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

7-59

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-6 Preheat function fails

Failure information

Engine does not preheat.

Related information

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of pre-

heat fuse

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

Between wire 21# and preheat relay wire 16#

Resistance Under 1

Failure of pre-

heat relay

When the preheat function is activated, if operation of the preheat relay

contact is heard, the relay is normal. The start switch is to be switched

HEAT

OFF

HEAT.

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.

Failure of pre-

heat control-

ler

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

Between preheat controller pin 3# and start switch
wire 61#

Resistance

Under 1

Between preheat controller pin 4# and preheat relay
wire 68#

Under 1

Between preheat controller pin 1# and preheat relay
wire 14#

Under 1

Between preheat controller pin 2# and low temp
switch wire 66#

Under 1

P600G

HL2

BR ACC

HEAT

OFF

TERMINAL

START

21n4-10430

F1-20A

F13-160A

F2-10A

GR-1 GLOW PLUG

BAT-1

ZX225-1005039

Control switch harness

Cab harness

Chassis harness

Start switch

Batt. relay

Preheat relay

Low temp SW

Preheat controller

Preheat indicator

Preheater

Battery

Fig. 7-38

7-60

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-7 All components not working

Failure information

The machine is motionless while operated after starting.

Related information

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of lockout

switch

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

Item

Lockout control lever

Resistance

Between wire 105# and wire

27#

LOCK Under

FREE

Above 1M

Short circuit of

wire (grounded)

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

Between 105# and ground

Resistance

Above 1M

Failure of coil

inside lockout

solenoid valve

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

Between CN-136F 1 and 2

Resistance

About 34

105

CN-201F

CN-205F

105 27

+24V

CN-302M

CN-136F

606

(D-12)

(AMP-2)

ZX225-1005040

Pilot
switch

Cab harness

Chassis harness

Fig. 7-39

7-61

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-8 Boom-up speed or power is low

Failure information

Boom-up speed or power is low.

Related information

Pilot pressure of the boom in operation can be
checked on the monitor.

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of sen-

sor

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

Levers in NEUTRAL, boom-up pressure signal

Pressure

0 KG

Lever in operation, boom-up pressure signal

0-39 KG

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 harness ( from controller pin 8 to CN-

126M A) and ground

Resistance

Above

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 controller pin 11 and CN-126M B

Resistance Under 1

Failure of con-

troller

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

controller if the reasons above are ruled out)

5 V

ZX225-1105009

206#

CN-126M

00#

50#

Controller

Boom-up pilot pressure
signal collecting port

GND

5V PWR

Boom-up pilot
press. sensor

Operator station

Chassis harness

Signal

GND

Fig. 7-40

7-62

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-9 Arm speed or power is low

Failure information

Arm speed or power is low during operation.

Related information

Pilot pressure of the arm in operation can be checked on the
monitor.

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of

sensor

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

Levers in NEUTRAL, arm-in and arm-out pressure

signals

Pressure

0 KG

Levers in operation, arm-in and dump pressure signal

0-39 KG

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 harness (from controller pin 35 to CN-

129M A) and ground

Between harness (from controller pin 22 to CN-

122M A) and ground

Resistance

Above 1M

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 controller pin 11 and CN-129M B
Between controller pin 11 and CN-122M B

Resistance Under 1

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)

CN-122M

DF-3

CN-129M

DF-3

ZX225-1105022

Controller

Operator Station

Chassis harness

Arm out
press. sensor

Arm in
press. sensor

Sensor GND

Sensor 5V

Signal

GND

Signal

GND

Fig. 7-41

7-63

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-10 Bucket speed or power is low

Failure information

Bucket speed or power is low during operation.

Related information

Pilot pressure of the bucket can be checked on the moni-
tor.

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of sen-

sor

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

Levers in NEUTRAL, bucket-dig/dump pressure

signals

Pressure

0 KG

Levers in operation, bucket-dig/dump pressure

signals

0-39 KG

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 harness (from controller pin 10 to CN-

124M A) and ground

Between harness (from controller pin 33 to CN-

128M A) and ground

Resistance Above 1M

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 controller pin 11 and CN-124M B
Between controller pin 11 and CN-128M B

Resistance Under 1

Defective buck-

et con

uence

solenoid valve

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

Between CN-134F 1 and 2

Resistance About 34

Failure of con-

troller

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

controller if the reasons above are ruled out)

7-64

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

CN-128M

DF-3

CN-124M

DF-3

CN-134F
AMP-2

ZX225-1105023

Controller

Signal

GND

Signal

GND

Signal

GND

Operator Station

Chassis harness

Bucket dump
press. sensor

Bucket dig
press. sensor

Bucket confluence
Proportional valve

Bucket dump
press. sensor

Bucket dig
press. sensor

Sensor GND

Sensor 5V

Bucket confluence
signal

Fig. 7-42

7-65

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-11 Travel speed or power is low

Failure information

Travel speed or power is low during operation.

Related information

Pilot pressure of travel operation can be checked on the
monitor.

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of sen-

sor

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

Levers in NEUTRAL, left and right travel pressure

signals

Pressure

0 KG

Levers in operation, left and right travel pressure

signals

0-39 KG

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 harness (from controller pin 34 to CN-

120M A) and ground

Between harness (from controller pin 30 to CN-

121M A) and ground

Resistance

Above

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 controller pin 11 and CN-120M B
Between controller pin 11 and CN-121M B

Resistance Under 1

Failure of con-

troller

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

controller if the reasons above are ruled out)

HCU_J2

HCU_J1

CN-121M

DF-3

CN-120M

DF-3

ZX225-1105024

Controller

R. travel press. sensor

L. travel press. sensor

Sensor grounding wire

Sensor 5V

Operator station

Chassis harness

R. travel press. sensor

L. travel press. sensor

Signal

GND

Fig. 7-39

Fig. 7-43

7-66

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-12 Blank monitor display

Failure information

Monitor display is blank after the machine is powered on.

Related information

Possible causes and standard values

Cause

Standard values and troubleshooting references

1 Failure of fuse

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

Between wire 42# and ground

Voltage

About 24V

Between wire 43# and ground

About 24V

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-7-113M pin 1 and CN-222F pin 4

Resistance

Under 1

Between CN-7-113M pin 2 and CN-222F pin 7

Under 1

Between CN-7-113M pin 9# 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 harness (from CN-7-113M pin 1 to CN-

222F pin 4 and ground

Resistance

Above 1M

Between harness (from CN-7-113M pin 2 to CN-

222F pin 7 and ground

Above 1M

Failure of

monitor

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 monitor.)

HCU-J2

CANL

CANH

CN-185M

CN-7-113M

CN-222F

11
31

CN-7-112F

CN-221M

15A

F11

F13 10A

CN-7-709M

CANH

CANL

ZX335-1005050

120 ohms

Controller

Operator station

Chassis harness

PWR

Monitor

Fig. 7-44

7-67

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-13 Monitor displays nothing

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of

resistance

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

Between CN-1-185M A and B

Resistance

120

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-7-112F pin A and controller pin 12

Resistance

Under 1

Between CN-7-112F pin B and controller pin 11

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 harness (from CN-7-112F pin A to con-

troller pin 12) and ground

Resistance

Above 1M

Between harness (from CN-7-112F pin B to con-

troller pin 11 and ground

Above 1M

Failure of

monitor or

controller

No troubleshooting can be done for it is internal failure. (If it is not one of the

failures stated above, it should be the failure of monitor or controller.)

Failure information

Display of monitor is illuminated but no information is
shown on the screen after machine is powered on.

Related information

HCU-J2

CANL

CANH

CN-185M

CN-7-113M

CN-222F

11
31

CN-7-112F

CN-221M

15A

F11

F13 10A

CN-7-709M

CANH

CANL

ZX335-1005050

120 ohms

Controller

Operator station

Chassis harness

PWR

Monitor

Fig. 7-45

7-68

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-14 Dual speed travel not functioning

Failure information

Only low speed travel is functioning during operation.

Related information

Press the Hi/Lo button on the monitor to change
travel speed.

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of dual

speed travel

solenoid valve

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

Between CN-131F A and B

Resistance About 34

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-131F pin A and controller pin 7

Resistance

Under 1

Between CN-131F pin B and controller pin 3

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 harness (from CN-131F pin A to con-
troller pin 7) and ground

Resistance

Above 1M

AMP-2

CN-131F

ZX225-1105025

Operator Station

Chassis harness

Controller

High speed travel
solenoid valve

GND

Signal

GND

Fig. 7-46

7-69

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-15 Incorrect engine coolant reading

Failure information

Engine coolant temperature sensor cannot correctly re

ect cur-

rent coolant temperature.

Related information

Coolant temperature can be checked on the monitor.

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of cool-

ant temperature

sensor

Standard values for engine coolant temperature sensor

130

48.5±4.2

100

26.7±2.5

110

Open circuit of

lead

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

Between wire 510# and controller pin 32

Resistance

Under 1

Short circuit of

lead (grounded)

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

Between wire 510# and ground

Resistance Above 1M

Lead short to

24V circuit

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

Wire 510# to ground

Voltage

Under 1V

510

ZX335-1005053

Operator Station

Chassis harness

Coolant temperature sensor

Controller

Fig. 7-47

7-70

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-16 Incorrect fuel level reading

Failure information

Engine fuel level sensor cannot correctly re

ect current fuel level.

Related information

Fuel level can be checked on the monitor.

Possible causes and standard values

Cause

Standard values and troubleshooting references

Fuel level sen-

sor error

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

Fuel level

Resistance

Between wire 509# and ground

FULL (Upper limit)

Approx. 10

EMPTY (Lower limit)

85-95

Open circuit of

lead

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

Between wire 509# and controller pin 17

Resistance

Under 1

Short circuit of

lead (ground-

ed)

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

Between wire 509# and ground

Resistance

Above 1M

Lead short to

24V

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

Wire 509# grounded

Voltage

Under 1V

509

ZX335-1005054

Operator Station

Chassis harness

Fuel level sensor

Controller

Fig. 7-48

7-71

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-17 Wiper does not work

Failure information

Wiper does not work.

Related information

Possible causes and standard values

Cause

Standard values and troubleshooting references

Internal Fail-

ure of wiper

motor

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

Between wiper wire 25# and ground

Resistance

Open circuit of

lead

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

Between CN-403F 1 and CN-1-110 2

Resistance

Under 1

Between wiper switch wire 35L# and

CN-1-110M 5

Under 1

Between wiper switch wire 35L# and

CN-1-110M 4

Under 1

Short circuit of

lead (ground-

ed)

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

Harness from CN-403F 1 to CN-1-110M

2 short to ground

Resistance

Above 1M

F5 5A

CN-403M

D-12

CN-401F

D-12

CN-204M

D-12

CN-203F

D-12

36
35L
35H

CN-1-110M

D-6

36
35L

35H

ZX225-1005049

Wiper switch

Operator station

PWR

Fig. 7-49

7-72

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-18 Incorrect arm-in pilot pressure reading

Failure information

Reading of arm-in pilot pressure is incorrect.

Related information

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of 5V

power supply

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

Between CN-129M

and

Voltage

Approx. 5V

Open circuit of

signal line

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

Between CN-129M

and controller pin 35

Resistance

Under 1

Short circuit of

signal line

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

Between CN-129M

and ground

Resistance Above 2M

Failure of sen-

sor

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

Between CN-129M

and ground

Voltage

0.5V- 4.5V

CN-129M

DF-3

ZX225-1105026

Controller

Arm in
pressure sensor

Sensor GND

Sensor 5V

Signal

GND

Operator Station

Chassis harness

Fig. 7-50

7-73

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-19 Incorrect arm-out pilot pressure reading

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of 5V

power supply

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

Between CN-122M

and

Voltage

About 5V

Open circuit of

signal line

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

Between CN-122M

and controller pin 22

Resistance Under 1

Short circuit of

signal line

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

Between CN-122M

and ground

Resistance Above 2M

Failure of sen-

sor

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

Between CN-122M

and ground

Voltage

0.5V- 4.5V

Failure information

Reading of arm-out pilot pressure is incorrect.

Related information

CN-122M

DF-3

ZX225-1105027

Controller

Arm out
pressure sensor

Sensor GND

Sensor 5V

Signal

GND

Operator Station

Chassis harness

Fig. 7-51

7-74

Troubleshooting

SY365(B)H-9 Crawler Hydraulic Excavator

E-20 Incorrect boom-up pilot pressure reading

Failure information

Incorrect Boom-up Pilot Pressure Reading

Related information

Possible causes and standard values

Cause

Standard values and troubleshooting references

Failure of 5V

power supply

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.

Between CN-126M

and

Voltage

About 5V

Open circuit of

signal line

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

Between CN-126M

and controller pin 8

Resistance Under 1

Short circuit of

signal line

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

Between CN-126M

and ground

Resistance Above 2M

Failure of sen-

sor

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.

Between CN-126M

and ground

Voltage

0.5V- 4.5V

CN-126M

DF-3

ZX225-1105028

Controller

Boom up
pressure sensor

Sensor GND

Sensor 5V

Signal

GND

Operator Station

Chassis harness

Fig. 7-52

SANY Crawler Hydraulic Excavator SY365H-9, SY365BH-9. Shop Manual (2014) - page 26