SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 24

7-7

Troubleshooting

4. Operate machine by yourself (trial run)

Confirming that the third item above is
normal, run startup check on the machine
to determine the cause of failure. If the
failure cannot be determined, turn off the
engine and get more information from the
operator.

5. Perform troubleshooting

Conduct deep analysis and determine the
cause of trouble according to the symp-
toms of the machine and the information
displayed on the monitor.

Remark:

●

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.

●

Failure codes may not indicate machine
trouble. Temporary electrical failure can oc-
cur in controller memory, such as low bat-
tery output voltage, or open circuit in switch
or sensor. Therefore, make repeated trials
to erase the accumulated failure codes
from the controller memory and confirm
whether the failure codes are displayed af-
ter repeated trials. That is to say, "reoccur-
rence" of this trouble is possible.

6. Find out possible causes

Before making a conclusion, check the
most possible causes again and try to de-
termine the root causes of troubles. Make
a feasible repair scheme according to your
conclusion.

7-8

Troubleshooting

Connec-

tor  No.

Type

No. of 

pin

Name of device

Location

Layout

Cab 

circuit

Engine 

circuit

Sensor, 

solenoid 

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

T-103

Terminal

1

Battery relay contact (out-
put)

M-2

D-1

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

Terminal

1

Body grounding

M-1

B-1

T-111

Terminal

1

Body grounding

K-6

T-112

Terminal

1

Preheating resistance wire 
terminal

J-7

H-9

T-115

Terminal

1

Starting motor grounding

J-6

L-3

T-119

Terminal

1

Body grounding (at the sides 
of battery)

M-1

B-9

T-201

Terminal

1

Body grounding

X-6

T-202

Terminal

1

Body grounding

X-6

K5

R

5

Horn relay

X-6

H-9

K6

R

5

Lamp relay

X-6

I-9

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

7.3  

Connector Location and Electrical Circuit Diagram

7-9

Troubleshooting

Connec-

tor  No.

Type

No. of 

pin

Name of device

Location

Layout

Cab 

circuit

Engine 

circuit

Sensor, 

solenoid 

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

A

2

Boom lamp (left)

E-7

K-1

CN-105M

A

2

Boom lamp (right)

E-7

K-2

CN-113M

A

2

Hydraulic oil temperature 
sensor

I-7

F-9

CN-101M

S

1

Fuel level sensor

F-6

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

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

7-10

Troubleshooting

Connec-

tor  No.

Type

No. of 

pin

Name of device

Location

Layout

Cab 

circuit

Engine 

circuit

Sensor, 

solenoid 

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

CN-135F

AMP

2

Boom priority solenoid valve 
2

J-6

F-2

CN-134F

AMP

2

Bucket Con

fl

 uence solenoid 

valve

J-6

F-3

CN-132F

AMP

2

Boom priority solenoid valve 
1

J-6

F-3

CN-136F

AMP

2

Pilot solenoid valve

J-6

L-2

CN-131F

AMP

2

Hi/Lo speed travel solenoid 
valve

J-6

F-1

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

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

7-11

Troubleshooting

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

7-12

Troubleshooting

7.3.1  Connector location layout

F

E

D

C

B

A

8

7

6

5

1

3

2

4

CN-104M

CN-101M

CN-102M

CN-105M

ZX215-1005033

7-13

Troubleshooting

M

L

K

J

I

H

G

F-104

CN-116M

CN-113M

F-108

T-112

CN-801F

CN-448M

T-106

CN-800M

CN-131F

CN-132F

CN-133F

CN-134F

CN-135F

CN-136F

F-103

CN-115M

CN-114F

CN-113F

T-115

CN-112M

CN-445M

T-107

T-111

ZX215-1005034

CN-127M

CN-128M

CN-126M

CN-125M

CN-124M

CN-123M

CN-122M

CN-121M

CN-120M

7-14

Troubleshooting

N

O

P

Q

R

S

T

4

2

3

1

5

6

7

8

9

CN-7-707

CN-7-705

CN-301M

CN-302

CN-104M

CN-303M

CN-304M

CN-305M

CN-307M

CN-306M

CN-131M

CN-132F

ZX215-1005035

7-15

Troubleshooting

T

U

V

W

X

Y

Z

CN-616F

CN-615F

CN-1-111

CN-1-112

CN-241M

CN-121F

CN-142M

CN-161M

CN-661F

CN-152M

T-201

K5

K6

K10

K3

K7

K8

CN-613F

CN-204F

KH

CN-412F

PF021

CN-106F

CN-107M

CN-207F

T-202

ZX215-1005036

7-17

Troubleshooting

AF

AE

AD

AC

AB

AA

CN-1-110

CN-1-004M

CN-1-103M

CN-1-002M

CN-1-001M

CN-1-005

4

2

3

1

5

6

7

8

9

CN-150M

ZX215-1005037

7-18

Troubleshooting

7.3.2  Electrical element circuit diagram (cab circuit)

1

2

KB

1

2

3 4 5

5

4

3

2

1

+

+

-

-

9

11

13

22

11

9

13

S-6

CN-332M

C

R2

BRACC

B

HEAT

ON

OFF

TERMINAL

R1

START

22 13

5

5

21

20

CN-615F

CAN-

CAN+

CAN-

CAN+

50

50

50

00

00

00

0

0

0

0

42

42

1

2

2

1

CN-152M

CN-153M

X-14

X-13

43

0

B

CAN-

CAN+

25

42

42

PF021

CN-132F
(D-12)

CN-241M
(D-12)

CN-121F
(D-12)

CN-204F
(A-2)

CN-412F
(A-3)

CN-302F
(A-3)

CN-131M
(D-12)

CN-142M
(D-12)

CN-7-705
(D-12)

CN-1-112
(D-3)

CN-1-111
(D-8)

35 H

X-12

31

23

X-11

23

1

2

3

4

5

12

35 H

72

X-10

X-9

72

70

35 L

X-8

36

35 L

33

37

25

24

36

X-7

25

X-6

37

X-5

24

X-4

33

70

28

X-3

12

5

4

3

2

1

2

1

2

1

3

3

X-2

2

1

2

1

3

3

4
5
6

4
5
6

00

50

X-1

CANL

29
22

0

CANH

00

506

50

00

506

50

00

506

50

GPS

1
2

1
2

2

1

2

1

3

3

3

3

2

1

1
2

F17

F15

70

49

10A

F14

43

F11

42

F10

29

F9

28

F7

26

25

F5

F4

24

F3

F1

506

CANL

CANH

23

21

22

20

1

3 4 5

12

11

10

9

8

8 9 10 11 12

5

4

3

15A

10A

20 A

5 A

5 A

10A

5 A

15A

5 A

20 A

1

2
4

9

12

11

10

10
11
12

9

4

2

2

1

3

3

3

1
2

1
2

2

1

2

1

12

10

9

8

4

3

3
4
8
9
10
12

12

10

9

8

4

3

81

1
2
3
4
5
6
7
8
9

10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57

58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80

82
83
84
85
86
87
88
89
90
91
92
93

94
95
96
97
98
99

100
101
102
103
104

105
106
107
108
109
110
111
112

113
114
115
116
117
118
119
120
121
122

9

8

7

6

5

4

2

3

1

A

F

E

B

AIN16

s GND

s GND

s GND

s PWR

s PWR

s PWR

CAN+
CAN-

D

C

CN-307M

CN-303M

CN-305M

CN-304M

CN-104M

CN-616F

ZX215-1005038

24Vpower

Ground

120

ȍ

 resistance 

Monitor

Fuel ctrl dial

Chassis GND

Start switch

Battery relay

Horn switch

Stabilized voltage diode

Top lamp switch

Wiper switch

Washer switch

Work lamp switch

24V

power supply

Ground
Ground

24V

power supply

Fuel control knob voltage

7-19

Troubleshooting

 

★

This circuit diagram has been compiled by extracting the wiper system and each switch control system 
from the overall electrical circuit diagram.

1
2

2

1

0

71

71

0

1
2

2

1

CN-112M

(A-2)

0

37

M

1
2

2

1

34

0

34

0

34

0

34

0

26

71

26

0

R+

R-

L+
L-

0

0

0

0

CN-109M

1

2

57

0

CN-150M

(S-8)

CN-207F

57

60 a

61 a

60a
61a

61a

60a

CN-7-111
(S-8)

4

8

4

8

8

7

CN-442F
(S-12)

8

7

R+

R-

L+

L-

20 b

0

20 b

38

38

0

38

1

5

6

7

8

4

21

F8

CN-107M

0

L-

L+

R-

2

2

R+

2

7

6

5

4

3

1

20 b

F6

21

X-14

0

0

26

0

1

2

2

1

26

X-13

8

7

6

5

4

3

1

8

7

6

5

4

3

1

8

7

6

5

4

3

1

1

0

2

5

4

3

2

71

1

3
4

5
6
7
8

34

3
4

4

3

CN-102M

(A-2)

1
2

2

1

CN-102M

(A-2)

1
2

2

1

1

2

71

70

72

34

24

33

32

23

G

L

J

H

7

8

9

6

4

5

3

2

1

K

I

X-12

X-11

X-10

X-9

X-8

X-7

X-6

X-5

X-4

X-3

X-2

X-1

1

2

3 4 5

5

4

3

2

1

1

2

3 4 5

5

4

3

2

1

1

2

3 4 5

5

4

3

2

1

1

1

2

1

28

31

32

0

1

3

4

5

M

25
36

35 L

35H

CN-161F

(S-16)

CN-661F

(S-12)

CN-102M

(A-2)

CN-1-110

(D-6)

F-104

(W-1)

F-103

(W-1)

1

1

8

K

6

K

5

K

ZX215-1005039

Left speaker

Ex air sensor

Right speaker

Cab lamp

Right boom 
work lamp

Left boom 
work lamp

Rotating stage 
work lamp

Left top lamp

Right top lamp

Washer motor

Horn

Wiper

Access lamp

Horn relay

Lamp relay

Top lamp relay

Air conditioner panel

Radio panel

Compressor clutch 

7-20

Troubleshooting

7.3.3  Electrical control circuit diagram (engine circuit)

7

0

42

50

507

MT+

00

MT-

X-14

X-13

X-12

X-11

X-10

8

9

11

10

CN-153M

CN-152M

1

2

2

1

42

0

14

14

CN-331F

7

606

X-9

1

2

3 4 5

5

4

3

2

1

12

12

CN-161F

105

27

CN-221M

1 1

F16

4

CN-241F

21

F11

0

42

506

42

42

0

0

2

1

1

2

3 4 5

5

4

3

2

1

11

105

0

T-110

T-102

50

00

00

00

72

50

1

2

3 4 5

5

4

3

2

1

11

16

13

22

G

E

START

R1

TERMINAL

OFF
ON

HEAT

B

ACC

BR

R2 C

CN-615F

CN-616F

F

C

B

A

1

3

2

4

5

6

7

8

9

122

121

120

119

118

117

116

115

114

113

112

111

110

109

108

107

106

105

104

103

102

101

100

99

98

97

96

95

94

93

92

91

90

89

88

87

86

85

84

83

82

80

79

78

77

76

75

74

50

73

71

70

69

68

67

66

65

64

63

62

61

60

59

58

57

56

55

54

53

52

51

50

49

48

47

46

45

44

43

42

41

40

39

38

37

36

35

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

81

-

+

+

-

20

20

22

F1    20A

F2     5A

21

10

21

20

9

9

11

11

2

1

1

2

22

X-1

16

10

11

13

22

12

X-2

X-3

X-4

X-5

X-6

X-7

21

X-8

D

11

9

8

22

13

11

CN-241F
(D-12)

CN-332M

S-6

21

21

13

18

18

22

12

0

T-119

T-103 T-104

T-101

T-102

KB

K3

CN-306M

PF021

MT-

MT+

ZX215-1005040

Body ground

Grounding

Controller power supply

Throttle position feedback

Pilot valve relay

Battery relay

Preheat switch

Locking relay

Pilot switch

Grounding

Throttle motor output signal+

Grounding

24V

power supply

24V power supply

5V

power supply

5V

power supply

5V

power supply

7-21

Troubleshooting

 

★

This circuit diagram has been compiled by extracting the engine preheat system, startup system and 
governor system from the overall electrical circuit diagram.

G

4

2

6

1

3

6

10

1

7

9

3

1

6

2

5

2

1

47

1

2

50

507

MT-

00

MT+

MT+

00

MT-

507

50

CN-316F
(AMP-2)

F-311

F-310

M13
(S-6)

6

5

3

2

1

5

2

6

1

3

X-14

X-13

X-12

X-11

X-10

0

17

606

0

14

10

1

2

12a

S

0

47

10

14

12 a

3

1

6

2

CN-613F

4

21

1

2

1

2

2

1

2

1

14
10

9

9

17

10

12

12

7

7

CN-442F
(D-12)

CN-112M

12a

12

12 a

2

1

CN-111F

1

2

2

1

21

12

65

63

64

13

CN-661M
(S-16)

15

15

65

0

63

64

3

1

6

2

4

4

CN-121F
(D-12)

5 5

CN-661F
(S-16)

12

64

63

65

9

606

7

1

10

6

606

18

22

21

10

21

13

12

0

X-9

0

K7

1

2

3

4

5

5

4

3

2

1

0

17

16

18

1

2

3

4

5

5

4

3

2

1

L

H

M

J

7

8

9

6

4

5

3

2

1

K

I

X-1

X-2

X-3

X-4

X-5

X-6

X-7

F13   160A

17

X-8

47

10

14

0

P

B

E

0

E

0

10

14

P

R

L

R

L

CN-801F
(H-6)

2

6

1

3

63

65

64

22

0

P2

P1

A

B

22

E

A3 

T-112

KH

T-108

T-109

ZX215-1005041

Body ground

Connector 282080-1

Throttle motor

AC-2000

Charging indicator

Starting motor

Pilot solenoid valve

Body ground

Generator

Safety relay

Preheater indicator

Preheater

Parking motor

Parking relay

Preheat relay

7-22

Troubleshooting

7.3.4  Electrical control circuit diagram (sensor and solenoid valve circuit)

F-108

(W-1)

C

CN-101M

(S-1)

1

1

50

50

50

50

50

50

50

50

50

50

C

B

A

C

B

A

0

C

B

A

C

B

A

0

C

B

A

C

B

A

0

C

B

A

C

B

A

0

C

B

A

C

B

A

0

C

B

A

C

B

A

0

C

B

A

C

B

A

0

C

B

A

C

B

A

0

0

C

B

A

A

B

C

C

B

A

C

B

A

0

C

B

A

s PWR

s GND

s GND

CN-121M

(DF-3)

201

50

0

CN-120M

(DF-3)

200

CN-123M

(DF-3)

208

CN-124M

(DF-3)

205

204

CN-127M

(DF-3)

207

206

CN-125M

(DF-3)

CN-126M

(DF-3)

CN-128M

(DF-3)

203

202

 

CN-122M

(DF-3)

CN-116M

(DF-3)

501

502

CN-115M

(DF-3)

C

A
B

0

508

 CN-131F
(AMP-2)

2

1

2

1

607

0

0

703

1

2

1
2

  CN-114F
(AMP-2)

CN-113F
(AMP-2)

2

1

2

1

702

0

0

603

0

602

0

604

0

608

CN-135F

(AMP-2)

2

1

2

1

CN-132F

(AMP-2)

2

1

2

1

CN-134F

(AMP-2)

2

1

2

1

1

2

1
2

CN-133F

(AMP-2)

509

510

511

CN-152M

(A-2)

2

1

1
2

0

240 
w1/4

42

511

108B

108A

2

1

1
2

CN-113M

(A-2)

CN-448M

(S-2)

2

1

1
2

D

B

G

A

1

3

2

4

5

6

7

8

9

122

121

120

119

118

117

116

115

114

113

112

111

110

109

108

107

106

105

104

103

102

101

100

99

98

97

96

95

94

93

92

91

90

89

88

87

86

85

84

83

82

80

79

78

77

76

75

74

73

72

71

70

69

68

67

66

65

64

63

62

61

60

59

58

57

56

55

54

53

52

51

50

49

48

47

46

45

44

43

42

41

40

39

38

37

36

35

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

81

CN-616F

CN-615F

E

F

ZX215-1005042

Boom lower pilot
pressure sensor

Arm in pilot
pressure sensor

Rear pump 
pressure sensor

Front pump 
pressure sensor

Arm out 
pressure sensor

Boom raise pilot 
pressure sensor 

Bucket dump pilot 
pressure sensor

Hi/Lo speed travel 
solenoid valve

Rear pump 
proportional 
solenoid valve

Front pump 
proportional 
solenoid valve

Boom priority 2-A4

proportional 
solenoid valve

Boom priority 1-A4
proportional 
solenoid valve

Bucket confluent-A5
proportional 
solenoid valve

Swing priority-A4
proportional 
solenoid valve

Bucket curl pilot 
pressure sensor

Swing pilot 
pressure sensor

Left travel pilot 
pressure sensor

Right travel pilot 
pressure sensor

Oil pressure switch

Fuel  level sensor

Coolant temp. sensor

Hydraulic oil temp. sensor

Engine speed sensor

Coolant temp. sensor

Oil level sensor

Hydraulic oil temp. sensor 

Pulse input

Speed sensor GND

Grounding

Controller power supply

Grounding

Grounding

24V

power supply

24V

power supply

24V

power supply

Boom priority 2

Boom priority 1

Bucket confluent valve

Swing priority solenoid valve

Rear pump solenoid proportional valve

Front pump solenoid proportional valve

Hi/Lo speed travel

5V

power supply GND

5V

power supply GND

Front pump main pressure sensor

Arm in sensor

Boom raise sensor

Bucket curl sensor

Swing sensor

Travel sensor (right)

5V power supply GND

Rear pump main pressure sensor

Arm out sensor

Boom lower sensor

Bucket dump sensor

Travel sensor (left)

Oil pressure switch

7-23

Troubleshooting

7.3.5  SWP type connector

7222-7414-40

7222-1424-40

7222-7464-40

7222-7484-40

7222-7564-40

Male (Plug)

Female (Socket)

7123-7414-40  (No.of pin: 1)

7123-1424-40  (No.of pin: 2)

7123-7464-40  (No.of pin: 6)

7123-7484-40  (No.of pin: 8)

7123-7564-40  (No.of pin: 16)