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

7-25

Troubleshooting

7.3.7 DT type connector

DT06-2S

DT04-2P

DT06-3S

DT06-6S

DT06-8S

DT06-12S

Shell (Plug)

Shell (Socket)

DT04-3P (No.of pin: 3)

DT04-6P (No.of pin: 6)

DT04-8P (No.of pin: 8)

DT04-12P (No.of pin: 12)

7-26

Troubleshooting

No.

Symptom

Troubleshooting

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

According
to displayed
code

Display Service Code in electrical system after checking
failure history

Display Failure Code in mechanical system after checking
failure history

Engine-related failure

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

S-1

5 Engine mis

res.

E-1

S-2

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

S-3

7 Engine pickup is poor.

S-4

8 Engine runs rough or is unstable.

E-2

S-5

9 Engine is short of output, or lacks power

H-2

S-6

10 Auto Idle fails.

E-4

H-5

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

S-7

12 Premature engine oil contamination

S-8

13 Excessive fuel consumption

S-9

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

S-10

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,
Travel Speed Lowers Largely

H-13

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

7.4

Failure Symptoms and Troubleshooting Codes

7-27

Troubleshooting

No.

Symptom

Troubleshooting

Code

E mode H mode (Engine)

Other work equipment moves, when speci

c work equip-

ment is relieved

H-12

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 dif

cult 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

Swing-related failure

37 Machine does not swing

H-19

38 Swing acceleration is poor, or swing speed is slow

H-20

Upper structure overruns remarkably when stopping
swinging

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

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

7-28

Troubleshooting

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
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
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 con

uence proportional solenoid coil current) ....................... 7-58

E453 (abnormality (B) in bucket con

uence 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

7-29

Troubleshooting

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.

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

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

●

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

●

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

●

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.

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.

7-30

Troubleshooting

User Code

Service Code

Trouble Controller memory fails and the system slows down.

E111

Failure description

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

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

Internal failure
of controller

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

E111 (controller memory failure (FROM))

7-31

Troubleshooting

User Code

Service Code

Trouble

Throttle motor loading circuit is abnormal and the
engine acceleration fails.

E212

Failure description

When the power is on, magnitude of throttle motor coil current is out of the
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.

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

Failure of throt-
tle motor coil

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Between CN-445M

③

and

⑥

Resistance

12.2

Open circuit of
harness

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Unplug the controller and measure the resistance
between pin 113 and pin 105.

Resistance

12.2

Short circuit
of harness
(grounded)

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Unplug the connector CN-445M and measure the
resistance between motor

③

(

⑥

) and the hous-

ing.

Resistance

≥

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.)

E212 (throttle motor current & motor connection abnormal)

113

105

50#

507#

MT-

MT+

CN-445M

MT+

MT-

ZX215-1005071

CONTROLLER

THROTTLE MOTOR

GREEN

WHITE

RED

YELLOW

BLUE

CAB

CHASSIS HARNESS

GND WIRE

SENSOR 5V

THRTL FEEDBACK VOLT.

7-32

Troubleshooting

User Code

Service Code

Trouble

Operation of throttle motor suspends and engine
acceleration fails.

E213

Failure description

The controller monitoring accuracy deviates by over 5%, which is normally
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.

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

Failure of throttle
motor coil

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Between CN-445M

③

and

⑥

Resistance

12.2

Failure of 5V
power supply

●

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

Between CN-445M

①

and

⑤

Voltage

About 5V

Open circuit of
harness

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Unplug the controller and measure the resistance

between pin 113 and pin 105.

Resistance

12.2

Failure of throttle
position sensor

●

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

Between CN-445M

②

and ground

Voltage 0.8V~3.5V

Short circuit
of harness
(grounded)

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Unplug the connector CN-445M and measure the

resistance between motor

③

(

⑥

) and the housing.

Resistance

≥

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.)

E213 (throttle motor operation suspends)

113

105

50#

507#

MT-

MT+

CN-445M

MT+

MT-

ZX215-1005071

CONTROLLER

THROTTLE MOTOR

GREEN

WHITE

RED

YELLOW

BLUE

CAB

CHASSIS HARNESS

GND WIRE

SENSOR 5V

THRTL FEEDBACK VOLT.

7-33

Troubleshooting

User Code

Service Code

Trouble

Throttle motor working range is abnormal and the
engine returns to auto idle.

E214

Failure description

The voltage is below 0.8V at the minimal stroke or above 4.2V at the maximal
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.

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

Failure of throt-
tle motor coil

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Between CN-445M

③

and

⑥

Resistance

12.2

Failure of 5V
power supply

●

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

Between CN-445M

①

and

⑤

Voltage

About

Open circuit of
harness

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Unplug the controller and measure the resistance

between pin 113 and pin 105.

Resistance

12.2

Failure of
throttle position
sensor

●

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

Between CN-445M

②

and ground

Voltage

0.8V—3.5V

Short circuit
of harness
(grounded)

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Unplug the connector CN-445M and measure the

resistance between motor

③

(

⑥

) and the hous-

ing.

Resistance

≥

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.)

E214 (throttle motor working range abnormal)

113

105

50#

507#

MT-

MT+

CN-445M

MT+

MT-

ZX215-1005071

CONTROLLER

THROTTLE MOTOR

GREEN

WHITE

RED

YELLOW

BLUE

CAB

CHASSIS HARNESS

GND WIRE

SENSOR 5V

THRTL FEEDBACK VOLT.

7-34

Troubleshooting

User Code

Service Code

Trouble Power supply voltage is abnormal.

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

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

Alternator

abnormal

●

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

Measure the voltage between the alternator terminal
B and ground.

Voltage

About 28V

E015 (power supply voltage abnormal)

CN-800M

F-107

1
2
3
4
5
6

CN-613

TERMINAL

HEAT

OFF

START

BR ACC R1 R2 C

ZX215-1005072

START SWITCH

SAFETY RELAY

BATTERY RELAY

ALTERNATOR

CAB

CHASSIS HARNESS

7-35

Troubleshooting

User Code

Service Code

Trouble

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

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

Internal

failure of

controller

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

E116 (controller internal temperature abnormal)

7-36

Troubleshooting

User Code

Service Code

Trouble

Abnormal output of power supply in sensor

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

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

≥

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.)

E017 (abnormal output of 5v power supply in sensor)

7-37

Troubleshooting

User Code

Service Code

Trouble

Abnormal communication between controller and
monitor

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

Failure of CAN

resistance

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Between CN-7-709

①

and

②

Resistance

Open circuit of

harness

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Unplug the controller and measure the resistance

between pin 60 and CN-7-705

③

Resistance

≤

Unplug the controller and measure the resistance

between pin 78 and CN-7-705

④

≤

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.)

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

2
3

1
2
3

F1 20A

F10 5A

CANH

CANL

ZX215-1005073

MONITOR

CAB

CHASSIS HARNESS

CONTROLLER

120

RESISTANCE

PWR

E118 (abnormal communication between controller and monitor)

7-38

Troubleshooting

User Code

Service Code

Trouble

Front pump output pressure is abnormal. Only output

alarm is enabled. .

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

Failure of 5V

power supply

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Between CN-115M A and B

Voltage

About 5V

Open circuit of

signal wire

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Between CN-115M C and pin 72 of controller

Resistance

≤

Between CN-115M B and ground

≤

Short circuit

of signal wire

(grounded)

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Between CN-115M C and ground

Resistance

≥

Failure of sen-

sor

●

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

Between CN-115M C and ground

Voltage

0.5±0.2V

CN-446M

501#

00#

50#

ZX215-1005074

FRONT PUMP
PRESS. SENSOR

FRONT PUMP PRESSUSRE
SIGNAL COLLECTING PORT

SIGNAL

GND WIRE

CONTROLLER

CAB

CHASSIS HARNESS

5VPWR SUPPLY

GND WIRE

E320 (abnormality in front pump output pressure)

7-39

Troubleshooting

User Code

Service Code

Trouble

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

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

Failure of 5V

power supply

●

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

Between CN-116M A and B

Voltage

About 5V

Open circuit of

signal wire

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Between CN-116M C and pin 53 of controller

Resistance

≤

Between CN-116M B and ground

≤

Short circuit

of signal wire

(grounded)

●

Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.

Between CN-116M C and ground

Resistance

≥

Failure of sen-

sor

●

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

Between CN-116M C and ground

Voltage

0.5±0.2V

CN-447M

502#

00#

50#

ZX215-1005075

SIGNAL

GND WIRE

CONTROLLER

5VPWR SUPPLY

GND WIRE

CAB

CHASSIS HARNESS

REAR PUMP
PRESS. SENSOR

REAR PUMP PRESSURE
SIGNAL COLLECT PORT

E321 (abnormality in rear pump output pressure)

SANY Crawler Hydraulic Excavator SY195C9, SY205C9, SY215C9, SY225C9. Service Manual - page 25