SANY Crawler Hydraulic Excavator SY215CLC (CUMMINS QSB6.7 engine). Shop Manual - page 25

Troubleshooting

SY215C

LC

7-26

7.4.7  A/AMP type connector

              Male (Plug)

Female (socket)

Part No.: 282104-1

Part No.: 282080-1   (No. of pin: 2) 

282105-1

282087-1           (No. of pin: 3) 

174354-2

174352-2    (No. of pin: 2) 

1473252-1

1473255-1    (No. of pin: 40) 

1473244-1

1473247-1    (No. of pin: 81) 

Troubleshooting

SY215C

LC

7-27

7.4.8  DT type connector 

Housing (Plug)

Housing (socket)

DT06-3S

DT04-3P         (No. of pin: 3) 

DT06-6S

DT04-6P         (No. of pin: 6) 

DT06-8S

DT04-8P       (No. of pin: 8) 

DT06-12S

DT04-12P     (No. of pin: 12) 

B

A

C

1

2

3

6

5

4

8

5

1

4

12

7

1

6

A

B

C

1

2

3

6

5

4

8

5

4

1

7

12

6

1

Troubleshooting

SY215C

LC

7-28

7.5  

Failure Symptoms and Service Codes

Service code

Description

E-

Troubleshooting of electrical system

H-

Troubleshooting of hydraulic and mechanical systems

No.

Symptom

Service code

Action to be taken concerning Service Code, User Code and Failure Code

1 Display User Code in monitor panel

2 Display Service Code in electrical system after checking failure history

3 Display Failure Code in mechanical system after checking failure history

Engine-related failure

4 Engine does not start up easily. (It always takes some time to start up the engine)

5 Engine does not start

E-1

6 Color of exhaust gas is too dark.(Incomplete combustion)

7 Engine pickup is poor.

8 Engine runs rough or is unstable

E-2

9 Engine speed drops sharply or engine stalls

H-2

10 Auto idle not functioning

E-4

H-5

11 Excessive engine oil consumption, or color of exhaust gas is blue

12 Premature engine oil contamination

13 Excessive fuel consumption

14 Engine cooling water is mixed with engine oil, spurts out or decreases

15 Engine oil amount increases. (Water or fuel gets in)

16 Abnormal noises are heard

17 Excessive vibrations are caused

Failure related to work equipment, swing and travel

18 Power supply of machine cannot be cut off

E-3

19 Abnormal noise in hydraulic pump

H-4

20 Work equipment, swing, and travel systems do not work

H-3

21 Work equipment speed slow, or swing and travel speeds slow

H-1

22 Travel speed drops considerably while swinging and travelling  

H-13

Work equipment-related failure

23 Work equipment does not work

E-6

24 Work equipment cylinders no response in separate operation

H-9

25 Work equipment drifts excessively

H-10

26 Work equipment moves sluggishly

H-11

27 Other work equipment moves while single oil circuit is relieved

H-12

Troubleshooting

SY215C

LC

7-29

No.

Symptom

Service code

28 Boom-raise 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 deviates during travel

H-14

34 Machine is not steered well or steering power is low

H-16

35 Travel speed cannot be changed

H-17

36 Travel system fails (only at one side)

H-18

Swing-related failure

37 Swing operation fails

H-19

38 Swing acceleration poor or swing speed low

H-20

39 Upper structure overruns remarkably when it stops swinging

H-21

40 Large shock is produced when upper structure stops swinging

H-22

41 High noise is produced when upper structure stops swinging

H-23

42 Swing drift excessive

H-24

Monitor panel-related failure

43 Blank monitor display

E-11

44 Monitor displays nothing

E-12

45 Incorrect engine coolant reading

E-14

46 Incorrect fuel level reading

E-15

47 Incorrect arm-in pilot pressure reading

E-17

48 Incorrect arm-out pilot pressure reading

E-18

49 Incorrect boom-raise pilot pressure reading

E-19

50 Incorrect boom-lower pilot pressure reading

E-20

51 Incorrect bucket-curl pilot pressure reading

E-21

52 Incorrect bucket-dump pilot pressure reading

E-22

53 Incorrect swing pilot pressure reading

E-23

54 Incorrect left travel pilot pressure reading

E-24

55 Incorrect right travel pilot pressure reading

E-25

Other failure

56 Preheating function fails

E-5

57 Wiper does not work

E-16

Troubleshooting

SY215C

LC

7-30

7.5.1  

Troubleshooting with an failure code

Information in troubleshooting table .......................................................................................... 7-31
E111 Controller memory error (FROM) ..................................................................................... 7-32
E015 Power supply voltage abnormal ....................................................................................... 7-33
E116 Controller internal temperature abnormal ......................................................................... 7-34
E017 Sensor 5V power output abnormal................................................................................... 7-35
E118 Communication abnormal between controller and monitor .............................................. 7-36
E320 Front pump output pressure abnormal ............................................................................. 7-37
E321 Rear pump output pressure abnormal ............................................................................. 7-38
E322 Arm-in pilot pressure abnormal ........................................................................................ 7-39
E323 Arm-out pilot pressure abnormal ...................................................................................... 7-40
E324 Boom-up pilot pressure abnormal .................................................................................... 7-41
E325 Boom-down pilot pressure abnormal ............................................................................... 7-42
E326 Bucket-dig pilot pressure abnormal.................................................................................. 7-43
E327 Bucket-dump pilot pressure abnormal ............................................................................. 7-44
E328 Swing pilot pressure abnormal ......................................................................................... 7-45
E329 Left travel pilot pressure abnormal ................................................................................... 7-46
E330 Right travel pilot pressure abnormal ................................................................................ 7-47
E231 Fuel control dial set voltage abnormal ............................................................................. 7-48
E237 Hydraulic oil temperature abnormal ................................................................................. 7-49
E450 Front pump proportional solenoid coil current abnormal A ............................................... 7-50
E450 Front pump proportional solenoid coil current abnormal B .............................................. 7-51
E451 Rear pump proportional solenoid coil current abnormal A ............................................... 7-52
E451 Rear pump proportional solenoid coil current abnormal B ............................................... 7-53
E452 Swing priority proportional solenoid coil current abnormal A ........................................... 7-54
E452 Swing priority proportional solenoid coil current abnormal B ........................................... 7-55
E453 Bucket con

fl

 uence proportional solenoid coil current abnormal A .................................... 7-56

E453 Bucket con

fl

 uence proportional solenoid coil current abnormal B ................................... 7-57

E455 Boom priority 2 proportional solenoid coil current abnormal A ......................................... 7-58
E455 Boom priority 2 proportional solenoid coil current abnormal B ........................................ 7-59
E460 Dual speed travel solenoid valve abnormal ..................................................................... 7-60

Troubleshooting

SY215C

LC

7-31

Information in troubleshooting table

Failure Code

Service Code

Trouble

Trouble description

Display on monitor

—

Failure description

Failure is described on the monitor display. 

Response from controller

When failure is detected, the controller has taken action to protect the affected 
system or equipment. 

Symptom of machine

Symptom that is shown on the machine due to action of controller. 

Possible causes and standard value in normal state

Cause

Standard value in normal state and remarks on troubleshooting

1

Possible causes 
of trouble (Given 
numbers are ref-
erence numbers, 
which do not indi-
cate priority)

<Inclusion>

 

●

Standard value under normal condition can be used to judge pos-
sible causes

 

●

Reference for passing the above "Good" or "No Good" judgement

<Symptom of Wiring Harness Failure>

 

●

Open circuit

Faulty contact with connector or open circuit in wiring harness 

 

●

Faulty grounding

An ungrounded wiring is grounded. 

 

●

Short circuit

A wiring has mistaken contact with a 24 V electric circuit. 

2

3

4

5

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. 

Troubleshooting

SY215C

LC

7-32

E111 Controller memory error (FROM)

Failure Code

Service Code

Trouble Controller memory fails and the system slows down. 

11

E111

Failure description

When the power is on, abnormality is detected by checking through FROM sum-
mation and RAM veri

fi

 cation. 

Response from controller Stop the operation of motor and solenoid coil. 

Symptom of machine

Engine acceleration fails and the machine acts slowly. . 

Possible causes and standard value in 

normal state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Internal failure 
of controller

No troubleshooting can be done for failure occurs in the inner of controller. (If 
this failure occurs, replace the controller.)

2

3

 

4

5

Troubleshooting

SY215C

LC

7-33

E015 Power supply voltage abnormal

Failure Code

Service Code

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. 
Symptom of machine

Engine acceleration fails and the machine acts slowly. 

Possible causes and standard value in normal 

state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Failure of 

power sup-

ply

 

★

 Turn engine start switch to OFF position. Keep it at OFF position to perform 
troubleshooting. 
Measure battery voltage

Voltage

≤

25V

2

Alternator 

abnormal

 

★

Turn engine start switch to OFF position. And Then, keep the engine running 
to perform troubleshooting. 

Measure the voltage between the alternator termi-
nal B and ground. 

Voltage

About 28V

3

4

5

ZX215-1005072

13

D0

：

P600G

11

F1-20A

13

10

S

E

M1

M

L

R

B

E

10a

K3 START RELAY

R2

HEAT

ON

OFF

TERMINAL

R1

START

0

21

20

22

k1

B1

+

-

-

+

21

ACC

C

B BR

11

12

F2-5A

105

0

22

0

ALTERNATOR

G

START MOTOR

0

14

HL2: CHARGING INDICATOR 

DIODE 6A10

START SWITCH

BATTERY RELAY

BATTERY

Troubleshooting

SY215C

LC

7-34

E116 Controller internal temperature abnormal

Failure Code

Service Code

Trouble

Internal temperature of controller is abnormal. Engine 
acceleration fails and the machine acts slowly.

16

E116

Failure description

Internal temperature of controller keeps above 80°C or below -30°C for 10 sec-
onds when the power is on. 

Response from controller The controller stops the motor and the solenoid coil. 
Symptom of machine

Engine acceleration fails and the machine acts slowly. 

Possible causes and standard value in nor-

mal state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Internal 

failure of 

controller

No troubleshooting can be done for failure occurs in the inner of controller. (If this 
failure occurs, replace the controller.)

2

3

  

4

5

Troubleshooting

SY215C

LC

7-35

E017 Sensor 5V power output abnormal

Failure Code

Service Code

Trouble

Abnormal output of power supply in sensor

17

E017

Failure description

The controller detects out over current or short circuit of sensor power source 
output when the power is on. 

Response from controller Only output alarm is enabled. 
Symptom of machine

—

Possible causes and standard value in normal 

state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Short circuit 

in harness 

(grounded)

 

★

 Turn engine start switch to OFF position. Keep it at OFF position to perform 
troubleshooting. 

Measure the resistance between pin 56, pin 75, pin 74 of 
controller KC-MB and the ground.  

Resistance

≥

2M

Ω

2

Internal 

failure of 

controller

No troubleshooting can be done for failure occurs in the inner of controller. (Except 
for the above reasons, the controller must be replaced in case of failure.)

3

 

4

5

Troubleshooting

SY215C

LC

7-36

E118 Communication abnormal between controller and monitor

Failure Code

Service Code

Trouble

Abnormal communication between controller and 
monitor

18

E118

Failure description

Communication of monitor is interrupted for 5 consecutive times when the 
power is on.

Response from controller Only output alarm is enabled.  

Symptom of machine

—

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Failure of CAN 

resistance

 

★

 Turn engine start switch to OFF position. Keep it at OFF position to 
perform troubleshooting.

 

Between CN-7-709 

①

 and 

②

Resistance

60

Ω

2

Open circuit of 

harness

 

★

 Turn engine start switch to OFF position. Keep it at OFF position to 
perform troubleshooting. 

Unplug the controller and measure the resis-
tance between pin 60 and CN-7-705 

③

 

Resistance

≤

1

Ω

Unplug the controller and measure the resis-
tance between pin 78 and CN-7-705 

④

≤

1

Ω

3

Internal failure 

of controller

No troubleshooting can be done for failure occurs in the inner of controller. 
(Except for the above reasons, the controller must be replaced in case of 
failure.)

4

5

60

78

 CN-7-709

 CN-7-705

CN-1-111

CN-441

3
4
8
9

10
12

3
4
8
9

10
12

3
4
8
9

10
12

29

29

20

21

22

22

0

1

1

2
3

3

1

3

1
2
3

F1 20A

F10 5A

CANH

CANH

CANH

CANL

CANL

CANL

1

2

1

2

ZX215-1005073

MONITOR

CAB

CHASSIS HARNESS

CONTROLLER

120

Ω

 RESISTANCE

PWR

PWR

Troubleshooting

SY215C

LC

7-37

E320 Front pump output pressure abnormal

Failure Code

Service Code

Trouble

Front pump output pressure is abnormal. Only output 

alarm is enabled. .

20

E320

Failure description

A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec 
when the power is on. 

Response from controller Only output alarm is enabled.  
Symptom of machine

—

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Failure of 5V 

power supply

 

★

 Turn engine start switch to OFF position. Keep it at OFF position to 
perform troubleshooting. 

Between CN-446M A and B

Voltage

About 5V

2

Open circuit of 

signal wire

 

★

 Turn engine start switch to OFF position. Keep it at OFF position to 
perform troubleshooting.

 

Between CN-446M C and pin 72 of controller

Resistance

≤

1

Ω

Between CN-446M B and ground

≤

1

Ω

3

Short circuit 

of signal wire 

(grounded)

 

★

 Turn engine start switch to OFF position. Keep it at OFF position to 
perform troubleshooting.

 

Between CN-446M C and ground

Resistance

≥

2M

Ω

4

Failure of sen-

sor

 

★

 Turn engine start switch to OFF position. Then, keep it at ON position to 
perform troubleshooting.

 

Between CN-446M C and ground

Voltage

0.5±0.2V

5

5V

72

54

56

C

B

A

CN-446M

501#

00#

50#

ZX215-1005074

FRONT PUMP 
PRESS. SENSOR

FRONT PUMP PRESSUSRE
SIGNAL COLLECTING PORT

SIGNAL

GND WIRE

CONTROLLER

CAB

CHASSIS HARNESS

5V PWR SUPPLY

GND WIRE

Troubleshooting

SY215C

LC

7-38

E321 Rear pump output pressure abnormal

Failure Code

Service Code

Trouble

Reading of rear pump output pressure is abnormal. 
Only output alarm is enabled. .

21

E321

Failure description

A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec 
when the power is on. 

Response from controller Only output alarm is enabled. 
Symptom of machine

—

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Failure of 5V 

power supply

 

★

 Turn engine start switch to OFF position. Then, keep it at ON position to 
perform troubleshooting.

 

Between CN-447M A and B

Voltage

About 5V

2

Open circuit of 

signal wire

 

★

 Turn engine start switch to OFF position. Keep it at OFF position to 
perform troubleshooting.

 

Between CN-447M C and pin 53 of controller

Resistance

≤

1

Ω

Between CN-447M B and ground

≤

1

Ω

3

Short circuit 

of signal wire 

(grounded)

 

★

 Turn engine start switch to OFF position. Keep it at OFF position to 
perform troubleshooting. 
Between CN-447M C and ground 

Resistance

≥

2M

Ω

4

Failure of sen-

sor

 

★

 Turn engine start switch to OFF position. Then, keep it at OFF position to 
perform troubleshooting. 
Between CN-447M C and ground  

Voltage

0.5±0.2V

5

5V

53

54

56

C

B

A

CN-447M

502#

00#

50#

ZX215-1005075

SIGNAL

GND WIRE

CONTROLLER

5V PWR SUPPLY

GND WIRE

CAB

CHASSIS HARNESS

REAR PUMP 
PRESS. SENSOR

REAR PUMP PRESSURE 
SIGNAL COLLECT PORT

Troubleshooting

SY215C

LC

7-39

E322 Arm-in pilot pressure abnormal

Failure Code

Service Code

Trouble

Arm-in pilot pressure is abnormal. Only output alarm 
is enabled. .

22

E322

Failure description

A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec 
when the power is on. 

Response from controller Only output alarm is enabled.  
Symptom of machine

The arm in motion is slow. 

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Failure of 5V 
power supply

 

★

 Turn engine start switch to OFF position. Then, keep it at ON position to 
perform troubleshooting. 
Between CN-428M A and B

Voltage

About 5V

2

Open circuit 
of signal wire

 

★

 Turn engine start switch to OFF position. Keep it at OFF position to perform 
troubleshooting. 
Between CN-428M C and pin 71 of controller

Resistance

≤

1

Ω

Between CN-428M B and ground

≤

1

Ω

3

Short circuit 
of signal wire 
(grounded)

 

★

 Turn engine start switch to OFF position. Keep it at OFF position to perform 
troubleshooting.

 

Between CN-428M C and ground

Resistance

≥

2M

Ω

4

Failure of 
sensor

 

★

 Turn engine start switch to OFF position. Then, keep it at ON position to 
perform troubleshooting.

 

Between CN-428M C and ground

Voltage

0.5±0.2V

5

5V

71

54

56

C

B

A

CN-428M

203#

00#

50#

ZX215-1005076

SIGNAL

GND WIRE

CONTROLLER

GND WIRE

5V PWR SUPPLY

CAB

CHASSIS HARNESS

ARM-IN PILOT 
PRESS. SENSOR

ARM-IN PILOT PRESSURE
SIGNAL COLLECTING PORT

Troubleshooting

SY215C

LC

7-40

E323 Arm-out pilot pressure abnormal

Failure Code

Service Code

Trouble

Reading of arm-out pilot pressure is abnormal. Only 
output alarm is enabled. 

23

E323

Failure description

A pressure feedback voltage other than 0.25 – 4.75V keeps more than 
200msec when the power is on. 

Response from controller Only output alarm is enabled.  
Symptom of machine

Arm-out motion is slow. 

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Failure of 5V 

power supply

 

★

 Turn engine start switch to OFF position. Then, keep it at ON position to 
perform troubleshooting.

 

Between CN-422M A and B

Voltage

About 5V

2

Open circuit 

of signal wire

 

★

 Turn engine start switch to OFF position. Keep it at OFF position to perform 
troubleshooting. 
Between CN-122M C and pin 52 of controller

Resistance

≤

1

Ω

Between CN-422M B and ground

≤

1

Ω

3

Short circuit 

of signal wire 

(grounded)

 

★

  Turn engine start switch to OFF position. Keep it at OFF position to perform 
troubleshooting.

 

Between CN-422M C and ground

Resistance

≥

2M

Ω

4

Failure of sen-

sor

 

★

  Turn engine start switch to OFF position. Then, keep it at ON position to 
perform troubleshooting.

 

Between CN-422M C and ground

Voltage

0.5±0.2V

5

5V

52

54

56

C

B

A

CN-422M

202#

00#

50#

ZX215-1005077

SIGNAL

CONTROLLER

GND WIRE

5V PWR SUPPLY

GND WIRE

CAB

CHASSIS HARNESS

ARM-OUT PILOT PRESSURE
SIGNAL COLLECTING PORT

ARM-OUT PILOT 
PRESS. SENSOR

Troubleshooting

SY215C

LC

7-41

E324 Boom-up pilot pressure abnormal

Failure Code

Service Code

Trouble

Reading of boom-raise pilot pressure is abnormal. 
Only output alarm is enabled. .  

24

E324

Failure description

A pressure feedback voltage other than 0.25 – 4.75V keeps more than 
200msec when the power is on. 

Response from controller Only output alarm is enabled.  
Symptom of machine

Boom-raise motion is slow. 

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

1

Failure of 5V 

power supply

 

★

 Turn engine start switch to OFF position. Then, keep it at ON position to 
perform troubleshooting.

 

Between CN-426M A and B 

Voltage

About 5V

2

Open circuit 

of signal wire

 

★

  Turn engine start switch to OFF position. Keep it at OFF position to perform 
troubleshooting. 
Between CN-426M C and 70 pin of controller

Resistance

≤

1

Ω

Between CN-426M B and ground

≤

1

Ω

3

Short circuit 

of signal wire 

(grounded)

 

★

  Turn engine start switch to OFF position. Keep it at OFF position to perform 
troubleshooting.

 

Between CN-426M C and ground

Resistance

≥

2M

Ω

4

Failure of 

sensor

 

★

 Turn engine start switch to OFF position. Then, keep it at ON position to 
perform troubleshooting.

 

Between CN-426M C and ground

Voltage

0.5±0.2V

5

5 V

70

54

56

C

B

A

CN-426M

206#

00#

50#

ZX215-1005078

SIGNAL

CONTROLLER

GND WIRE

5V PWR SUPPLY

GND WIRE

CAB

CHASSIS HARNESS

BOOM-RAISE PILOT
PRESS. SENSOR

BOOM-RAISE PILOT PRESS.
SIGNAL COLLECTING PORT