SANY Crawler Hydraulic Excavator SY365H-9, SY365BH-9. Shop Manual (2014)

7-43

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E435 Rear pump proportional solenoid current abnormal (A)

Failure code

Failure symptom

Rear pump proportional solenoid current is abnor-
mal. The system operates slowly.

E435

Failure description

Abnormality occurs in loaded circuit of proportional solenoid. Current which is
above 1.3A lasts for 3 second. Differential current occurs in drive protection
loop.

Controller reaction

Stop the solenoid when failure is detected. Power supply must be restored.

Symptom on machine System operates slowly.

Possible causes and standard values

Cause

Standard values and troubleshooting references

Open circuit of

harness

Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

Between CN-113F

and pin 17 of controller

Resistance

Under 1

Between CN-113F

and ground

Under 1

Short circuit

of harness

(grounded)

Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

Between CN-113F

and wire 0#

Resistance Above 1M

Failure of pro-

portional valve

coil

Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

Unplug the connector CN-113F, and measure the

resistance between solenoid valve's

and

Resistance

17.5

Failure of con-

troller

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

this failure.)

CN-151F

703#

ZX225-1105015

Controller

Rear pump SV
signal output port

GND

Rear pump SV

Signal

GND

Operator station

Chassis harness

Fig. 7-29

7-44

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E436 Front pump proportional solenoid current abnormal (B)

Failure code

Failure symptom

Front pump proportional solenoid current is ab-
normal. The system operates slowly.

E436

Failure description

Abnormality occurs in loaded circuit of proportional solenoid. Current which is
under 0.2 A lasts for 3 seconds and PWM output is greater than 10V.

Controller reaction

Stop the solenoid when failure is detected. Power supply must be restored.

Symptom on machine System operates slowly.

Possible causes and standard values

Cause

Standard values and troubleshooting references

Open circuit of

harness

Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

Between CN-150F

and pin 28 of controller

Resistance

Under 1

Between CN-150F

and ground

Under 1

Short circuit

of harness

(grounded)

Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

Between CN-150F

and wire 0#

Resistance Above 1M

Failure of pro-

portional valve

coil

Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

Unplug the connector CN-150F, and measure

the resistance between solenoid valve's

and

Resistance

17.5

Failure of con-

troller

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

this failure.)

CN-150F

702#

ZX225-1105014

Controller

Front pump SV
signal output port

GND

Operator station

Chassis harness

Front pump SV

Signal

GND

Fig. 7-30

7-45

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E437 Rear pump proportional solenoid current abnormal (B)

Fig. 7-31

Failure code

Failure symptom

Rear pump proportional solenoid current is abnor-
mal. The system operates slowly.

E437

Failure description

Abnormality occurs in loaded circuit of proportional solenoid. Current which is
under 0.2 A lasts for 3 seconds and PWM output is greater than 10V.

Controller reaction

Stop the solenoid when failure is detected. Power supply must be restored.

Symptom on machine System operates slowly.

Possible causes and standard values

Cause

Standard values and troubleshooting references

Open circuit of

harness

Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

Between CN-151F

and pin 17of controller

Resistance

Under 1

Between CN-151F

and ground

Under 1

Short circuit

of harness

(grounded)

Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

Between CN-151F

and wire 0#

Resistance Above 1M

Failure of pro-

portional valve

coil

Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

Unplug the connector CN-151F, and measure

the resistance between solenoid valve's

and

Resistance

17.5

Failure of con-

troller

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

this failure.)

CN-151F

703#

ZX225-1105015

Controller

Rear pump SV
signal output port

GND

Rear pump SV

Signal

GND

Operator station

Chassis harness

7-46

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E543 Engine speed abnormal

Failure code

Failure symptom

Engine speed is abnormal. Only alarm output is
effective.

E543

Failure description

CPU detects out that engine speed is too low (below 100 rpm).

Controller reaction

Only alarm output is effective. The alarm resets automatically when conditions
become normal.

Symptom on machine

——

Possible causes and standard values

Cause

Standard values and troubleshooting references

Normal condi-

tion

Code 43 will be displayed on the monitor when the engine start switch is

turned from the OFF position to the ON position.

Open circuit of

harness

Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

Between CN-125M

and pin 16 of controller

Resistance

Under 1

Between CN-125M

and pin 6 of controller

Under 1

Short circuit

of harness

(grounded)

Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

Between CN-125M

and ground

Resistance Above 1M

Failure of sen-

sor

Turn engine start switch to the OFF position before troubleshooting.
Keep it in the OFF position while troubleshooting is performed.

Unplug the connector CN-125M, and measure

the resistance between

and

of the speed

sensor.

Resistance

2.3 0.2

CN-125M

ZX225-1105017

108A

108B

Controller

Engine speed collection

GND

Engine speed sensor

Signal

GND

Operator station

Chassis harness

Fig. 7-32

7-47

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E244 Fuel control dial setting voltage abnormal

Failure code

Failure symptom

Fuel control dial setting voltage is abnormal and engine

returns auto deceleration.

E544

Failure description

When power is on, voltage of fuel control dial other than 0.25-4.75V lasts for over

200 msec.

Controller reaction

Throttle is moved to idle position.

Symptom on machine

Engine returns auto deceleration.

CN-7-113M

CN-209F

CN-501F

50#

506#

ZX225-1105018

Sensor 5V

GND

Fuel control dial
setting voltage

Yellow

Red

Blue

Fuel
control
dial

Operator station

Possible causes and standard values

Causes

Standard values and troubleshooting references

5V power

failure

Turn the start switch to the OFF position before troubleshooting. Keep it in the
ON position while troubleshooting is performed.

CN-501F

and

Volt

About 5V

Open circuit

of signal

line

Turn the start switch to the OFF position before troubleshooting. Keep it in the
OFF position while troubleshooting is performed.

CN-501F

and controller pin19

Resistance

Under 1

Short cir-

cuit of

signal line

(grounded)

Turn the start switch to the OFF position before troubleshooting. Keep it in the
OFF position while troubleshooting is performed.

CN-501F

and ground

Resistance

Above 2M

Short circuit

of signal

line (con-

tact with

power sup-

ply)

Turn the start switch to the OFF position before troubleshooting. Keep it in the
ON position while troubleshooting is performed.

CN-501F

and ground

Volt

Under 5V

Dial failure

Turn the start switch to the OFF position before troubleshooting. Keep it in the
OFF position while troubleshooting is performed.

Unplug connector CN-501F and measure fuel con-

trol dial

and

Resistance

5K±15%

Fig. 7-33

7-48

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E145 CAN bus abnormal

Failure code

Failure symptom

Abnormality of CAN bus activates alarm.

E145

Failure description

Time-out of CAN bus communication lasts for over 3s.

Controller reaction

Only alarm output is effective.

Symptom on machine

----

Possible causes and standard values

Causes

Standard values and troubleshooting references

CAN re-

sistance

failure

Turn the start switch to the OFF position before troubleshooting. Keep it in the
OFF position while troubleshooting is performed.

Between CN-7-709 A and B

Resistance

Between CN-185 A and B

Resistance

Open circuit

of Harness

Turn the start switch to the OFF position before troubleshooting. Keep it in the
OFF position while troubleshooting is performed.

Unplug controller connector and measure pin

12 and CN-7-112 A.

Resistance

Under 1

Unplug controller connector and measure pin

11 and CN-7-112 B.

Under 1

Control-

ler internal

failure

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 this failure.)

CN-185M

CN-221M

CN-7-112F

CN222F

CN-7-113M

CN-7-709M

2
9

CANH

CANL

35
12

F11 15A

F13 10A

ZX335-1005040

Controller

120 ohms

Monitor

Operator station

Chassis harness

PWR

7 30

Fig. 7-34

7-49

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

7.5 Troubleshooting Electrical System (E-Mode)

E-1 Engine does not crank .......................................................................................... 7-51
E-2 Engine runs rough or is unstable .......................................................................... 7-54
E-3 Power supply of machine cannot be cut off .......................................................... 7-55
E-4 Throttle motor not working .................................................................................... 7-56
E-5 Auto idle not functioning ........................................................................................ 7-57
E-6 Preheat function fails ............................................................................................ 7-59
E-7 All components not working .................................................................................. 7-60
E-8 Boom-up speed or power is low............................................................................ 7-61
E-9 Arm speed or power is low .................................................................................... 7-62
E-10 Bucket speed or power is low ............................................................................. 7-63
E-11 Travel speed or power is low ............................................................................... 7-65
E-12 Blank monitor display .......................................................................................... 7-66
E-13 Monitor displays nothing ..................................................................................... 7-67
E-14 Dual speed travel not functioning........................................................................ 7-68
E-15 Incorrect engine coolant reading......................................................................... 7-69
E-16 Incorrect fuel level reading .................................................................................. 7-70
E-17 Wiper does not work ........................................................................................... 7-71
E-18 Incorrect arm-in pilot pressure reading ............................................................... 7-72
E-19 Incorrect arm-out pilot pressure reading ............................................................. 7-73
E-20 Incorrect boom-up pilot pressure reading ........................................................... 7-74
E-21 Incorrect boom-down pilot pressure reading....................................................... 7-75
E-22 Incorrect bucket-dig pilot pressure reading ......................................................... 7-76
E-23 Incorrect bucket-dump pilot pressure reading..................................................... 7-77
E-24 Incorrect swing pilot pressure reading ............................................................... 7-78
E-25 Left travel pilot pressure reading incorrect .......................................................... 7-79
E-26 Right travel pilot pressure reading incorrect ....................................................... 7-80

7-50

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

Fuse box connection table

●

This table gives all power supply units and rated currents of fuse box power supplies.

●

If power supply is normal, check the fuse box and fuses when you perform troubleshooting of
the electrical system.

Information contained in troubleshooting table

Failure information

Symptom on machine

Related information

Failure occurred and troubleshooting information

Possible causes and standard values

Cause

Standard values and troubleshooting referenc-

Possible causes of trouble
(Given numbers are refer-
ence numbers, which do not
indicate priority)

●

Standard value under normal condition can
be used to judge possible causes

●

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

●

Open circuit

Faulty contact with connector or open cir-
cuit in wiring harness

●

Faulty grounding

An ungrounded wiring is grounded.

●

Short circuit

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

7-51

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-1 Engine does not crank

Trouble

Engine cannot be started.

Related information

Possible causes and standard values

Cause

Standard values and troubleshooting references

Low battery
capacity

★

Turn engine start switch to the OFF position before troubleshooting. Keep

it in the OFF position while troubleshooting is performed.

Battery voltage

Voltage

≥

24V

Internal fail-
ure of engine
start switch

★

Turn engine start switch to the OFF position before troubleshooting. Keep

it in the OFF position while troubleshooting is performed.

OFF position: between wire 22# and wire 11# Resistance

≥

Failure of pilot
switch

★

Turn engine start switch to the OFF position before troubleshooting. Keep

it in the OFF position while troubleshooting is performed.

Lockout control in unlocked position: between
105 # and 27# wire

Resistance

≤

Lockout control in locked position: between wire
105 # and wire 27#

≥

1 M

4 Failure of

start motor

★

Turn engine start switch to OFF position. Keep the engine running during

troubleshooting. (When all power supplies, grounding, signal and engine
inputs are normal except engine output, it is the failure of start motor)

Engine starting motor

Start switch

Voltage

Power supply: Terminal B and ground

Start

—

30V

Between start motor input terminal S and ground

—

30V

Open circuit
of harness

★

Turn engine start switch to OFF position before proceeding. Turn it to the

ON position to perform troubleshooting.

Wire 21# and start motor terminal B

Resistance

≤

Wire 12# and start motor terminal S

≤

Start relay terminal L and safety relay terminal S

≤

7-52

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of fuse
F1

Battery terminal "+" (wire 20#) and control dial
wire 22#

Resistance

≤

Short circuit
of harness
(grounded)

★

Turn engine start switch to the OFF position before troubleshooting.

Keep it in the OFF position while troubleshooting is performed.

Start relay terminal S and ground

Resistance

≥

1 M

Start motor input terminal S and ground

≥

1 M

Internal failure
of alternator

★

Turn engine start switch to the OFF position before troubleshooting. Turn

the start switch to the ON position and keep it in the ON position while
troubleshooting is performed.

Alternator terminal R and ground

Voltage

≤

1.5V

9 Start relay

★

Turn engine start switch to OFF position. Move it to ON position when

performing troubleshooting.
Between relay coils

Resistance

≥

300

Between start relay terminal B and line 11#

≤

Failure of
parking unit

★

Turn engine start switch to the OFF position before troubleshooting. Turn

the start switch to the ON position and keep it in the ON position while
troubleshooting is performed.

Check parking relay

Resistance

—

Measure resistance of motor coil.

Approx 63

7-53

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

ZX225-1105020

k11

BR ACC

HEAT

OFF

TERMINAL

START

897044-4180

105

61 11

F1-20A

F13-160A

F2-10A

HLR

GR-1 GLOW PLUG

BAT-1

F7-10A

606

D-10

D-1

k-8

15a

620

11a

P600G

11b

HL2

R
B

VA7

Start switch

Low-temp switch

Preheat
relay

PReheat indicator

Preheat controller

Preheater

Charging indicator

Start motor

Engine

Parking motor

Parking relay

Safety relay

Pilot solenoid valve

Lockout relay

Start relay

SQ1 Pilot switch

Shutdown relay

Pilot valve relay

Battery

Battery
relay

Fig. 7-35

7-54

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-2 Engine runs rough or is unstable

Failure information

Engine Runs Rough or Is Unstable

Related information

Engine speed can be read on the monitor.

Possible causes and standard values

Cause

Standard values and troubleshooting references

Open circuit of

harness

Turn engine start switch to the OFF position before troubleshooting. Keep it in
the OFF position while troubleshooting is performed.

Unplug the connector controller, and measure

the resistance between pin 16 and pin 7.

Resistance

2.3±0.2 K

Internal failure

in sensor

Turn engine start switch to the OFF position before troubleshooting. Keep it in
the OFF position while troubleshooting is performed.

Between CN-125M A and B

Resistance

2.3±0.2 K

Short circuit

of harness

(grounded)

Turn engine start switch to the OFF position before troubleshooting. Keep it in
the OFF position while troubleshooting is performed.

Between CN-125M A and ground

Resistance

Above 1M

Internal failure
of controller

No troubleshooting can be done due to internal failure. (Failure lies in the control-

ler if the reasons above are ruled out)

GND

HCU_J1

S-2

CN-125M

ZX225-1105021

Controller

RPM sensor

Signal

GND

Chassis harness

Operator station

RPM sensor
input signal

Fig. 7-36

7-55

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-3 Power supply of machine cannot be cut off

Failure information

Engine cannot be stopped.

Related information

Engine stalls when start switch it turned to OFF position. There
is no time delay for power cutout.

Possible causes and standard

values

Cause

Standard values and troubleshooting references

Failure of battery

relay

When the engine start switch is operated, if the operation of battery relay con-

tact is heard, the battery is normal. Turn the start switch OFF

OFF.

Breakdown of

surge diode

Turn engine start switch to the OFF position before troubleshooting. Keep
it in the OFF position while troubleshooting is performed.

Between battery relay wire 20# and wire 21#

Resistance Above 1M

ZX225-1105020

k11

BR ACC

HEAT

OFF

TERMINAL

START

897044-4180

105

61 11

F1-20A

F13-160A

F2-10A

HLR

GR-1 GLOW PLUG

BAT-1

F7-10A

606

D-10

D-1

k-8

15a

620

11a

P600G

11b

HL2

R
B

VA7

Start switch

Low-temp switch

Preheat
relay

PReheat indicator

Preheat controller

Preheater

Charging indicator

Start motor

Engine

Parking motor

Parking relay

Safety relay

Pilot solenoid valve

Lockout relay

Start relay

SQ1 Pilot switch

Shutdown relay

Pilot valve relay

Battery

Battery
relay

Fig. 7-37

7-56

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-4 Throttle motor not working

Failure information

Engine speed does not increase or decrease.

Related information

Turn the fuel control dial but engine speed does not

change.

Possible causes and standard values

Causes

Standard values and troubleshooting references

Preheat

fuse fail-

ure.

Turn he start switch to the ON position and keep it in the ON position while trouble-
shooting is performed.

The monitor shows failure code 41. Coolant temperature and oil level are normal.

Sensor

power

abnormal

Turn he start switch to the ON position and keep it in the ON position while trouble-
shooting is performed.

Measure the voltage between motor plug, 50# wire

and ground.

Volt

5.0V

Throttle

motor

failure

Unplug the connector of the harness between throttle motor and chassis.

Measure the resistance between the blue and red

wires.

Resistance

8~15

Measure the resistance between the yellow and

green wires.

± 10%

Throttle

motor

failure

Turn he start switch to the ON position and keep it in the ON position while trouble-
shooting is performed.

The monitor shows failure codes 41, 12, 13, 14 and 32.

7-57

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-5 Auto idle not functioning

Failure information

Auto idle speed do not work

Related information

Engine speed do not decrease wen the mode is auto idle
speed and grip keeps still in NEUTRAL position

Possible causes and standard values

Cause

Standard values and troubleshooting references

Error of boom-

up signal

Turn engine start switch to OFF position. Start the engine and keep it run-
ning to perform troubleshooting.

Levers in NEUTRAL, pressure signal transmitted

Pressure

0 KG

Lever in operation, pressure signal transmitted

0-39 KG

Error of boom-

down signal

Turn engine start switch to OFF position. Start the engine and keep it run-
ning to perform troubleshooting.

Levers in NEUTRAL, pressure signal transmitted

Pressure

0 KG

Lever in operation, pressure signal transmitted

0-39 KG

Error of arm-in

signal

Turn engine start switch to OFF position. Start the engine and keep it run-
ning to perform troubleshooting.

Levers in NEUTRAL, pressure signal transmitted

Pressure

0 KG

Lever in operation, pressure signal transmitted

0-39 KG

Error of arm-out

signal

Turn engine start switch to OFF position. Start the engine and keep it run-
ning to perform troubleshooting.

Levers in NEUTRAL, pressure signal transmitted

Pressure

0 KG

Lever in operation, pressure signal transmitted

0-39 KG

Error of bucket-

dig signal

Turn engine start switch to OFF position. Start the engine and keep it run-
ning to perform troubleshooting.

Levers in NEUTRAL, pressure signal transmitted

Pressure

0 KG

Lever in operation, pressure signal transmitted

0-39 KG

7-58

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

Possible causes and standard values

Cause

Standard values and troubleshooting references

Error of Bucket-

dump signal

Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.

Levers in NEUTRAL, pressure signal

transmitted

Pressure

0 KG

Lever in operation, pressure signal

transmitted

0-39 KG

Error of swing

signal

Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.

Levers in NEUTRAL, pressure signal

transmitted

Pressure

0 KG

Lever in operation, pressure signal

transmitted

0-39 KG

Error of travel

signal

urn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.

Levers in NEUTRAL, pressure signal

transmitted

Pressure

0 KG

Lever in operation, pressure signal

transmitted

0-39 KG

Error of attach-

ment signal

Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.

Levers in NEUTRAL, pressure signal

transmitted

Pressure

0 KG

Lever in operation, pressure signal

transmitted

0-39 KG

Failure of con-

troller

No troubleshooting can be done for it is internal failure. (If it is not caused

by one of the factors listed above, it should be the failure of controller.)

SANY Crawler Hydraulic Excavator SY365H-9, SY365BH-9. Shop Manual (2014) - page 25