2 D1
a3 a4
P2 P3 P3 P2
PT PT
BREAKER SET PRESS16.7±6.9kpa
BYPASS SET PRESS 0.3±0.02Mpa Pi1 Pi2
A
P1 P2
0.25Mpa Engine
FRONT REAR
P1 P4 P4 P1 0.45Mpa
As
A B B A
DR B1 B3 A3
ZX225-1108005
10.2 Air-Conditioning Electrical Circuit Diagram

CONTROL PANEL
ACM
10
6
7
11
17
18
19
21
22
23
26
27
28
29
30
31
32
35
36
1
2
3
4
5
8
9
12
13
14
15
16
20
24
25
33
34
CN-M30 CN-M29
11
10
10
12
13
14
15
16
6
7
1
2
3
4
5
6
7
11
17
18
19
1
2
3
4
5
8
9
8
9
12
13
14
15
16
0.5BrW
0.5BrY
0.5LgR
0.5WY
0.5GO
0.5WO
0.5OW
0.5GW
0.5RY
0.5VR
0.5RW
0.5WR
0.5LO
0.5BG
0.5BW
0.5VW
0.5BR
0.5BL
0.5BY
0.5PB
0.5YB
0.5PG
0.5Sb
0.5R
0.5B
8
0.5LgR
0.5BrW
0.5BrY
0.5BW
0.5WO
0.5OW
0.5GW
0.5WR
0.5VW
0.5WY
0.5RY
0.5GO
0.5BY
0.5RW
0.5LO
0.5BG
0.5YB
0.5PG
0.5VR
0.5BR
0.5PB
0.5BL
0.5Sb
0.5R
0.5B
SWP SWP SWP
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
6
7
1
2
3
4
5
8
CN-M28 CN-M27 CN-M33
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
6
7
1
2
3
4
5
8
1
2
3
4
5
6
7
8
9
10
11
12
7
0.5LgR
0.5BrW
0.5RW
0.5BW
0.5WO
0.5OW
0.5GW
0.5WR
0.5BrY
0.5WY
0.5BG
0.5VW
0.5GO
0.5RY
0.5BY
0.5LO
0.5YB
0.5PG
0.5BR
0.5VR
0.5PB
0.5BL
0.5Sb
0.5R
0.5B
MOTOR - SERVO CONVERSION
MV 2
SENSOR - INTERNAL TEMP.
FACE(DEF)
THI
FOOT
GND
Vz
Pt
6
PD
7
6
5
4
3
2
1
CN-M34
1
2
7
6
5
4
3
2
1
1
2
0.5GW
0.5OW
0.5BW
0.5GO
0.5BR
0.5BR
0.5Sb
050
CN-P15
2 2
1 1
S S 0.5WY FACE
7 7
0.5WR FOOT
6 6
0.5BrW Pt
5 5 5
4 4 SERVO MOTOR - CONVERSION
0.5BW Vz
3 3
2 2
0.5BR GND
1 1 MV I
CN-A30
2 2 0.5YB FRE
7 7
ECC
EC
CN-E06
T HA
1
M
1
S
IO 0.5VW
0.5WO
0.5BW
0.5BR
0.5PB
6
5
4
3
2
1
6
5
4
3
2
1
REC
Pt
Vz
GND
Mcool
SERVO MOTOR -
AIR RECIRCU/FRESH AIR
1
7 7
CN-M26 0.5VR Mhot
6 6
1
12 12 0.5BG Pt
5 5
11 11 4 4 SERVO MOTOR - A/M
TO CN-M26-A TO CN-E06-1 0.85W 0.5BW Vz
10 10 3 3
3 9 9 2B 2 2
0.5BR GND
8 8 1 1 MA M
TO CN-M26-7 TO CN-P15-1 0.5BW
7 7
TO CN-M26-7 TO CN-A30-2 0.5RW
6 6
2Br
5 5 1.25R
20A 4 4
TO CN-M26-2 TO CN-P15-2 3 3 0.5RY 5A
2 2
TO CN-M26-1 TO CN-A30-1 0.5BR
1 1
24V 0.5BR
1 1 SENSOR - LOW TEMP
0.5PG
2 2
THF
1.25G
1.25RL 72C 40C 1.25G

2
1.25RL
1.25RL
2G
2RL
0.5BL
2G
2B
0.5BrY
0.85W
0.5LO
0.5R
0.5R
2RL
0.5lgR
2RL
2Br
2Br
0.5BR
0.5BY
2G
0.5B
4
3
4
3
3
4
2
1
3
4
2
1
2
1
2
1
2
1
3
4
2
1
2
1
3
4
2
1
PROTECTION
FOR TEMP.
2
1
2
1
DRIVING TRANSACTION OF
CIRCUIT INPUT SIGNEL
RL RL VOLTAGE
CORRECTION
R LC C R LB M MB BLC SPH L THW

1 RELAY - BLOWER
RELAY - COMPRESSOR CLUTCH MOTOR - BLOWER SWITCH - HIGH/LOW PRESSURE SENSOR - WATER TEMP
A B C D E F G H I J K L M N

10.3 Fuse Box Relay
HORN RELAY HEADLIGHT RELAY PILOT VALVE RELAY START RELAY PARKING RELAY TOP LIGHT RELAY
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
8 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 1 2 3 4 5
31 23 32 33 24 34 105 27 606 105 11 12 13 64 63 65 72 71 70
PD
6
606 34 32 65 12 0 63 64
70 27 24 23 71 72 33 31 105 13 11
0
13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
5 2 1 2 1 2 1
CN-661F
CN-661M
TO CHASSIS HARNESS CN-461M
TO CAB HARNESS N-161F
CONNECTOR 282080-1（3）
3
Fuse
F1
F2
F3
F4
F5
Fuse Box Harness
Rated Value
20A
10A
5A
15A
5A
System
Start Circuit
Charging Indication
Horn Circuit
Work Lamp
Wiper & Washer
IO 20
F1
22
21
F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F14 F15 F16 F17
10 23 24 25 20 b 26 38 28 29 42 43 49 27 70
22
10
29
42
49
43
1
2
3
4
5
6
7
8
F6 10A Speaker 9
20 10
F7 10A Cab Light
11
F8 20A Air Conditioner 12
21
F9 5A Access Lamp
20 b CN-241F
2
F10 5A Monitor
TO CHASSIS HARNESS CN-441M
F11 20A Controller 23 24 25 26
F14 10A Aux. Controller 27 28 38 70 10
F15 15A Cigar Lighter 1 2 3 4 5 6 7 8 9 10 11 12
F16 10A Solenoid Valve GP

F17 10A Top Light
1 CN-221M
至驾驶室线束CN-121F

10.4 Control Switches and Monitor Electrical Diagram
START SWITCH WORK LAMP SWITCH WIPER SWITCH WASHER SWITCH
TERMINAL B BR ACC R1 R2 C CN-303M CN-304M CN-305M
HEAT 50
1
506
OFF 1 3 5 7 1 3 5 7 1 3 5 7 2
00
33 24 3
8
ON 35 H 25 35 L 36 37 25
35 L
4
START 72 5
70
6
22 13 16 11
18
7
17 8
9
10
7
11
12
CN-331F
TO CAB HARNESS CN-131M
PD
6
25
1
33
2
35 H 3
36
50 506 00 18 16 4
72 70 37 5
0 6
10 14 17 0 10
5 1 2 3 1 3 5 7 1 3 5 7 7
11
8
13
9
CN-302F CN-306M CN-307M 14
10
F-310 F-311 F-312 F-313 22
TO CONTROL DIAL SWITCH PREHEAT SWITCH TOP LIGHT SWITCH 11
24 12
3
CN-7-705M
CAN+
CAN-
1
2
3
CAN+
IO CIGAR LIGHTER
0
1
CN-7-707M
100
SUNLIGHT SENSOR
61
CN-7-706M
60
2
0
22
29
CN-332M
TO CAB HARNESS CN-132F
CN-7-111F
TO CHASSIS HARNESS CN-1-111M
1
2
3
CAN- 4
4 0
5
100
5 6
60 7
6
61 8
24V 7
2 29
24V 8
22
GND 9
CAN+
0 A
10 CAN-
GND B
11
0 C
12 A B
1 CN-7-709 CN-7-112F
A B
120Ω

10.5 Operator Cab Electrical Circuit Diagram
TO FUSE BOX RELAY HARNESS CN-221M TO CHASSIS HARNESS CN-442F TO FUSE BOX RELAY HARNESS CN-661M
9
CN-121F CN-142M CN-161F
TO WIPER MOTOR
CN-112M
TO ACCESS LAMP
1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0 37 0 28 27 28 38 70 22 70 27 24 23 71 72 33 31 0 105
1020 b23 24 25 26 50 506 0060 a 57 18 17 61a 14 13 0 10 18 13 11
CN-131M CN-113M
TO CONTROL SW
8
MONITOR HARNESS CN-331F 23
2 1
2 CN-104M
50 31
1 1 TO HORN S/W
2 506
00
3
35 L
4 105
72 1 CN-106F
7
5 TO PILOT S/W
70 27 2
6
7 18
8 17
9
10 1
PD
6
11 25 2
36
12 3 CN-110M
TO WIPER HARNESS
35 H 4
CN-132F
TO CONTROL SW MONITOR HARNESS CN-332M 35 L 5
25 6
5 1
2 33
3 35 H
57
4 36
1
5 37 61a
4
4
3
6
7
8
9
10
11
12
00
10
11
13
14
22
24
IO 60 a
0
38
38 8
26
5
6
7
CN-207F
TO A/C PANEL
8
CN-107M 0 7
TO RADIO PANEL
20 b 71 6
1
R+ 0 5 CN-150M
2 L- TO SPEAKER,
2
L+ 4
3 L+
CAB LAMP HARNESS
4 0 3
R-
5 20 b 2
R- R+
6 1
L-
7
1
TO CONSOLE GND

10.6 Chassis Electrical Circuit Diagram
CN-616F CN-441M CN-501M CN-1-111M CN-442F

CN-152M CN-153M
GROUND 1 1 2 1 2 TO FUSE BOX RELAY HARNESS CN-241F TO CONTROL SW MONITOR HARNESS CN-7-111F TO CAB HARNESS CN-142M
2 0 TO GPS
9
3 CN-204F CN-412F CN-7-112F F-106 CN-101M F-108 CN-113M
24V POWER 4
2 1 CN-152M
5
6
42
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 2 1
43 0 CAN+ B
1 2 3 A B C
CAN- CAN+ CAN- 508 509 510 42 511 2 1
7
8
22 29 42 49 43 20 20 21 21 0 22 29 0 49 60a 61a 50 506 00 60 a 57 18 17 61a 14 13 0 10
9
240Ω/0.25W
FUEL LEVEL INPUT 10
11
509
AIN16 12 T-119
13 B TO PWR GND
14
T-110
15
507 0
T-102
16 13
8 17 T-101TO BAT RELAY
RPM SENSOR INPUT 18
20
19
108 B T-104
20
21
22 B06 21
23 B05 T-103
B07 1 2
24 CN-702F
25
57
26 T-107TO COMPRESSOR CLUTCH
27 0
28 0 57 T-111
1 2
WATER TEMP INPUT 29
30 510
HYD OIL TEMP INPUT
31 511 CN-109M
7 32
21 T-108
FUEL CTRL DIAL VOLT 33
34
506 16 TO PREHEAT FUSE
35
36
T-109
37
RMP SENSOR INPUT
38
108 A
39
108 A
40
B04 CN-448M
41
42 B07 108 B
43
B08 50 1
44
507 2
45
46
MT- 3 CN-445M
47 4 TO THROTTLE MOTOR
PD
M OIL PRESS INPUT
6 PRESS INPUT - TRAVEL(L) 48
508 00 5
200 MT+
BUCKET DUMP PRESS INPUT 49
204 6
BOOM LOWER PRESS INPUT 50
207 17
ARM OUT PRESS INPUT 51 TO PREHEAT FUSE
202 16
REAR PUMP PRESS INPUT 52
53
502 17
s GND
00
s GND 54
00 18 TO PREHEAT RELAY
s PWR 55
50 0 12
56
CAN- 57
CAN- 21
58 ALTERNATOR TERM B
CAN+ 59 10
60
CAN+ 14 ALTERNATOR TERM L/R
61 B01 47
62
ALTERNATOR TERM P
5 63
64 12a 1
65 14 2
PRESS INPUT - TRAVEL (R) 66 10 CN-613F
67
201 3
SWING PRESS INPUT
BUCKET CURL PRESS INPUT 68
208 47 4 TO SAFETY RELAY
BOOM RAISE PERSS INPUT 69
205 5
206 0 6
ARM IN PRESS INPUT 70
FRONT PUMP PRESS INPUT 71
203
501 22 1
s GND 72
00 B01 1
s PWR 73
50 B02 2 64 2
74
63 3 CN-801F
3
s PWR
CAN+
CAN-
CN-615F
SPEED CONTROL OUTPUT
F. PUMP PRPTL VALVE OUTPUT
R. PUMP PRPTL VALVE OUTPUT

75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
50
CAN+
CAN-
B02
B03
B01
607
702
703
B03 3
B04 4
B05 5
B06 6
B07 7
B08 8
42
0 2
1
CN-158M
CALIBRATOR CONNECTOR
CN-159M
IO F PUMP PRESS SENSOR R PUMP PRESS SENSOR
50
CN-115M
A B C
00 501
CN-116M
50
A B C
00 502
CONNECTOR 282080-1
0 606
1 2
0 607
1 2
702
703
0
0 4
65 5
6
2
TO PARK MOTOR
CN-113F
F PUMP SOL
PROP VALVE
CN-114F
R PUMP SOL
PROP VALVE
95 606
96
1
SWING PRTY PRPTL VALVE OUTPUT 97
CN-136F
608
BUCKET CONFL PRPTL VALVE OUTPUT 98
604 0 PILOT SOL VALVE
99 2
100
101
102 604 1
103
CN-134F
FUEL CTRL MOTOR SIGNAL OUTPUT 104
MT+ BKT CONFLUENCE
105 0 SOL VALVE
2 106
2
107
108
608
109 1
110
CN-133F
111 SWING PRIORITY
FUEL CTRL MOTOR SIGNAL OUTPUT 112 0 2 SOL VALVE
GROUND 113
GROUND 114
0 606 34 32 65 12 0 63 64 50 00 50 00 201 50 00 202 50 00 208 50 00 205 50 00 207 50 00 206 50 00 204 50 00 203
115
0
607
116
117 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A B C A B C A B C A B C A B C A B C A B C A B C A B C 1 CN-131F
24V POWER 118
42
HI/LO TRAVEL
24V POWER 119
42 0 2 SPD SOL VALVE
120
CN-120M CN-121M CN-122M CN-123M CN-124M CN-125M CN-126M CN-127M CN-128M
1 121
CN-461M CN-112M 12 12 a 0 21
122
0 0 34
1 2 2 1
L TRAVEL R TRAVEL ARM-OUT SWING BKT DIG BOOM DOWN BOOM UP BKT DUMP ARM IN
1 2 1 2 TO FUSE BOX RELAY HARNESS CN-661F 282104-1
CN-111F PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR
TO WORK LAMP F-104 F-103 TO START MOTOR
CN-102M CN-106M TO HORN

LATEST SY195-205-215C9-shop MANUAL-20130104

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LATEST SY195-205-215C9-shop MANUAL-20130104

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www.sanygroup.

com Quailty Changes the World

SANY HEAVY MACHINERY LIMITED

Tel: (86) 21 5700 8518

Documentation No.: B06T03ENAM1-SY195/205/215C9

Shop Manual - December 2012 I

2.2.16 Fire Extinguisher and Emergency Exits ..................................................... 2-14

4 Structure and Function

II Shop Manual - December 2012

4.2.3 Swing machinery.......................................................................................... 4-10

Shop Manual - December 2012 III

4.6.4.1 Operation drawing............................................................................... 4-86

IV Shop Manual - December 2012

4.9.1 Control function .......................................................................................... 4-165

6 Testing and Adjusting

Shop Manual - December 2012 V

6.3.1 Testing............................................................................................................ 6-7

VI Shop Manual - December 2012

7.3.6 A/AMP type connector ................................................................................. 7-24

8 Disassembly and Assembly

Shop Manual - December 2012 VII

8.11 Final Drive AS - Disassemble and Assemble ....................................................... 8-35

VIII Shop Manual - December 2012

8.23.2 Installation .................................................................................................. 8-87

Shop Manual - December 2012 IX

8.36.3 Installation ................................................................................................ 8-148

X Shop Manual - December 2012

9.2.2.6 Piston .................................................................................................. 9-10

Shop Manual - December 2012 XI

9.2.12.4 Assembling method........................................................................... 9-68

XII Shop Manual - December 2012

9.4.2.2 Fuel tank ........................................................................................... 9-121

Shop Manual - December 2012 XIII

9.5.4.4 Release air in the cooling system ..................................................... 9-172

XIV Shop Manual - December 2012

9.7.3.1 Alternator with a neutral diode .......................................................... 9-204

Shop Manual - December 2012 XV

XVI Shop Manual - December 2012

Shop Manual - December 2012 1-1

1-2 Shop Manual - December 2012

1.1 How to Read the Shop Manual

1. Composition of shop manual

This shop manual contains the necessary

This section provides an overview of what is

This section covers basic shop safety infor-

Technical specification of work equipment and

Structure and function

This section explains the structure and func-

This section explains the standard values for

Shop Manual - December 2012 1-3

values in testing and adjusting and to judge

Testing and adjusting

This section details the inspection before and

This section explains the way to detect faulty

Disassembly and assembly

This section explains the procedures as well

This section provides hydraulic circuit dia-

2. Revision and distribution

Any additions, revisions, or other change of

1-4 Shop Manual - December 2012

In this shop manual, the units are indicated

Shop Manual - December 2012 1-5

1.2 Terms for Maintenance Standard

The maintenance standard values necessary