LATEST SY195-205-215C9-shop MANUAL-20130104
LATEST SY195-205-215C9-shop MANUAL-20130104
LATEST SY195-205-215C9-shop MANUAL-20130104
Crawler Hydraulic
Excavator
SY195C-9
SY205C-9
SY215C-9
Shop Manual
SY195/205/215C9
Crawler Hydraulic Excavator
Shop Manual
● Compiled for experienced technicians, this shop manual aims to provide technical information
required for maintenance and repair of the machine.
● Work equipment or optional components not available locally may be included in this shop
manual. Consult authorized Sany dealers for information on these parts and components.
Material or technical specification is subject to change without prior notice.
● SY195C9, SY205C9 and SY215C9 excavators employ MITSUBISHI 6D34TL-20 engine.
Information on the engine is in Chapter 9.
WARNING
Read and follow the safety precautions and
instructions in this manual and on the ma-
chine decals. Failure to do so may cause
serious injury, death or property damage.
SY195-205-215C9 Crawler Hydraulic Excavator Table of Contents
Table of Contents
1 Introduction
1.1 How to Read the Shop Manual ................................................................................ 1-3
1.2 Terms for Maintenance Standard............................................................................. 1-6
1.3 Handling Electrical and Hydraulic Components....................................................... 1-9
1.3.1 Points to remember when handling electric components .............................. 1-9
1.3.2 Points to remember when handling hydraulic equipment ............................ 1-18
1.4 Hose Connector ..................................................................................................... 1-20
1.4.1 Type of hose connector................................................................................ 1-21
1.4.2 Hose connector tightening torque table ....................................................... 1-21
1.4.3 Connection of O-rings .................................................................................. 1-22
1.5 Table of Standard Tightening Torques .................................................................. 1-23
PD
1.6 Type of Bolts .......................................................................................................... 1-24
1.7 Tightening Sequence ............................................................................................. 1-24
1.8 Maintenance of Half Flanges ................................................................................. 1-25
1.8.1 Table of tightening torques for half flange bolts ........................................... 1-25
1.9 Conversion Table ................................................................................................... 1-26
2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3
IO
2.2 General Shop Safety ............................................................................................... 2-6
2.2.1 Rules and shop behavior ............................................................................... 2-7
2.2.2 Housekeeping ................................................................................................ 2-7
2.2.3 Shop Liquids Storage..................................................................................... 2-8
2.2.4 Cleaning Parts ............................................................................................... 2-8
2.2.5 Jacking Up the Machine................................................................................. 2-9
2.2.6 Electrical Dangers .......................................................................................... 2-9
2.2.7 Removing Attachments ................................................................................ 2-10
2.2.8 Cleaning the Machine .................................................................................. 2-10
2.2.9 Using the Correct Tools................................................................................ 2-10
2.2.10 Hoisting a Load ...........................................................................................2-11
2.2.11 Appropriate Working Apparel ..................................................................... 2-12
2.2.12 Safety Partners .......................................................................................... 2-12
2.2.13 Two people when engine running .............................................................. 2-13
2.2.14 Driving Pins ................................................................................................ 2-13
2.2.15 Aligning Parts or Components ................................................................... 2-14
3 Specifications
3.1 Dimensions .............................................................................................................. 3-3
3.2 Working Ranges ...................................................................................................... 3-4
3.3 Technical Specifications........................................................................................... 3-5
IO
3.3.1 Engine ............................................................................................................ 3-5
3.3.2 Swing motor ................................................................................................... 3-5
3.3.3 Control valve .................................................................................................. 3-5
3.3.4 Travel motor ................................................................................................... 3-6
3.4 Weight Table ............................................................................................................ 3-7
3.5 Recommended Oil, Fuel and Coolant...................................................................... 3-8
3.6 Capacity Table ......................................................................................................... 3-9
3.7 Engine Performance Curve ................................................................................... 3-10
4.5
PD
4.4.5 Regulator .................................................................................................... 4-35
4.4.5.1 Control mechanism makeup ............................................................... 4-37
4.4.5.2 Adjustment of the regulator ................................................................. 4-38
4.4.5.3 Operation ............................................................................................ 4-40
Hydraulic System, Part 2 ....................................................................................... 4-43
4.5.1 Control valve ................................................................................................ 4-43
4.5.2 Operating principle ....................................................................................... 4-46
4.5.2.1 When spool is in neutral position ........................................................ 4-46
IO
4.5.2.2 Travel .................................................................................................. 4-48
4.5.2.3 Arm...................................................................................................... 4-49
4.5.2.4 Boom................................................................................................... 4-54
4.5.2.5 Bucket ................................................................................................. 4-57
4.5.2.6 Swing .................................................................................................. 4-59
4.5.2.7 Option ................................................................................................. 4-61
4.5.2.8 Travel straight ..................................................................................... 4-62
4.5.2.9 Lock valve function ............................................................................. 4-63
4.5.2.10 Main relief valve function .................................................................. 4-65
4.5.2.11 Port relief valve function .................................................................... 4-66
4.5.3 Section view ................................................................................................. 4-70
4.6 Hydraulic System, Part 3 ....................................................................................... 4-81
4.6.1 Swing motor ................................................................................................. 4-81
4.6.2 Swing holding brake..................................................................................... 4-83
4.6.3 Relief valve portion ...................................................................................... 4-84
4.6.4 Reverse prevention valve ............................................................................ 4-86
5 Standard Values
5.1 Standard Values of Engine - related Parts............................................................... 5-3
5.2 Standard Values of Chassis-related Parts ............................................................... 5-4
7 Troubleshooting
7.1 Points to Remember When Troubleshooting ........................................................... 7-3
7.2 Troubleshooting Procedures .................................................................................... 7-5
7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-8
7.3.1 Connector location layout ............................................................................ 7-12
7.3.2 Electrical element circuit diagram (cab circuit)............................................. 7-18
7.3.3 Electrical control circuit diagram (engine circuit).......................................... 7-20
7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit) ........... 7-22
7.3.5 SWP type connector .................................................................................... 7-23
9 Engine
9.1 General .................................................................................................................... 9-3
9.1.1 Terms and standard ....................................................................................... 9-3
9.1.2 Engine serial No. and name plate .................................................................. 9-5
9.2 Engine Assembly ..................................................................................................... 9-6
9.2.1 Specifications ................................................................................................. 9-6
9.2.2 Structure and operating principle ................................................................... 9-7
9.2.2.1 Structure layout ..................................................................................... 9-7
9.2.2.2 Valve mechanism .................................................................................. 9-8
9.2.2.3 Cylinder head gasket ............................................................................ 9-9
9.2.2.4 Water director........................................................................................ 9-9
9.2.2.5 Connecting rod.................................................................................... 9-10
10 System Schematics
10.1 Hydraulic System Diagram .................................................................................. 10-3
10.2 Air-Conditioning Electrical Circuit Diagram .......................................................... 10-4
10.3 Fuse Box Relay ................................................................................................... 10-5
10.4 Control Switches and Monitor Electrical Diagram ............................................... 10-6
10.5 Operator Cab Electrical Circuit Diagram.............................................................. 10-7
10.6 Chassis Electrical Circuit Diagram....................................................................... 10-8
PD
IO
Introduction
1 Introduction
1.1 How to Read the Shop Manual ................................................................................ 1-3
1.2 Terms for Maintenance Standard............................................................................. 1-6
PD
1.3 Handling Electrical and Hydraulic Components....................................................... 1-9
1.4 Hose Connector ..................................................................................................... 1-20
1.5 Table of Standard Tightening Torques .................................................................. 1-23
1.6 Type of Bolts .......................................................................................................... 1-24
1.7 Tightening Sequence ............................................................................................. 1-24
1.8 Maintenance of Half Flanges ................................................................................. 1-25
1.9 Conversion Table ................................................................................................... 1-26
IO
PD
IO
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
1 INTRODUCTION
Introduction
Shop Safety
Standard Values
Troubleshooting
Engine
IO
This section explains the disassembling and
assembling of engine components. Detailed
information on the cooling system, lubricating
system, electrical system and the alternator is
also provided in this section.
System Schematics
3. Units
PD
IO
"tolerance".
PD
the "standard size" and the range of differ-
ence from the standard size is called the
Example
IO
Standard size Tolerance
–0.022
120 Std.size F 60
–0.126
Tolerance of hole
NOTE: The tolerance may be indicated in (upper):+0.046
Std.clearance (max.):0.122
the text and a table as [standard size (upper
limit of tolerance/lower limit of tolerance)]. Std.clearance (min.):0.030
Example
Tolerance
Standard size
Shaft Hole
-0.030 +0.046
φ60
-0.076 0
3. Standard interference
5. Clearance limit
6. Interference limit
tors
PD
1. Handling wiring harnesses and connec-
ZX215-1000007
NOTE:
1) Disconnecting connectors
ZX215-1000012
2) Connecting connectors
3) Connecting DT connectors
2 a 1 c
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
● Male connector: 1
● Female connector: 2
d
b
● Normal locking state (Horizontal): a, b, ZX215-1000016
d
ZX215-1000009
a. Disconnect the connector and wipe off
the water with a dry cloth.
ZX215-1000021
3. Sealing openings
ture is high
6. Flushing operations
7. Cleaning operations
NOTICE
Connector
● Do not over-tighten the nut (3). Exces-
ZX215-1000028
sive force applied on the metal sealing
IO
surface (4) and (5) may cause the joint
(1) to break. Be sure to tighten nut (3)
according to technical specifications.
24°
24°
Male Female
ZX215-1000029
24° Male
PD19
22
27
36
41
19
22
27
36
41
59(6,44)
98(10,72)
118(12,87)
235(24,173)
295(30,218)
50 50 490(50,361)
60 60 670(68,494)
70 70 980(100,723)
IO
19 17 44(4.5,32)
22 19 59(6,44)
27 22 118(12,87)
24° Female
36 30, 32 235(24,173)
41 36 295(30,218)
50 46 490(50,361)
NOTICE
● The torque values listed in the table are
intended for general application.
NOTICE
● Replace o-rings (6) with new ones
when re-connecting hoses. Hose connector
8 10
● Unless specified otherwise, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
Bolt Bolt Wrench Hex wrench Hexagonal bolt Hexagonal socket head bolt
diameter grade size size N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6 10.9 10 4 13.2 1.37 9.74 13.2 1.37 9.74
M8 10.9 13 6 31 3.16 22.87 31 3.16 22.87
M10 10.9 17 8 66 6.73 48.7 66 6.73 48.7
M12 10.9 19 10 113 11.53 83.39 113 11.53 83.39
M14 10.9 22 12 177 18.06 130.6 177 18.06 130.6
M16 10.9 24 14 279 28.47 205.9 279 28.47 205.9
M18
M20
M27
M10
10.9
10.9
10.9
12.9
27
30
41
17
PD
14
17
19
6
382
549
1320
78
38.98
56.02
134.7
7.96
281.9
405.16
974.16
57.76
382
549
1320
78
38.98
56.02
134.7
7.96
281.9
405.16
974.16
57.76
M12 12.9 19 8 137 13.98 101.1 137 13.98 101.1
M16 12.9 24 14 339 34.6 250.18 339 34.6 250.18
M20 12.9 30 17 664 67.75 490 664 67.75 490
IO
NOTICE
The following items apply to fine thread and coarse thread.
● Apply grease (zinc white B dissolved in spindle oil) onto the nuts and bolts to reduce
the friction coefficient. Thrust bolts do not require greasing.
● Always use bolts of correct length. The tip of bolts with excessive length may contact
the bottom of the bolt hole, resulting in under-tightening. Bolts with inadequate length
may result in insufficient fastening.
● The torque values listed in the table are intended for general application. If different
torque values are specified for a special purpose, the torque values in this table are
not applicable any more.
● Make sure the threads are free of dirt or rusts before installation of nuts and bolts.
Use correct bolts and tighten them properly 8.8 10.9 12.9
when assembling machines or components.
ZX215-1000031
12 9 4 1 6 7 14
IO
13 8 5 2 3 10 11
ZX215-1000032
CAUTION
● Always use suitable tools for specific
work. Use of improper tools and meth-
ods may cause a hazardous situation.
ZX215-1000035
IO
1.8.1 Table of tightening torques for half flange bolts
● Unless specified otherwise, tighten the half flange bolts to the torques below.
Example:
1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw
a horizontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular
line down from (B).
PD
3) Take the point where the two lines cross as (C). This point (C) gives the value when con-
verting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point
one place to the left) to convert it to 55 mm.
Length
Millimeters to Inches
(B) 1mm=0.03937in
0 1 2 3 4 5 6 7 8 9
0 0.000 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.535
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 PD 2.874 2.913 2.953 2.992 3.031 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Millimeters to Inches
1mm=0.03937in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
IO
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.535
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.031 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Inches to Millimeters
in. mm in. mm
1/64 0.3969 33/64 13.0969
1/32 0.7938 17/32 13.4938
3/64 1.1906 35/64 13.8906
1/16 1.5875 9/16 14.2875
5/64 1.9844 37/64 14.6844
3/32 2.3813 19/32 15.0813
7/64 2.7781 39/64 15.4781
1/8 3.1750 5/8 15.8750
9/64 3.5719 41/64 16.2719
5/32 3.9688 21/32 16.6688
11/64 4.3656 43/64 17.0656
3/16
7/32
13/64
15/64
PD4.7625
5.1594
5.5563
5.9531
11/16
23/32
45/64
47/64
17.4625
17.8594
18.2563
18.6531
1/4 6.3500 3/4 19.0500
17/64 6.7469 49/64 19.4469
9/32 7.1438 25/32 19.8438
19/64 7.5406 51/64 20.2406
IO
5/16 7.9375 13/16 20.6375
21/64 8.3344 53/64 21.0344
11/32 8.7313 27/32 21.4313
23/64 9.1281 55/64 21.8281
3/8 9.5250 7/8 22.2250
25/64 9.9219 57/64 22.6219
13/32 10.3188 29/32 23.0188
27/64 10.7156 59/64 23.4156
7/16 11.1125 15/16 23.8125
29/64 11.5094 61/64 24.2094
15/32 11.9063 31/32 24.6063
31/64 12.3031 63/64 25.0031
1/2 12.7000 1 25.4000
Feet to Meters
ft. 0 1 2 3 4 5 6 7 8 9 ft.
m m m m m m m m m m
- - 0.305 0.610 0.914 1.219 1.524 1.829 2.134 2.438 2.743 -
10 3.048 3.353 3.658 3.962 4.267 4.572 4.877 5.182 5.486 5.791 10
20 6.096 6.401 6.706 7.010 7.315 7.620 7.925 8.230 8.534 8.839 20
30 9.144 9.449 9.754 10.058 10.363 10.668 10.973 11.278 11.582 11.887 30
40 12.192 12.497 12.802 13.106 13.411 13.716 14.021 14.326 14.630 14.935 40
50 15.240 15.545 15.850 16.154 16.459 16.764 17.069 17.374 17.678 17.983 50
60 18.288 18.593 18.898 19.202 19.507 19.812 20.117 20.422 20.726 21.031 60
70 21.336 21.641 21.946 22.250 22.555 22.860 23.165 23.470 23.774 24.079 70
80 24.384 24.689 24.994 25.298 25.603 25.908 26.213 26.518 26.822 27.127 80
90 27.432 27.737 28.042 28.346 28.651 28.956 29.261 29.566 29.870 30.175 90
100
Meters to Feet
PD
30.480 30.785 31.090 31.394 31.699 32.004 32.309 32.614 32.918 33.223 100
m 0 1 2 3 4 5 6 7 8 9 m
ft. ft. ft. ft. ft. ft. ft. ft. ft. ft.
- - 3.2808 6.5617 9.8425 13.1234 16.4042 19.6850 22.9659 26.2467 29.5276 -
IO
10 32.8084 36.0892 39.3701 42.6509 45.9318 49.2126 52.4934 55.7743 59.0551 62.3360 10
20 65.6168 68.8976 72.1785 75.4593 78.7402 82.0210 85.3018 88.5827 91.8635 95.1444 20
30 98.4252 101.7060 104.9869 108.2677 111.5486 114.8294 118.1102 121.3911 124.6719 127.9528 30
40 131.2336 134.5144 137.7953 141.0761 144.3570 147.6378 150.9186 154.1995 157.4803 160.7612 40
50 164.0420 167.3228 170.6037 173.8845 177.1654 180.4462 183.7270 187.0079 190.2887 193.5696 50
60 196.8504 200.1312 203.4121 206.6929 209.9738 213.2546 216.5354 219.8163 223.0971 226.3780 60
70 229.6588 232.9396 236.2205 239.5013 242.7822 246.0630 249.3438 252.6247 255.9055 259.1864 70
80 262.4672 265.7480 269.0289 272.3097 275.5906 278.8714 282.1522 285.4331 288.7139 291.9948 80
90 295.2756 298.5564 301.8373 305.1181 308.3990 311.6798 314.9606 318.2415 321.5223 324.8032 90
100 328.0840 331.3648 334.6457 337.9265 341.2074 344.4882 347.7690 351.0499 354.3307 357.6116 100
Miles to Kilometers
miles 0 1 2 3 4 5 6 7 8 9 miles
km km km km km km km km km km
- - 1.609 3.219 4.828 6.437 8.047 9.656 11.265 12.875 14.484 -
10 16.093 17.703 19.312 20.921 22.531 24.140 25.749 27.359 28.968 30.577 10
20 32.187 33.796 35.405 37.015 38.624 40.234 41.843 43.452 45.062 46.671 20
30 48.280 49.890 51.499 53.108 54.718 56.327 57.936 59.546 61.155 62.764 30
40 64.374 65.983 67.592 69.202 70.811 72.420 74.030 75.639 77.248 78.858 40
50 80.467 82.077 83.686 85.295 86.904 88.514 90.123 91.732 93.342 94.951 50
60 96.561 98.170 99.779 101.388 102.998 104.607 106.216 107.826 109.435 111.044 60
70 112.654 114.263 115.872 117.482 119.091 120.701 122.310 123.919 125.529 127.138 70
80 128.748 130.357 131.966 133.575 135.185 136.794 138.403 140.013 141.622 143.231 80
90 144.841 146.450 148.059 149.669 151.278 152.887 154.497 156.106 157.715 159.325 90
PD
100 160.934 162.543 164.153 165.762 167.371 168.981 170.590 172.199 173.809 175.418 100
Kilometers to Miles
km 0 1 2 3 4 5 6 7 8 9 km
miles miles miles miles miles miles miles miles miles miles
- - 0.621 1.243 1.864 2.485 3.107 3.728 4.350 4.971 5.592 -
10 6.214 6.835 7.456 8.078 8.699 9.321 9.942 10.563 11.185 11.806 10
IO
20 12.427 13.049 13.670 14.292 14.913 15.534 16.156 16.777 17.398 18.020 20
30 18.641 19.262 19.884 20.505 21.127 21.748 22.369 22.991 23.612 24.233 30
40 24.855 25.476 26.098 26.719 27.340 27.962 28.583 29.204 29.826 30.447 40
50 31.069 31.690 32.311 32.933 33.554 34.175 34.797 35.418 36.039 36.661 50
60 37.282 37.904 38.525 39.146 39.768 40.389 41.010 41.632 42.253 42.875 60
70 43.496 44.117 44.739 45.360 45.981 46.603 47.224 47.845 48.467 49.088 70
80 49.710 50.331 50.952 51.574 52.195 52.816 53.438 54.059 54.681 55.302 80
90 55.923 56.545 57.166 57.787 58.409 59.030 59.652 60.273 60.894 61.516 90
100 62.137 62.758 63.380 64.001 64.622 65.244 65.865 66.487 67.108 67.729 100
Area
in2 0 1 2 3 4 5 6 7 8 9 in2
cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2
- - 6.452 12.903 19.355 25.806 32.258 38.710 45.161 51.613 58.064 -
10 64.516 70.968 77.419 83.871 90.322 96.774 103.226 109.677 116.129 122.580 10
20 129.032 135.484 141.935 148.387 154.838 161.290 167.742 174.193 180.645 187.096 20
30 193.548 200.000 206.451 212.903 219.354 225.806 232.258 238.709 245.161 251.612 30
40 258.064 264.516 270.967 277.419 283.870 290.322 296.774 303.225 309.677 316.128 40
50 322.580 329.032 335.483 341.935 348.386 354.838 361.290 367.741 374.193 380.644 50
60 387.096 393.548 399.999 406.451 412.902 419.354 425.806 432.257 438.709 445.160 60
70 451.612 458.064 464.515 470.967 477.418 483.870 490.322 496.773 503.225 509.676 70
80 516.128 522.580 529.031 535.483 541.934 548.386 554.838 561.289 567.741 574.192
PD 80
90 580.644 587.096 593.547 599.999 606.450 612.902 619.354 625.805 632.257 638.708 90
100 645.160 651.612 658.063 664.515 670.966 677.418 683.870 690.321 696.773 703.224 100
cm2 0 1 2 3 4 5 6 7 8 9 cm2
in2 in2 in2 in2 in2 in2 in2 in2 in2 in2
- - 0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395 -
IO
10 1.550 1.705 1.860 2.015 2.170 2.325 2.480 2.635 2.790 2.945 10
20 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340 4.495 20
30 4.650 4.805 4.960 5.115 5.270 5.425 5.580 5.735 5.890 6.045 30
40 6.200 6.355 6.510 6.665 6.820 6.975 7.130 7.285 7.440 7.595 40
50 7.750 7.905 8.060 8.215 8.370 8.525 8.680 8.835 8.990 9.145 50
60 9.300 9.455 9.610 9.765 9.920 10.075 10.230 10.385 10.540 10.695 60
70 10.850 11.005 11.160 11.315 11.470 11.625 11.780 11.935 12.090 12.245 70
80 12.400 12.555 12.710 12.865 13.020 13.175 13.330 13.485 13.640 13.795 80
90 13.950 14.105 14.260 14.415 14.570 14.725 14.880 15.035 15.190 15.345 90
100 15.500 15.655 15.810 15.965 16.120 16.275 16.430 16.585 16.740 16.895 100
Volume
in3 0 1 2 3 4 5 6 7 8 9 in3
cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc)
- - 16.387 32.774 49.161 65.548 81.935 98.322 114.709 131.096 147.484 -
10 163.871 180.258 196.645 213.032 229.419 245.806 262.193 278.580 294.967 311.354 10
20 327.741 344.128 360.515 376.902 393.289 409.677 426.064 442.451 458.838 475.225 20
30 491.612 507.999 524.386 540.773 557.160 573.547 589.934 606.321 622.708 639.095 30
40 655.482 671.869 688.257 704.644 721.031 737.418 753.805 770.192 786.579 802.966 40
50 819.353 835.740 852.127 868.514 884.901 901.288 917.675 934.062 950.449 966.837 50
60 983.224 999.611 1015.998 1032.385 1048.772 1065.159 1081.546 1097.933 1114.320 1130.707 60
70 1147.094 1163.481 1179.868 1196.255 1212.642 1229.030 1245.417 1261.804 1278.191 1294.578 70
80 1310.965 1327.352 1343.739 1360.126 1376.513 1392.900 1409.287 1425.674 1442.061 1458.448 80
PD
90 1474.835 1491.222 1507.610 1523.997 1540.384 1556.771 1573.158 1589.545 1605.932 1622.319 90
100 1638.706 1655.093 1671.480 1687.867 1704.254 1720.641 1737.028 1753.415 1769.802 1786.190 100
cm3 cm3
0 1 2 3 4 5 6 7 8 9
(cc) (cc)
3 3 3 3 3 3 3 3 3 3
in in in in in in in in in in
- - 0.0610 0.1220 0.1831 0.2441 0.3051 0.3661 0.4272 0.4882 0.5492 -
IO
10 0.6102 0.6713 0.7323 0.7933 0.8543 0.9153 0.9764 1.0374 1.0984 1.1594 10
20 1.2205 1.2815 1.3425 1.4035 1.4646 1.5256 1.5866 1.6476 1.7086 1.7697 20
30 1.8307 1.8917 1.9527 2.0138 2.0748 2.1358 2.1968 2.2579 2.3189 2.3799 30
40 2.4409 2.5019 2.5630 2.6240 2.6850 2.7460 2.8071 2.8681 2.9291 2.9901 40
50 3.0512 3.1122 3.1732 3.2342 3.2952 3.3563 3.4173 3.4783 3.5393 3.6004 50
60 3.6614 3.7224 3.7834 3.8444 3.9055 3.9665 4.0275 4.0885 4.1496 4.2106 60
70 4.2716 4.3326 4.3937 4.4547 4.5157 4.5767 4.6377 4.6988 4.7598 4.8208 70
80 4.8818 4.9429 5.0039 5.0649 5.1259 5.1870 5.2480 5.3090 5.3700 5.4310 80
90 5.4921 5.5531 5.6141 5.6751 5.7362 5.7972 5.8582 5.9192 5.9803 6.0413 90
100 6.1023 6.1633 6.2243 6.2854 6.3464 6.4074 6.4684 6.5295 6.5905 6.6515 100
U.S. U.S.
0 1 2 3 4 5 6 7 8 9
gal gal
liters liters liters liters liters liters liters liters liters liters
- - 3.7854 7.5709 11.3563 15.1417 18.9271 22.7126 26.4980 30.2834 34.0688 -
10 37.8543 41.6397 45.4251 49.2106 52.9960 56.7814 60.5668 64.3523 68.1377 71.9231 10
20 75.7085 79.4940 83.2794 87.0648 90.8502 94.6357 98.4211 102.2065 105.9920 109.7774 20
30 113.5628 117.3482 121.1337 124.9191 128.7045 132.4899 136.2754 140.0608 143.8462 147.6317 30
40 151.4171 155.2025 158.9879 162.7734 166.5588 170.3442 174.1296 177.9151 181.7005 185.4859 40
50 189.2714 193.0568 196.8422 200.6276 204.4131 208.1985 211.9839 215.7693 219.5548 223.3402 50
60 227.1256 230.9110 234.6965 238.4819 242.2673 246.0528 249.8382 253.6236 257.4090 261.1945 60
70 264.9799 268.7653 272.5507 276.3362 280.1216 283.9070 287.6925 291.4779 295.2633 299.0487 70
80 302.8342 306.6196 310.4050 314.1904 317.9759 321.7613 325.5467 329.3321 333.1176 336.9030 80
90 340.6884 344.4739 348.2593 352.0447 355.8301 359.6156 363.4010 367.1864 370.9718 374.7573 90
PD
100 378.5427 382.3281 386.1136 389.8990 393.6844 397.4698 401.2553 405.0407 408.8261 412.6115 100
liters 0 1 2 3 4 5 6 7 8 9 liters
gal gal gal gal gal gal gal gal gal gal
- - 0.2642 0.5283 0.7925 1.0567 1.3209 1.5850 1.8492 2.1134 2.3775 -
IO
10 2.6417 2.9059 3.1701 3.4342 3.6984 3.9626 4.2268 4.4909 4.7551 5.0193 10
20 5.2834 5.5476 5.8118 6.0760 6.3401 6.6043 6.8685 7.1326 7.3968 7.6610 20
30 7.9252 8.1893 8.4535 8.7177 8.9818 9.2460 9.5102 9.7744 10.0385 10.3027 30
40 10.5669 10.8311 11.0952 11.3594 11.6236 11.8877 12.1519 12.4161 12.6803 12.9444 40
50 13.2086 13.4728 13.7369 14.0011 14.2653 14.5295 14.7936 15.0578 15.3220 15.5861 50
60 15.8503 16.1145 16.3787 16.6428 16.9070 17.1712 17.4354 17.6995 17.9637 18.2279 60
70 18.4920 18.7562 19.0204 19.2846 19.5487 19.8129 20.0771 20.3412 20.6054 20.8696 70
80 21.1338 21.3979 21.6621 21.9263 22.1904 22.4546 22.7188 22.9830 23.2471 23.5113 80
90 23.7755 24.0397 24.3038 24.5680 24.8322 25.0963 25.3605 25.6247 25.8889 26.1530 90
100 26.4172 26.6814 26.9455 27.2097 27.4739 27.7381 28.0022 28.2664 28.5306 28.7947 100
lmp lmp
0 1 2 3 4 5 6 7 8 9
gal gal
liters liters liters liters liters liters liters liters liters liters
- - 4.5459 9.0918 13.6377 18.1836 22.7295 27.2754 31.8213 36.3672 40.9131 -
10 45.4590 50.0049 54.5508 59.0967 63.6426 68.1885 72.7344 77.2803 81.8262 86.3721 10
20 90.9180 95.4639 100.0098 104.5557 109.1016 113.6475 118.1934 122.7393 127.2852 131.8311 20
30 136.3770 140.9229 145.4688 150.0147 154.5606 159.1065 163.6524 168.1983 172.7442 177.2901 30
40 181.8360 186.3819 190.9278 195.4737 200.0196 204.5655 209.1114 213.6573 218.2032 222.7491 40
50 227.2950 231.8409 236.3868 240.9327 245.4786 250.0245 254.5704 259.1163 263.6622 268.2081 50
60 272.7540 277.2999 281.8458 286.3917 290.9376 295.4835 300.0294 304.5753 309.1212 313.6671 60
70 318.2130 322.7589 327.3048 331.8507 336.3966 340.9425 345.4884 350.0343 354.5802 359.1261 70
80 363.6720 368.2179 372.7638 377.3097 381.8556 386.4015 390.9474 395.4933 400.0392 404.5851 80
90 409.1310 413.6769 418.2228 422.7687 427.3146 431.8605 436.4064 440.9523 445.4982 450.0441 90
PD
100 454.5900 459.1359 463.6818 468.2277 472.7736 477.3195 481.8654 486.4113 490.9572 495.5031 100
liters 0 1 2 3 4 5 6 7 8 9 liters
gal gal gal gal gal gal gal gal gal gal
- - 0.2200 0.4400 0.6599 0.8799 1.0999 1.3199 1.5399 1.7598 1.9798 -
10 2.1998 2.4198 2.6398 2.8597 3.0797 3.2997 3.5197 3.7397 3.9596 4.1796 10
IO
20 4.3996 4.6196 4.8396 5.0595 5.2795 5.4995 5.7195 5.9395 6.1594 6.3794 20
30 6.5994 6.8194 7.0394 7.2593 7.4793 7.6993 7.9193 8.1393 8.3592 8.5792 30
40 8.7992 9.0192 9.2392 9.4591 9.6791 9.8991 10.1191 10.3391 10.5590 10.7790 40
50 10.9990 11.2190 11.4390 11.6589 11.8789 12.0989 12.3189 12.5389 12.7588 12.9788 50
60 13.1988 13.4188 13.6388 13.8587 14.0787 14.2987 14.5187 14.7387 14.9586 15.1786 60
70 15.3986 15.6186 15.8386 16.0585 16.2785 16.4985 16.7185 16.9385 17.1584 17.3784 70
80 17.5984 17.8184 18.0384 18.2583 18.4783 18.6983 18.9183 19.1383 19.3582 19.5782 80
90 19.7982 20.0182 20.2382 20.4581 20.6781 20.8981 21.1181 21.3381 21.5580 21.7780 90
100 21.9980 22.2180 22.4380 22.6579 22.8779 23.0979 23.3179 23.5379 23.7578 23.9778 100
Weight
Pound to Kilogram
lbs. 0 1 2 3 4 5 6 7 8 9 lbs.
kg kg kg kg kg kg kg kg kg kg
- - 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 -
10 4.536 4.989 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618 10
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154 20
30 13.608 14.061 14.515 14.968 15.422 15.876 16.329 16.783 17.236 17.690 30
40 18.144 18.597 19.051 19.504 19.958 20.412 20.865 21.319 21.772 22.226 40
50 22.680 23.133 23.587 24.040 24.494 24.947 25.401 25.855 26.308 26.762 50
60 27.215 27.669 28.123 28.576 29.030 29.483 29.937 30.391 30.844 31.298 60
70 31.751 32.205 32.658 33.112 33.566 34.019 34.473 34.926 35.380 35.834 70
80 36.287 36.741 37.194 37.648 38.102 38.555 39.009 39.462 39.916 40.370 80
90 40.823
100 45.359
41.277
45.813
41.730
46.266
PD
42.184
46.720
42.637
47.173
43.091
47.627
43.545
48.081
43.998
48.534
44.452
48.988
44.905
49.441 100
90
Kilogram to Pound
kg 0 1 2 3 4 5 6 7 8 9 kg
lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs.
IO
- - 2.205 4.409 6.614 8.818 11.023 13.228 15.432 17.637 19.842 -
10 22.046 24.251 26.455 28.660 30.865 33.069 35.274 37.479 39.683 41.888 10
20 44.092 46.297 48.502 50.706 52.911 55.116 57.320 59.525 61.729 63.934 20
30 66.139 68.343 70.548 72.752 74.957 77.162 79.366 81.571 83.776 85.980 30
40 88.185 90.389 92.594 94.799 97.003 99.208 101.413 103.617 105.822 108.026 40
50 110.231 112.436 114.640 116.845 119.049 121.254 123.459 125.663 127.868 130.073 50
60 132.277 134.482 136.686 138.891 141.096 143.300 145.505 147.710 149.914 152.119 60
70 154.323 156.528 158.733 160.937 163.142 165.347 167.551 169.756 171.960 174.165 70
80 176.370 178.574 180.779 182.983 185.188 187.393 189.597 191.802 194.007 196.211 80
90 198.416 200.620 202.825 205.030 207.234 209.439 211.644 213.848 216.053 218.257 90
100 220.462 222.667 224.871 227.076 229.280 231.485 233.690 235.894 238.099 240.304 100
Newton to Kilogram
N 0 10 20 30 40 50 60 70 80 90 N
kg kg kg kg kg kg kg kg kg kg
- - 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 -
100 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 100
200 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 200
300 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 300
400 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 400
500 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 500
600 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 600
700 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 700
800 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 800
900 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 900
PD
1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 1000
Kilogram to Newton
kg 0 1 2 3 4 5 6 7 8 9 kg
N N N N N N N N N N
- - 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 -
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
IO
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.34 500.14 509.95 519.76 529.56 539.37 549.18 558.98 568.79 578.60 50
60 588.40 598.21 608.02 617.82 627.63 637.44 647.24 657.05 666.86 676.66 60
70 686.47 696.28 706.08 715.89 725.70 735.50 745.31 755.12 764.92 774.73 70
80 784.54 794.34 804.15 813.96 823.76 833.57 843.38 853.18 862.99 872.80 80
90 882.60 892.41 902.22 912.02 921.83 931.64 941.44 951.25 961.06 970.86 90
100 980.67 990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100
Pressure
Lb/in² to Kg/cm²
lb/
0 1 2 3 4 5 6 7 8 9 lb/in2
in2
(psi) kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 (psi)
- - 0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5625 0.6328 -
10 0.7031 0.7734 0.8437 0.9140 0.9843 1.0546 1.1249 1.1952 1.2655 1.3358 10
20 1.4061 1.4764 1.5468 1.6171 1.6874 1.7577 1.8280 1.8983 1.9686 2.0389 20
30 2.1092 2.1795 2.2498 2.3201 2.3904 2.4607 2.5311 2.6014 2.6717 2.7420 30
40 2.8123 2.8826 2.9529 3.0232 3.0935 3.1638 3.2341 3.3044 3.3747 3.4450 40
50 3.5154 3.5857 3.6560 3.7263 3.7966 3.8669 3.9372 4.0075 4.0778 4.1481 50
60 4.2184 4.2887 4.3590 4.4293 4.4996 4.5700 4.6403 4.7106 4.7809 4.8512 60
70 4.9215 4.9918 5.0621 5.1324 5.2027 5.2730 5.3433 5.4136 5.4839 5.5543 70
80 5.6246 5.6949 5.7652 5.8355
PD 5.9058 5.9761 6.0464 6.1167 6.1870 6.2573 80
90 6.3276 6.3979 6.4682 6.5386 6.6089 6.6792 6.7495 6.8198 6.8901 6.9604 90
100 7.0307 7.1010 7.1713 7.2416 7.3119 7.3822 7.4525 7.5228 7.5932 7.6635 100
Kg/cm² to Lb/in²
kg/
0 1 2 3 4 5 6 7 8 9 kg/cm2
cm2
lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2 lb/in2
(psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi) (psi)
IO
- - 14.22 28.45 42.67 56.89 71.12 85.34 99.56 113.78 128.01 -
10 142.23 156.45 170.68 184.90 199.12 213.35 227.57 241.79 256.01 270.24 10
20 284.46 298.68 312.91 327.13 341.35 355.58 369.80 384.02 398.24 412.47 20
30 426.69 440.91 455.14 469.36 483.58 497.81 512.03 526.25 540.47 554.70 30
40 568.92 583.14 597.37 611.59 625.81 640.04 654.26 668.48 682.70 696.93 40
50 711.15 725.37 739.60 753.82 768.04 782.27 796.49 810.71 824.93 839.16 50
60 853.38 867.60 881.83 896.05 910.27 924.50 938.72 952.94 967.16 981.39 60
70 995.61 1009.83 1024.06 1038.28 1052.50 1066.73 1080.95 1095.17 1109.39 1123.62 70
80 1137.84 1152.06 1166.29 1180.51 1194.73 1208.96 1223.18 1237.40 1251.62 1265.85 80
90 1280.07 1294.29 1308.52 1322.74 1336.96 1351.19 1365.41 1379.63 1393.85 1408.08 90
100 1422.30 1436.52 1450.75 1464.97 1479.19 1493.42 1507.64 1521.86 1536.08 1550.31 100
Kg/cm² to Kpa
kg/ kg/
0 1 2 3 4 5 6 7 8 9
cm2 cm2
Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa Kpa
- - 98.1 196.1 294.2 392.3 490.3 588.4 686.5 784.5 882.6 -
10 980.7 1078.7 1176.8 1274.9 1372.9 1471.0 1569.1 1667.1 1765.2 1863.3 10
20 1961.3 2059.4 2157.5 2255.5 2353.6 2451.7 2549.7 2647.8 2745.9 2843.9 20
30 2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6 30
40 3922.7 4020.7 4118.8 4216.9 4314.9 4413.0 4511.1 4609.1 4707.2 4805.3 40
50 4903.4 5001.4 5099.5 5197.6 5295.6 5393.7 5491.8 5589.8 5687.9 5786.0 50
60 5884.0 5982.1 6080.2 6178.2 6276.3 6374.4 6472.4 6570.5 6668.6 6766.6 60
70 6864.7 6962.8 7060.8 7158.9 7257.0 7355.0 7453.1 7551.2 7649.2 7747.3 70
80 7845.4 7943.4 8041.5 8139.6 8237.6 8335.7 8433.8 8531.8 8629.9 8728.0 80
90 8826.0 8924.1 9022.2 9120.2 9218.3 9316.4 9414.4 9512.5 9610.6 9708.6
PD 90
100 9806.7 9904.8 10002.8 10100.9 10199.0 10297.0 10395.1 10493.2 10591.2 10689.3 100
Kpa to Kg/cm²
Kpa 0 100 200 300 400 500 600 700 800 900 Kpa
2 2 2 2 2 2 2 2 2 2
kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm
- - 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 -
1000 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 1000
IO
2000 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 2000
3000 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 3000
4000 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 4000
5000 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 5000
6000 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 6000
7000 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 7000
8000 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 8000
9000 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 9000
10000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 10000
Torque
Ft·lbs to Kg·m
ft·lbs 0 1 2 3 4 5 6 7 8 9 ft·lbs
kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m
- - 0.138 0.277 0.415 0.553 0.691 0.830 0.968 1.106 1.244 -
10 1.383 1.521 1.659 1.797 1.936 2.074 2.212 2.350 2.489 2.627 10
20 2.765 2.903 3.042 3.180 3.318 3.457 3.595 3.733 3.871 4.010 20
30 4.148 4.286 4.424 4.563 4.701 4.839 4.977 5.116 5.254 5.392 30
40 5.530 5.669 5.807 5.945 6.083 6.222 6.360 6.498 6.636 6.775 40
50 6.913 7.051 7.190 7.328 7.466 7.604 7.743 7.881 8.019 8.157 50
60 8.296 8.434 8.572 8.710 8.849 8.987 9.125 9.263 9.402 9.540 60
70 9.678 9.816 9.955 10.093 10.231 10.370 10.508 10.646 10.784 10.923 70
80 11.061 11.199 11.337 11.476
PD 11.614 11.752 11.890 12.029 12.167 12.305 80
90 12.443 12.582 12.720 12.858 12.996 13.135 13.273 13.411 13.549 13.688 90
100 13.826 13.964 14.103 14.241 14.379 14.517 14.656 14.794 14.932 15.070 100
Kg·m to Ft·lbs
kg·m 0 1 2 3 4 5 6 7 8 9 kg·m
ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs ft·lbs
- - 7.23 14.47 21.70 28.93 36.17 43.40 50.63 57.86 65.10 -
IO
10 72.33 79.56 86.80 94.03 101.26 108.50 115.73 122.96 130.19 137.43 10
20 144.66 151.89 159.13 166.36 173.59 180.83 188.06 195.29 202.52 209.76 20
30 216.99 224.22 231.46 238.69 245.92 253.16 260.39 267.62 274.85 282.09 30
40 289.32 296.55 303.79 311.02 318.25 325.49 332.72 339.95 347.18 354.42 40
50 361.65 368.88 376.12 383.35 390.58 397.82 405.05 412.28 419.51 426.75 50
60 433.98 441.21 448.45 455.68 462.91 470.15 477.38 484.61 491.84 499.08 60
70 506.31 513.54 520.78 528.01 535.24 542.48 549.71 556.94 564.17 571.41 70
80 578.64 585.87 593.11 600.34 607.57 614.81 622.04 629.27 636.50 643.74 80
90 650.97 658.20 665.44 672.67 679.90 687.14 694.37 701.60 708.83 716.07 90
100 723.30 730.53 737.77 745.00 752.23 759.47 766.70 773.93 781.16 788.40 100
Kg·m to N·m
kg·m 0 1 2 3 4 5 6 7 8 9 kg·m
N·m N·m N·m N·m N·m N·m N·m N·m N·m N·m
- - 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 -
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.34 500.14 509.95 519.76 529.56 539.37 549.18 558.98 568.79 578.60 50
60 588.40 598.21 608.02 617.82 627.63 637.44 647.24 657.05 666.86 676.66 60
70 686.47 696.28 706.08 715.89 725.70 735.50 745.31 755.12 764.92 774.73 70
80 784.54 794.34 804.15 813.96 823.76 833.57 843.38 853.18 862.99 872.80 80
90 882.60 892.41 902.22 912.02 921.83 931.64 941.44 951.25 961.06 970.86 90
100 980.67
N·m to Kg·m
PD
990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100
N·m 0 10 20 30 40 50 60 70 80 90 N·m
kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m kg·m
- - 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 -
100 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 10
IO
200 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 20
300 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 30
400 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 40
500 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 50
600 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 60
700 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 70
800 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 80
900 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 90
1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 100
Temperature
A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading
(or vice versa) is to enter the following table in the center (boldface column) of figures. These fig-
ures refer to the temperature in either Fahrenheit or Centigrade degrees.
To convert from Fahrenheit to Centigrade degrees, consider the center column as Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
To convert from Centigrade to Fahrenheit degrees, consider the center column as Centigrade val-
ues, and read the corresponding Fahrenheit temperature on the right.
PD
IO
1°C = 33.8°F
°C °F °C °F °C °F °C °F
-40.0 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -2
-20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6
PD 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
IO
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0.0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.8 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
E
G
PPDA
IAONK
BL
E
PPDAG
A IONK
BL
Shop Safety
2 Shop Safety
2.1 Hazard Alert Information .......................................................................................... 2-3
2.2 General Shop Safety ............................................................................................... 2-6
PD
2.3 Precautions for sling work and giving signals ........................................................ 2-25
IO
PD
IO
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
2 SHOP SAFETY
DANGER
Indicates an imminent hazard which WILL
result in serious injury or death if message
is ignored.
IO
WARNING
Indicates a potentially hazardous situation
which COULD result in serious injury or
death if message is ignored.
CAUTION
Indicates a potentially hazardous situation
which COULD RESULT IN MINOR OR MA-
JOR INJURY if message is ignored.
NOTICE
Indicates THE MACHINE MAY BE DAM-
AGED if improperly operated or main-
tained.
WARNING
● Improper repair procedures on this ma-
chine can be hazardous and could re-
sult in serious injury or even death.
PD
● All precautions outlined in this manual
apply only to intended repair proce-
dures of the machine or system. If you
perform any repairs not specifically pro-
hibited, you must be sure that it is safe
for you and others. In no event should
you or others engage in prohibited uses
or actions as described in this manual.
WARNING
Mistakes in operation are extremely haz-
IO
ardous. Read the Safety, Operation &
Maintenance Manual that came with the
machine carefully before operating the
machine. Failure to follow this alert could
result in serious injury or death.
2.2.2 Housekeeping
2.2.19 Accumulator
CAUTION
Never use a welder or a machine with a
higher voltage system to jump-start the
machine. Doing so may damage the ma-
chine’s electrical system or cause an unex-
pected explosion or fire resulting in minor
or major injury.
2.2.28 Lockout/tagout
Returning to service
IO
1. The authorized person who performed the
Lock out/Tagout procedure shall check the
area around the machine to ensure that no
one is exposed to any hazard before start-
up.
kg}.
PD
jected to a force as large as 39.2 kN {4,000
ing.
Select adequate ropes as per the weight of parts to be hoisted, referring to the table below.
Wire ropes
(Standard “Z” twist ropes without galvanizing)
Nominal Diameter of Rope Allowable Load
mm kN Ton
10 9.8 1.0
11.5 13.7 1.4
12.5 15.7 1.6
14 21.6 2.2
16 27.5 2.8
18 35.5 3.6
20
22.4
30
40
PD 43.1
54.9
98.1
176.5
4.4
5.6
10.0
18.0
50 274.6 28.0
60 392.2 40.0
CAUTION
IO
The allowable load is one-sixth of the
breaking strength of the rope used (Safety
coefficient: 6).
E
G
PPDA
A IONK
BL
E
PPDAG
A IONK
BL
Specifications
3 Specifications
3.1 Dimensions .............................................................................................................. 3-3
3.2 Working Ranges ...................................................................................................... 3-4
PD
3.3 Technical Specifications........................................................................................... 3-5
3.4 Weight Table ............................................................................................................ 3-7
3.5 Recommended Oil, Fuel and Coolant...................................................................... 3-8
3.6 Capacity Table ......................................................................................................... 3-9
3.7 Engine Performance Curve ................................................................................... 3-10
IO
PD
IO
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
3 SPECIFICATIONS
3.1 Dimensions
A
D
I
E C
H
F J
G
B PD K
ZX215-1001001
g
b
PD
e
c
d
IO
ZX215-1001002
3.3.1 Engine
Item Specification
Producer KAWASAKI
Model M5×180CHB-12A-51A/260
angle type, piston type
Type
(swing brake controller)
IO
Theoretical displacement cm³/rev 129.2
Safety valve set pressure MPa {Kg/cm³} 25.5 {260}
Rated engine speed rpm 2050
Brake release pressure MPa {Kg/cm³} 3.4 {34}
Item Specification
Model KMX15RB
Standard flow rate (equivalent to one pump) 300 L/min
When main relief valve is normal 34.3 MPa
Maximum pressure
When main relief valve is boosting 37.3 MPa
Maximum pressure When port relief valve is normal 39.2 MPa
Working oil temperature -20~90°C
Drained oil maximum pressure 0.3 MPa
Maker KYB
Model MAG-170VP-3400E
Variable displacement piston type
Type
(w/ brake valve and parking brake)
Weight kg 275
Equivalent displacement cm³/rev qxi
Large displacement q1 cm³/rev 130.4
Motor displacement q
Small displacement q2 cm³/rev 74.9
Speed reduction rate i 60
2-speed switching Lo-Hi Mpa > 6.86
Pilot pressure Hi-Lo Mpa > 1.96
Braking torque N·m 398
Operating displacement PD L/min 228
Operating pressure Mpa 33.34
Peak pressure Mpa within 44.1
Acting times (above 34.3Mpa and below 44.1Mpa) times < 1,200,000
Large flow rpm 1679
Motor shaft
Small flow rpm 2861
Swing speed
Large flow rpm 28
Reducer
Small flow rpm 47.7
Output torque KN·m within 37
IO
Normal PS
Input power
Maximum PS within 210 (within 30 consecutive sec.)
Normal Mpa within 0.2
Drain pressure
Momentary maximum Mpa within 0.5 (below 0.3 MHz)
Track frame
PD 200
300×2
56
2280
200
300×2
56
2432
200
300×2
56
2746
Swing bearing 286 286 286
Idler 116×2 116×2 116×2
Tensioning device 135×2 135×2 135×2
Carrier roller 25.5×4 25.5×4 25.5×4
IO
Track roller 40×14 40×14 40×16
Ambient temperature
Fluid
Reservoir -22 -4 14 32 50 68 86 104 122°F
type
-30 -20 -10 0 10 20 30 40 50°C
SAE 30
SAE 10W
Engine oil pan
SAE 10W-30
SAE 15W-40
Swing machinery
case Engine oil PD
Idler
SAE 30
Track roller
Carrier roller
SAE 10W
SAE 10W-30
SAE 15W-40
IO
Hydraulic system
L-HV32 Low-temp, wear-resistant
hydraulic oil
Hydraulic
oil L-HM46 Wear-resistant hydraulic oil
Diesel
Fuel tank GB252 Super-20 Diesel fuel
fuel
● Machine oil above API CF-4 (no lower than APC CD) is recommended.
● Gear oil GL-5 is recommended.
● Obtain genuine oil from Sany Heavy Machine or its authorized dealers.
PD
IO
N·m
Torque
600
Torque
500
400
300
kW
120
100
PD Power output
Power output
80
IO
60
40
g/kw·h
Fuel consumption
20 240
Fuel consumption
230
220
210
E
G
PPDA
IAONK
BL
E
PPDAG
IOK
AN
BL
PD
IO
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
PD
IO
1 2 3 4 5 6 7
ZX215-1002001
1) Fan Specification
2) Front engine mount
3) Fuel filter Oil capacity: 22 L
4) Start motor
5) Rubber damper assembly
6) Rear engine mount
7) Muffler
1 2 3 4 5 6
PD 7
9
IO
10
ZX215-1002002
3 2 1
4 5
PD 6 7 8 9
10
IO
ZX215-1002003
1 2 3 19 4 17
73±3.6 N·m
205±10 N·m
5
59±4.9 N·m
20
7
PD 18
8
IO
157±8 N·m
12
11 16 10 9
ZX215-1002004
13
14
15
ZX215-1002005
Specifications
Reduction ratio:
No.
16
Check item
PD
Backlash between No. 2 sun gear
and No.2 planetary gear
Backlash between No. 1 planetary
Standard clearance
0.13 – 0.47
Criteria
Clearance limit
1.00
Remedy
Replace
2 3 4 5 6
102 ±16 Nm
98 ±20 Nm
7
PD 8
10
IO
98 ±20 Nm
12 ±2.5 Nm
12 709 ±108 Nm
11
ZX215-1002006
14 13
IN
OIL LEVEL
DRAIN
15 ZX225-1102047
Specifications
Reduction ratio: 60
PD
IO
20
19
8
21
7
22
59~74 Nm
PD 10
6
23
5 24
11
4
12
25
26
13
IO
3
27
1 14
15
16
17
18
28
ZX215-1002007
Specifications
Reduction ratio:
A
A
1
PD 2
3
IO
549±50 Nm
549±50 Nm
A-A
ZX215-1002008
1 2 3 4
8
PD 7 6 5
10
11
IO
X
ZX215-1002009
Model
SY195C9M SY205C9M SY215C9M
Item
Shoe width(mm) 600 600 600
Link pitch(mm) 190 190 190
Q'ty (One side) 45 46 47
Unit: mm
4.3.2 Idler
4
3
7
8
157~255 Nm 9
1 2
PD
IO
ZX215-1002010
Unit: mm
8
Interference between idler
and bushing
72
PD Shaft
+0.108
+0.008
Standard clearance
Hole
-0.032
-0.062
ference
0.040 – 0.170
Clearance limit
ence limit
—
Replace
bushing
5 3
PD 6 7
2 1
ZX215-1002011
Unit: mm
IO
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange
169 —
2 Outside diameter of tread 144 130
3 Width of tread 43 —
4 Thickness of tread 34 27
5 Width of flange 17 —
Standard Tolerance Standard Clearance
Clearance between shaft size Shaft Hole clearance limit Replace
6
and bushing – 0.05 +0.10
40 0.05 – 0.20 —
– 0.10 0
Standard Tolerance Standard Interfer-
Interference between roller size Shaft Hole interference ence limit
7
and bushing +0.16 -0.040
47 0.12 – 0.24 —
+0.12 -0.08
Standard clearance Clearance limit
8 Axial clearance of roller
0.44 – 0.76 —
10
8 9 2 1
549±59 Nm
PD 7
4
5 6
ZX215-1002012
Unit: mm
8
PD
20
22 24
16 12
13
5
11 21
IO
23 25
7 6 15 2 9 3 14
10
18 17 19
ZX215-1002013
Unit: mm
12
Link
Protrusion of pin
PD
Inside width
Overall width
Tread width
Regular
82.69
2.65
40
38
Unit: mm
PD
IO
5 6 7
1
8
2
3 4
Unit: mm
Remedy
1 Height
26 16
2 Thickness 10
3 29.5
Length of base
IO
4 22 Build-up welding
5 20.5 or replace
6 Length at tip 17
7 18
Standard size Repair limit
8 Thickness
36 26
1) Bucket cylinder
2) Arm cylinder
2
3) Boom cylinder
4) Hydraulic tank
5) Hydraulic oil filter
6) Control valve
7) Hydraulic pump
8) Radiator
9) Accumulator
10) Left travel motor
11) Right travel motor
12) Swing motor
13) Lockout lever
14) Left pilot valve
PD
15) Center swivel joint
16) Right pilot valve 1
ZX215-1002015
3 4 5 6 7 8
PD
IO
A
10
11
A
12
18A
13 18B
14 18C
18D
15 18E
16 18F
17
18
ZX225-1102001
2
1
3 PD 4 5 6
A
A
IO
7
A-A
ZX215-1002017
a5
A1 {16N·m}
A2
a4
{36N·m}
PD
Clockwise
B3
DR1{170N·m}
B1 DR2{170N·m}
a3
5 Psv2 {36N·m}
4
IO
A3
DR3{170N·m} DR4{170N·m}
3 2 1
ZX215-1002018
Outline
● This pump consists of 2 variable capacity swash plate plunger pumps, 2 regulators, and 1 pi-
lot gear pump.
NOTE: For the location of the hydraulic pump on the machine, see “Hydraulic equipment layout”
on page 4-24.
2 3 13 6 7 14 8 9 16 10
15
1
12
1)
4
Front shaft
5
PD 9) End cover
11
ZX215-1002019
B 6 13 7 8
18
18 4 5
A 17 PD ZX215-1002020
Function
Structure
Operation of pump
(5).
PD
face (A) acts as a cam in relation to slipper
7
E
ZX215-1002022
between volumes (E) and (F) is created
inside cylinder block (7).
Control of delivery
NOTE: For the location of the pilot pump on the machine, see “Hydraulic equipment layout” on
page 4-24.
434
310
355
732
311
312
PD
309 307 308 434 850 466 725 435 361 353
ZX215-1002025
Function
PSV B
KDRDE5C-1
624 627 646 897 415
A
325
408 a
496
924
801 601
755 402 614
466
543
656
407 643 755
A
IO 733 756
631 708 545
724
731 887 611
651 652 733 541
SY195-205-215C9 Crawler Hydraulic Excavator
A-A
(KDRDE5K) PSV
ZX225-1102002
NOTE: Both the front pump and the rear pump are equipped with a regulator. For the location of
Structure and Function
4-35
Structure and Function SY195-205-215C9 Crawler Hydraulic Excavator
Function PSV
Current control
953
PSV
548: Feedback pin
KDRDE5C-1
Output flow Q
maximum flow changes.
Command current I
ZX215-1002033
PD
Minimum flow adjustment (pump block
side)
Command current I
ZX215-1002034
Output flow Q
When the hexagon socket head locating
screw (924) is being tightened, the control
diagram (as shown) will move to the right.
Command current I
ZX215-1002037
4.4.5.3 Operation
PD
Flow control
Output flow Q
Command current I
ZX215-1002030
completely closed.
IO
ZX225-1102008
BaR XAa2
BoR
BkR
Psp
BbR
XAb1
Dr2
XBtr
XBtL
XAs
PD
Dr6
XBtr
Dr3
(PTa)
PnA2
Dr7
Pns
Bs Btr As Atr
IO
Pz AtL PX PG
PbL
TRAVEL STRAIGHT
Py MR TRAVEL RIGHT
XAtr
TRAVEL LEFT SWING
XBb1
BOOM1
Bb(Rod) SWING PRIORITY BOOM2
XAb2
AbR
BUCKET OPTION
R1
R1
ZX225-1102009
XAtr : R. travel (reverse) pilot port XBp2: Bypass cut spool pilot port (P2 side)
XBtr : R. travel (forward) pilot port XAb2: Boom confluence (UP) pilot pressure
(XAo): (Option pilot port) Psp: Swing priority pilot port
(XBo): (Option pilot port) R1: Return port
XAk: Bucket (DIG) pilot port R2: Oil feed port
XBk: Bucket (DUMP) pilot port Atr: R. travel motor port (reverse)
XAb1: Boom 1 (UP) pilot port Btr: R. travel motor port (forward)
XBb1: Boom 2 (DOWN) pilot port (Ao): Option
XAa2: Arm 2 (OUT) pilot port (Bo): Option
XBa2: Arm 2 (IN) pilot port Ak: Bucket cylinder head end port (DIG)
XAtL: L. travel (reverse) pilot port Bk: Bucket cylinder rod end port (DUMP)
XBtL: L. travel (forward) pilot port Ab: Boom cylinder head end port (UP)
XAs: Swing (left) pilot port Bb: Boom cylinder rod end port (DOWN)
XBs: Swing (right) pilot port AtL: L. travel motor port (reverse)
XAa1: Arm 1 (OUT) pilot port
XBa:
Dr1:
Px:
Py:
Arm 1 (IN) pilot port
Drain port
Work equipment signal port
Travel signal port
PD BtL:
As:
Bs:
Aa:
Ba:
L. travel motor port (forward)
Swing motor port (left swing)
Swing motor port (right swing)
Arm cylinder rod end port (OUT)
Arm cylinder head end port (IN)
Pz: Main relief valve boosting pressure P1: Pump port (P1 side)
PG: Pilot pressure resource port P2: Pump port (P2 side)
Pns: Swing logic control valve pilot port MR: Main relief valve
IO
PCK: Bucket (DIG) stroke limit pilot port AR: Arm regeneration check valve
PnA2: Arm 2 logic control valve pilot port AbR: Port relief valve
Dr2: Drain port BbR: Port relief valve
Dr3: Drain port AkR: Port relief valve
Dr6: Drain port BkR: Port relief valve
Dr7: Drain port AoR: Port relief valve
Pal: Lock valve pilot port (arm rod end) BoR: Port relief valve
PbL: Lock valve pilot port (boom head end) AaR: Port relief valve
(XBp1):Bypass cut spool pilot port (P1 side) BaR: Port relief valve
NOTE: For more technical information about the control valve, see “Control valve” on page 3-5.
P2 (P3) R1 (P0) P1 PG
d1 d2 d3
Φ0.7 Φ0.7 Φ0.7
MR
CMR2
CMR1
Pz
TRAVEL R XBtr
(PTa) TRAVEL
XAtr STRAIGHT
Px
Atr CPG
Btr
CP1
Dr2
Dr6 LCs Py
XBs
SWING 4-Φ2.1 XBtl TRAVEL L
XAs XAtl
As Btl
Bs Atl
Pns C2
Dr1
SWING
PRIORITY Psp LCb
XBb1
BOOM2XAb2
PD
CCb
BbR
HVb
AbR
XAb1
Bb
(ROD)
Ab
(HEAD)
PbL
BOOM1
LCk
LCo
PCk
(XBo)
XBk
OPTION (XAo)
BUCKET
XAk
AoR
(Ao) BkR (ROD)
(Bo) Bk
IO
Ak
AkR (HEAD)
BoR
AR
PnA2
Dr3 Dr7
LCa LCAT2
2-Φ1.0 LCAP2
2-Φ2.0
XAa1 XBa2
ARM2
ARM1 XBa1 XAa2
(HEAD)
AaR
Ba
BaR
Aa
CCo
(ROD)
HVa
CCk PaL
BYPASS (XBp1)
CUT R2
XBp2
(P5)
ZX225-1102010
[Main circuit]
● When all the spools are in neutral position, ● Working oil supplied from the hydraulic
working oil supplied from the hydraulic pump (Rear) flows in through pump port P2
pump (Front) flows in through pump port and is introduced into the main passage
P1 and is introduced into the main pas- (3). It passes the neutral bypass (2) (neutral
sage (1). It passes the neutral bypass (2) M-shaped spool mechanism) of the spools
(neutral M-shaped spool mechanism) of of R travel (301), swing (305), boom con-
the spools of straight travel (308), L. travel fluence (boom 2: 307), option (309), arm 1
(301), boom 1 (303), bucket (304) and arm (302), and flows back into the working oil
2 (306), and flows back into the working oil tank via return port (R1).
tank via return port (R1).
PD
IO
(1)
(2)
(PTa)
XAtL XBtL
XBb1 XAbL
XAk PCk
X8k
XBa2 XAa2
PD CCo CCk
P2 (P3) R1
(3)
(2)
XBtr XAtr
XAs XBs
Psp XAb2
IO
(XAo) (XBo)
XAa1 XBa1
XBp2 (XBp1)
ZX225-1102011
4.5.2.2 Travel
[Main circuit] ● On the other hand, return oil from the left
and right travel motor passes the left (right)
● When pressure at pilot port XBtL for left travel spool via port Atl (Atr), and returns to
travel spool (301) rises, neutral bypass (2) working oil tank via return port (R1).
at boom 1 side is closed, and working oil
supplied from the hydraulic pump (front) is ● The principle is the same when travel on
introduced into the left travel motor via port the opposite side is operated (when pres-
Btl. PD sure at pilot port XAtr and XAtl rises).
XAtr XBtr
IO
Atr Btr
4.5.2.3 Arm
R H
Aa 256-101
511
PD XAa2
XAa1
IO
Ba
511
ZX225-1102013
(2) Arm IN
● Light load
Arm weight
R H
Aa
PD
XBa2
(302-317)
IO
XBa1
(b)
(a) Ba
ZX225-1102014
R H
Aa
PD
XBa2
IO
(302-317)
XBa1
(c)
(257-211) Ba
(a)
ZX225-1102015
4.5.2.4 Boom
(1) Boom UP
H R
511
Ab
Bb
XAb2
PD XAb1
IO
511
ZX225-1102016
511
Ab Bb
XBb1
(b) (a)
(303-317)
ZX225-1102017
4.5.2.5 Bucket
● When bucket DIG is operated, pilot pres- ● When boom UP and bucket DIG are oper-
sure oil is supplied into port XAk and buck- ated simultaneously, pilot pressure oil is
et spool (304) moves to the right. Working supplied to port Pck. Therefore, the stroke
oil from port P1 is introduced into neutral
PD of bucket spool is not limited at stroke end,
bypass (2) via main passage (1). Neutral but on any position halfway. As a result,
bypass is cut off by switching bucket spool bucket cylinder passage is throttled and
(304). Therefore, working oil in the paral- working oil flows into boom 1 spool (303)
lel passage pushes open the cone valve via bucket spool (304). In this way, boom
(511) of the check valve, and flows into UP operation takes precedence.
the bucket spool (304) via the U passage.
H R
IO
Ak Bk
H
XAk
Pck
ZX225-1102018
H
PD R
Ak Bk
IO
XBk
ZX225-1102019
● When bucket DIG is operated, pilot pres- switching neutral bypass valve spool (310).
sure oil is supplied into port XBp2 and the Therefore, working oil pushes open the
neutral bypass cutoff valve spool (310) is check valve, and interconnects with the U
switched. Working oil from port P2 is in- passage via the inside path, and converg-
troduced into neutral bypass (2) via main es with bucket spool (304).
passage (3). Neutral bypass is cut off by
4.5.2.6 Swing
● When swing is operated, pilot pressure ● On the other hand, return oil from the
oil is supplied into port XAs (or XBs) and swing motor flows in via port Bs (or port
swing spool (305) is switched. Working As). Then, it flows into tank port (R1) via
oil from port P2 is introduced into neutral the spool periphery and returns to the
bypass (2) via main passage (3). Neutral working oil tank.
XBs
PD
bypass is cut off by switching swing spool
XAs
IO
As Bs
(254-101)
Psp
PD
ZX225-1102021
IO
4.5.2.7 Option
XAo
XBo
IO
Ao Bo
ZX225-1102022
When travel spool (301) and other spool are [Main circuit]
operated simultaneously.
● When straight travel spool (308) is
The following case shows when travel spool switched, the right/left travel spool (301)
(301) and swing spool (305) are operated si- are interconnected with port P2. The paral-
multaneously. (When pilot pressure oil is sup- lel passage of swing/boom 2/option/arm
plied to port XAtL, port XAtr and port Xas) 1 circuit and boom 1/bucket/arm 2 circuit
are interconnected with port P1. Therefore,
[Pilot circuit] working oil supplied from port P2 flows into
port Atl and port Atr, and is supplied to the
● The side path of right/left travel spool (301) two travel motors equally.
and the side path of the swing spool (305)
at the downflow side are closed. ● On the other hand, working oil from port P1
is supplied to the swing motor via port As.
● Pilot oil from port PG is supplied to port
PD
PTa and straight travel spool (308) is ● When oil pressure at port P2 is lower than
switched. that at port P1, part of the working oil form
port P1 is supplied to port P2. In this way,
sharp decrease of travel speed is averted.
P1 P2
IO
PTa
ZX225-1102023
● The lock valve option set (252) is installed ● When boom 1 spool (303) is in neutral po-
between the arm cylinder rod end (R) and sition, spool (252-511) in the lock valve op-
arm 2 spool (302) and arm 2 spool (306). tion set is pressed against the valve seat
It is used to reduce the internal leakage of of the valve sleeve (252-541) inside the
the spool due to cylinder pressure. lock valve option set, as shown in the illus-
tration, via the spring force of spring (252-
● Likewise, lockout option set (252) is also 321).
installed between boom cylinder head end
(H) and boom 2 spool (303) to reduce the ● At this position, working oil at the boom
internal leakage of he spool due to cylinder cylinder head end (H) flows in via hole (a)
pressure. and flows out from hole (b) through the
periphery of the lock valve option set spool
(1) Spool in neutral position (252-511), pressing the cone valve (513)
against the valve seat of the valve block
● The following shows when boom 1 spool
PD via hole (b). By this means, oil leakage is
(303) is in neutral position. (The same is reduced.
with arm 2 spool (306))
252-321 252-511
252-541
(b)
IO
513
(a)
ZX225-1102024
● When boom DOWN is operated, pilot pres- in the spring chamber (RH) flows into drain
sure oil is supplied to port PbL and port circuit via hole (b). In this way, the cone
XBb1. Spool (252-511) inside the lock valve (513) is pushed up by the pressure
valve option set moves to the top by via pi- at boom cylinder head end (H) and the
lot pressure oil. Through the movement of function of the lock valve option set (252)
spool (252-511) inside the lock valve option is released.
set, hole (a) is cutoff and working oil from
boom cylinder head end (H) does not flow
into spring chamber (RH). In addition, oil
252-511
(b) (RH)
PD 513
(a)
PbL
IO
XBb
ZX225-1102025
The main relief valve is installed on the valve and enters low-pressure path (R).
block A (101). Its function is described below:
● Opening of cone valve (611) causes pres-
● Working oil flows into chamber (a) from sure in chamber (a) to drop and valve rod
passage (P) via the hole of valve seat (541) (512) is open. In this way, working oil in
and hole on valve rod (512). Valve rod (512) passage (P) flows into low-pressure path
is pressed against valve seat (541), form- (R) directly.
ing a tight seal.
● When pressure oil high than 3MPa is sup-
● When pressure in passage (P) exceeds plied to port Pz, this pressure oil pushes
the elastic force of spring (621), cone valve plunger (614) to the left. The set load of
(611) is pushed open. Therefore, working spring (621) is changed and pressure of
oil flows through the hole on valve sleeve the main relief valve rises.
(103) via the periphery of cone valve (611)
541
PD 611 621
P
IO
R
Pz
A
B
PD
P
IO
R
301 511 541
ZX225-1102027
A B
301 R
511 541
ZX225-1102028
R
PD 611 621
ZX225-1102029
C
IO
P
R
621
611
ZX225-1102030
R PD
511 611
ZX225-1102031
B
IO
P
R
511 611
ZX225-1102032
R
PD
541 ZX225-1102033
IO
R
541 ZX225-1102034
B A 273×10
153
(Po)
XAtr
561 TRAVEL
TRAVEL R STRAIGHTC
C 273×12 HR
XBa1 XBa2
ARM1 PD ARM2
G AR G
Dr3
IO
View O-O
274×4
CCo
Pns (P5)
Dr6 Dr7
PnA2
CCk P P
210
153 561
(P5)
Viw P-P
XAa2
XBp2 PCk
ZX225-1102035
N
543
101 159 541 542 166
550
(PTa)
XAtL XBtL
XBb1
XAk
PD XAbL
PCk
XBk
XBa2 XAa2
IO
CCo CCk
514 521 561 551 551 561 521 514
View A-A
PB 156
2-156
View N-N
ZX225-1102036
Section B-B
XBtr XAtr
975
XAs XBs
975
Psp XAb2
975
(XAo)
975
PD (XBo)
975
XAb1 XBa1
975
XBp2 (XBp1)
IO
975
975
165 165 165
ZX225-1102037
154
164
201 TRAVEL TRAVEL 201
RIGHT STRAIGHT
336 336
332 XAtr 332
335 323
321 335
320
332
332
332 MR
261
261
308
163 601
314
165
163
511
Atr
PD Pz
512
522
553
521
551
CP1 CMR1
561 562
IO
165 562
163
163 Btr
CMR2
163
553
522
512
159
264 159
264
204
XBtr (PTa) 204
164
Viw C-C
154
ZX225-1102038
201
SWING TRAVEL LEFT 336
201
336 332
XBs XAtL
332 335
335
321
321
320
320
332
261
332
314
261
305
161 PD
163
163 AtL
As
254 511
521
C2
551
561
IO
BtL
251
Bs
165
Dr2
264
264
XAs XBtl
204
204
163 163
View D-D
ZX225-1102039
551
561
165
CCb
PD CRb
523
552
561
513
511
307 521
LCb
163
Xb2
551
551 561
IO
561
Bb
311
161 303
163
264
261 602
332 XAb1 204
BbR
320
329 158
339
332
336
202 Psp
SWING
PRIORITY
View E-E View L-L
ZX225-1102040
259
164
201
201
OPTION BUCKET 336
336
(XBo) 332
332
335 335
321 321
320 320
602
332 AkR 332
261 261
604 304
163
209
971×4
165
309
163 (Ao)
PD Ak
163
511 511
521
521
LCo
IO
551
551
561
561
(Bo)
Bk
163
165
971×4
209
163
264 602
604 264
(XAo) 206
204 BkR
211
164 BoR XBk
561
154 258
PCk
View F-F ZX225-1102041
201
201 336
336
332
332 XBa1 XBa2
335
335
321 321
320 320
257 Dr3
AR 332
332
261
261
306
L L
158
163
165
162
152
165
162
152
PD CRa
513
523
561
552
251
302
511
521
R2 521
511
165
163
264 264
602 XAa2
XAa1
BaR 204
205
View G-G
ZX225-1102042
612 169 162 152 158 154 164 152 162 162 152 164 154 158 152 162 164 154 169 612 162 152
PCV2 PCV1
XBp2
(XBp1)
View H-H
165 310 163 262 331 337 373 372 331333 203
ZX225-1102043
IO
Mounting Mounting
NO. Part name Q’ty NO. Part name Q’ty
torque (N·m) torque (N·m)
SPOOL ASS’Y, travel
101 BLOCK, valve A 1 308 1
straight
102 BLOCK, valve B 1 309 SPOOL, option 1
13~17 151 PLUG 3 310 SPOOL, bypass cut 2
34~39 152 PLUG 7 311 SPOOL, swing priority 1
220~250 153 PLUG 3 320 SPRING 9
69~78 154 PLUG 6 321 SPRING 8
7.4~9.8 156 PLUG, orifice 3 322 SPRING 1
7.5~10 158 PLUG 5 323 SPRING 1
10~14 159 PLUG 3 326 SPRING 1
161 O-RING 3 327 SPRING 1
162 O-RING 7 329 SPRING 1
163 O-RING PD 21 331 SPRING SEAT 4
164 O-RING 7 332 SPRING SEAT 22
165 O-RING 14 16~18 333 FLANGE SOCKET 2
166 O-RING 1 335 STOPPER 9
168 O-RING 3 16~18 336 FLANGE SOCKET 11
169 O-RING 2 337 STOPPER 2
201 COVER, spring 9 339 STOPPER 2
202 COVER, spring 2 372 SPRING 2
203 COVER, spring 2 373 SPRING 2
IO
204 COVER, spool 7 511 VALVE, cone 8
205 COVER, spool 1 512 VALVE, cone 2
206 COVER, spool 1 513 VALVE, cone 2
209 FLANGE 2 514 VALVE, cone 2
210 PLATE 1 521 SPRING 10
211 PISTON 1 522 SPRING 2
49~65 251 VALVE, logic control 2 523 SPRING 2
OPTION ASS’Y, lock
9.8~14 252 2 541 BALL 1
valve
254 VALVE GP, swing logic 1 542 SPRING SEAT 1
256 VALVE GP, arm 2 logic 1 543 SPRING 1
CHECK VALVE ASS’Y,
69~78 257 1 25~29 550 PLUG 1
arm regeneration
258 PLUG 1 230~260 551 PLUG 11
259 PLUG 1 230~260 552 PLUG 2
261 O-RING 11 130~150 553 PLUG 2
Mounting Mounting
NO. Part name Q’ty NO. Part name Q’ty
torque (N·m) torque (N·m)
262 O-RING 2 561 O-RING 17
264 O-RING 9 562 O-RING 2
25~34 273 SCREW, hex, S,H,C 44 69~78 601 VALVE, main relief 1
98~120 274 SCREW, hex, S,H,C 4 69~78 602 VALVE, port relief 6
301 SPOOL, travel 2 120~140 604 VALVE, port relief 2
302 SPOOL ASS’Y, arm 1 1 69~78 612 PLUG 2
303 SPOOL ASS’Y, boom 1 1 49~65 971 SCREW, hex, S,H,C 8
304 SPOOL, bucket 1 140~180 975 SCREW, hex, S,H,C 10
305 SPOOL, swing 1 977 PLATE name 1
306 SPOOL, arm 2 1 978 PIN 2
307 SPOOL, boom 2 1
PD
IO
L
PD SH PG
PB
B
IP
PA A
1
M DB
IO
2
ZX215-1002081
7
6
A-A
5
A
PD 8 9
4
IO
10
11
3
12
2
13
1
ZX215-1002082
● Port PG is connected with the pilot gear pump directly, and a pressure of 3.9MPa is main-
tained.
M
Pump a
1
Main valve
7
PX
PG
6
SH
PD 5
ZX215-1002083
● Port SH is connected with port PX of the main valve. Once any movement other than travel
is applied on the main valve, pressure will be generated at port PX, and port PG is intercon-
nected with chamber a beneath piston 7. The pressurized oil compresses brake spring (1)
and pushes the brake piston up. Disc (5) is separated from plate (6), releasing the brake.
IO
M
Pump a
1
Main valve
7
PX
PG
6
SH
ZX215-1002084
● Otherwise, no pressure is generated at port PX, and port PG is shut off from chamber a be-
neath piston (7). Brake piston (7) is pushed down by brake spring (1). Disc (5) and plate (6)
are pushed together, and the brake is applied.
Structure
Function
Operation
NOTE: For the location of the reverse prevention valve on the swing motor, see “Swing motor” on
page 4-81.
A T1
T2 B
1 PD
2
3 4
7 6 5
Swing
motor T
IO
B A
Pressure MA
Containment pressure
Reversal pressure
Pressure MB
1st reversal
2nd reversal
Motor speed
Start
PD Brake Reversal
Time
ZX215-1002088
Outline
Operation
a 2 3
NOTE: For the location of the central swivel joint on the machine, see “Hydraulic equipment lay-
out” on page 4-24.
Z
7 8 13 9 10
6 H
11
5 12
4 D
PDB
A
3
F1
IO
G1 H-H H
G
D1
A1
B1
C1
Z
ZX215-1002092
PD
IO
NOTE: For the location of the travel motor on the machine, see “Hydraulic equipment layout” on
page 4-24.
Ps Pm1 Tin 1 Dr P1 A
Pm2
PD
Pp 2 P2 B
ZX215-1002132
Ps: Duo speed pilot hose port A. Mounting surface with sprocket
Pm1: Pressure detection port B. Mounting surface with undercarriage
Pm2: Pressure detection port 1. Mounting hole with sprocket
IO
Tin: Motor case inner oil port 2. Mounting hole with undercarriage
Pp: Brake release port
Dr: Oil drain port
P1: Main oil port
P2: Main oil port
NOTE: For more technical information about the travel motor, see “Travel motor” on page 3-6.
Connected to sprocket
1-6
PD 1-2
1-1
3
IO
2-4 2-3 2-2 2-6 2-5
ZX215-1002093
Counterbalance valve
Function
A. Stopped state
● When the main valve is neutralized (motor pressure is generated at port P1 and port
stopped), port M1 and port M2 are shut off P2. The motor is not rotating.
by spool (1) and check valve (2) since no
8-1
8-2
Circuit B
Circuit C2
Circuit C1
Orifice D1
Damper chamber A1
Orifice D2
M1 PD M2
Orifice D3
Damper chamber A2
Orifice D4
Spring chamber 2
Spring chamber 1
P1 P2
6-1 6-2
IO
7-1 7-2
● When hydraulic oil from the main pump damper chamber (A1) via orifice (4-1) and
enters port P1 of the counterbalance valve, check valve (5-1). The force generated in
spring (3) is pushed to the left by check this way pushes spring (7-2) on the other
valve (2-1), opening circuit C1. The hy- side and moves piston (1) to the right. At
draulic oil enters the piston motor via port this time, return oil from port M2 passes
M, trying to make the motor rotating. At the through circuit of the notch on the periph-
same time, return oil from the piston motor ery of piston (1), and through port P2 when
enters the counterbalance via port M2, but pressure is generated at port M2, and en-
it is stopped by check valve (2-2). The out- ters the tank via the main valve finally. The
put pressure of the main pump increases motor is activated at this time.
as a result, and the hydraulic oil works
on the inside of spring chamber (1) and
8-2
8
8-1
PD
Circuit B
Circuit C2
Circuit C1 M1 M2
Orifice D3
Orifice D1
IO
Damper chamber A2
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
P1 P2
6-2
6-1
7-1 7-2
C. Counterbalance function
D. Braking of motor
● The counterbalance valve and the relief braking force of motor rotation. When the
valve forms the braking circuit. When the pressure at port M2 reaches the set pres-
main valve is neutralized position, hydrau- sure of relief valve (8), cone valve (8-1) at
lic oil from the main pump is cut off, and port M1 overcomes the force of spring (8-
pressure at port P1 and P2 is the same. 2) and moves to the left, and hydraulic oil
As a result, piston (1) moves to the neutral flows the port M1. In this way, the impact-
position, and the opening area of circuit B ing force due to inertia at port M2 is under
decreases. At the same time, because of control, and vacuum at port M1 is avoided.
the inertia of external force, the motor does
not stop rotating (pump effect), and pres-
sure at port M2 rises and serves as the
8-2
8
8-1
PD Circuit B
Circuit C2
Circuit C1 M1 M2
Orifice D3
Orifice D1
Damper chamber A2
IO
Damper chamber A1
Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1
P1 P2
6-1 6-2
7-1
7-2
● The counterbalance valve can function ber E to release travel brake. In addition,
as a shuttle valve to release travel brake. piston (1) moves to neutral position, as
When hydraulic oil is fed to port P1, piston shown in fig 5 when motor stops. Circuit D
(1) moves to the right, as shown in fig. 4. is closed and drain circuit F of motor body
At this time, drain circuit F of motor body is connected. Hydraulic oil in travel brak-
is cut off, and circuit D leading to cylinder ing cylinder chamber E is conducted to the
chamber E for travel braking is connected. drain circuit of motor body, and travel brake
Hydraulic oil flows to circuit G via the ori- is applied.
fice, and enters travel brake cylinder cham-
1
Circuit D
PD Circuit D
Orifice
Circuit F
Circuit F
Circuit D Circuit G Circuit G
Cylinder chamber E
ZX215-1002097
IO
1
Circuit D
Circuit D
Orifice
Circuit F
Circuit F
Circuit D Circuit G Circuit G Cylinder chamber E
ZX215-1002098
18
MA MB
PD
1) Counterbalance valve and check valve
Function
ZX215-1002101
19 MA MB
Operation when pressurized oil is supplied
ZX215-1002102
● Operating the travel lever conducts the
pressurized oil from the control valve to
port (PA). The pressurized oil opens suc-
tion safety valve (8A) and then flows to
motor outlet port (MB) via motor inlet port
(MA). The motor outlet side is closed by
suction safety valve (8B) and spool (19),
so the pressure at the supply side rises.
19
MA MB
E1 E2
ZX215-1002103
PA PB
20
2) Safety valve
Function
Spool MB MA
ZX215-1002107
PA PB 8B
● As the travel lever is operated, the pres-
surized oil from the pump moves spool (19) 8A
toward right. The passage to the suction
safety valve functions as a circuit which
passes through notch (B2) of spool (19),
S1
producing large differential pressure. The
pump pressure rises, providing a large
tractional force to the valve. 19
MA MB
E1 B2
ZX215-1002106
3) Relief valve PD
● The structure of the relief valve is shown
in the right figure. This valve is area dif-
ference and direct flow type. It has impact
damping function during starting and brak-
ing.
ZX215-1002108
IO
A. Operation principle and function
B. Damping function
IO
4
7
6
1 2
5
PD 10
3
5 9
6 7
11 12
8 10
IO
13
4
11
1 12
ZX215-1002112
P3
P2
A
T
P
2
3
P
1
4
P4
PD
64~73.5Nm
A
19~22Nm
P1
IO
ZX215-1002113
6
7
3
PD 9
10
2
IO
1
A-A ZX215-1002114
Operation
1. When in neutral
f
● The relationship of the position of plunger
(1) and body (10) [orifice (f) is in the middle
between drain chamber (D) and pump 1 T
pressure chamber (PP)] does not change
until retainer (9) contacts plunger (1). Me- P
tering spring (2) contracts in proportion to
the stroke of the control lever. Pressure
at port (P1) also rises in proportion to the
stroke of the control lever. In this way, the Pilot
pump P1 P2
control valve spool moves to a position
where the pressure of chamber (A) (same
as pressure at port (P1)) and the force of
the return spring of the control valve spool A M M B
are balanced. Control valve
ZX215-1002116
P
P
P2
P5
PD P1
P5 A
P6
IO
2 1
4 3
P4 P3
ZX215-1002119
37~30Nm
B
65~45Nm
1 8~6Nm
5 PD
6
C C
7
B-B
2,4 1,3
B
13~11Nm
IO
C-C
8~6Nm
ZX215-1002120
Operation
1. When in neutral
f T
● If the pressure of port (P1) is lowered ex-
P
cessively, plunger (1) is pushed down by f’
metering spring (2).
1
Pilot pump PP
● Orifice (f) is shut off from drain chamber (D), P1 P2
and it is almost simultaneously intercon-
nected to pump pressure chamber (PP).PD A Control valve B
4. At full stroke f
T
● Lever (5) pushes down piston (4), and re- P
f’
tainer (9) pushes down plunger (1).
1
● Orifice (f) is shut off from drain chamber (D), Pilot pump PP
and is interconnected to pump pressure P1 P2
chamber (PP).
A Control valve B
● Therefore, the pilot pressure oil from
ZX215-1002124
the self pressure reducing valve passes
through orifice (f) and flows to chamber
(A) from port (P1) to push the control valve
spool.
P1
P2
T1
A8 A7 A6 A5 A4 A3 A2 A1
5 4 3 2 6
P T2
P2
A8
A7
PD A6 A5 A4 A3 A2 A1
1
T1
P1
P2
ZX225-1102044
NOTE: For the location of the solenoid valve on the machine, see “Hydraulic equipment layout”
on page 4-24.
4.6.10 Accumulator
6
PD ZX215-1002126
1
K
2
Model
Pressure
Precision
3
PD 5
6
IO
3
ZX215-1002127
Specifications
1 2 3
A B
4
ZX215-1002128
1) Pressure connector
2) Name plate
3) Connector
4) Vent hole
Function
PD
● This sensor measures pump oil pressure
and uses it to control various machine op-
erations. When oil pressure compresses
the diaphragm, it deforms and this is de-
tected in the form of electric signals.
IO
5340±50N·m
2 1 544.9±5.1kgm 3
56.9±10.7N·m
267±35N·m 5.8±1.1kgm
27.2±3.6kgm
ZX215-1002129
PD 7900±50N·m
2 1 806.1±5.1kgm 3
56.9±10.7N·m
367±35N·m
5.8±1.1kgm
37.4±3.6kgm
ZX215-1002130
IO
5480±50N·m
2 1 559.2±5.1kgm
3
56.9±10.7N·m
267±35N·m
5.8±1.1kgm
27.2±3.6kgm
ZX215-1002131
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Cylinder
size Shaft Hole clearance limit
-0.036 +0.222
Clearance between pis- Boom 85 0.083 – 0.312 0.412 Replace
1 -0.090 +0.047
ton rod and bushing -0.036 +0.222 bushing
Arm 95 0.083 – 0.312 0.412
-0.090 +0.047
-0.036 +0.258
Bucket 80 0.078 – 0.334 0.434
-0.076 +0.048
-0.030 +0.246
Boom 80 0.230 – 0.322 1.0
Clearance between pis- -0.076 +0.200
-0.030 +0.246
2 ton rod support pin and Arm 80 0.230 – 0.322 1.0
-0.076 +0.200
bushing -0.030 +0.246
Bucket PD70 0.230 – 0.322 1.0 Replace
-0.076 +0.200
pin or
-0.030 +0.246
Boom 70 0.230 – 0.322 1.0 bushing
Clearance between cyl- -0.076 +0.200
-0.030 +0.246
3 inder bottom support pin Arm 80 0.230 – 0.322 1.0
-0.076 +0.200
and bushing -0.030 +0.246
Bucket 70 0.230 – 0.322 1.0
-0.076 +0.200
IO
F
D
G E
,
PD A
K H B
ZX215-1002133
IO
1
6
3 ,-,
A-A
C-C
5
B-B
2 4 J-J
G-G
H-H
Unit: mm
Unit: mm
Arm dimension
11
B 19
12 5
A C D
A
D 6
B 14 C
10
8 7
13
PD
18
16
IO
17 15
A-A B-B
3 2
1
4
C-C D-D
ZX215-1002135
Unit: mm
SY195C-9 SY205C-9 SY215C-9
No. Standard Standard Standard
Tolerance Tolerance Tolerance
size size size
+0.1 +0.1 +0.1
1 φ80 φ80 φ80
0 0 0
—
PD
±1
±0.2
2,919
2,631.3
411
640 ±0.2
—
±1
—
2,919
2,631.3
411
640 ±0.2
—
±1
—
Bucket dimension
2 5
A
18 17
6
1 4
16
19 PD
7
21 20 10
15 8 14
IO
13
14 8
11 9 10
12
A-A ZX215-1002136
Unit: mm
SY195C-9 SY205C-9 SY215C-9
No.
Standard size Tolerance Standard size Tolerance Standard size Tolerance
1 457.5 ±0.5 457.5 ±0.5 457.5 ±0.5
2 22 ±0.5 22 ±0.5 22 ±0.5
3 92°45’ — 92°45’ — 92°45’ —
4 458.1 — 458.1 — 458.1 —
5 1490 — 1490 — 1490 —
6 164 — 164 — 162.9 —
7 45° — 45° — 45° —
+0.2
8 φ80 ±0.2 φ80 ±0.2 φ80
0
9 326.5 ±1 326.5 ±1 326.5 ±1
10 57 — 57 — 57 —
11 107 — PD 107 — 107 —
12 471.5 — 471.5 — 471.5 —
13 φ23.5 — φ23.5 — φ23.5 —
14 φ136 — φ136 — φ136 —
15 φ190 — φ190 — φ190 —
16 130.9 — 130.9 — 132.3 —
17 125 — 125 — 125 —
18 107 — 107 — 110 —
IO
19 82 — 82 — 82 —
+1 +1 +1
20 348.5 348.5
0 0 348.5 0
21 37 — 37 — 37 —
1
2
C
PD C
C B 6
IO
C
8
ZX215-1002137
4) Condenser (SG447750-A040)
C. Warm air/cool air
5) Receiver tank (DENSO.4)
6) Hot water return piping
7) A/C unit assembly (SG443180-9320)
8) Air duct
2
1
3
4
PD
IO
7 6
ZX215-1002138
1 2 3 4 5
Monitor
OFF
MODE AUTO
FULL AUTO AIRCONDITION
TEMP
A/C 9
6 7 8
ZX215-1002139
ZX215-1002140
SW
1.25R
7
FURM B G1 G2 ACC M ST
PD
3
FL1
3 8
H
FUCD 20A FUM OFF
60A 15A 8
1.25R 5A ACC
2 13 ON
START MRF
8 8
2
CMB RLCD RLCC RLBM
13 15 13
M
RLCC RLCD RLBM
GND
REC
FFE
1
Vz
2RL 1.25RL
Pt
10 1.25L 15
16 16 19 25 24 22 26 25
1
D MR
FLZ
MCD SPCD M 200W
RLSF 5 2 40A
M 11
1.256 10 2G 13 +B 16 19 25 24 26
5
80W 10 BLCM
6 16 19 22 23 1
10
5
G
1
BAT
4
CMB
ACC
SW
7
7
4
4
6
D1
D2
02
1.25B
RCD RLCH
02 02
RLCH
03
9
ECC
40W
BLC
4
1
3
2
RLCH
12 12
G
8
12
28 15
14
15
IO 14
17
THAM THW THI THF
15
18
15
12
20
15
13 3
22 21
22
16
SSD
27 4
15 23
21
27
ACM
28
20
29
2 24
30
30
25
31
31 22 32
32
9
15
38
32
33
26
34 35
34 35 35 22
10
1.25B
3
SPHL
CM
Structure and Function
0.85B
0.50
02 02
M M M
2B
4.7.3 Circuit diagram
06 0.5B
2B 2B
01 02
06
03
MAM MV1 MV2
4-130
SY195-205-215C9 Crawler Hydraulic Excavator Structure and Function
Wire No. Diameter/Color code Wire color Wire No. Diameter/Color code Wire color
B Black 0.5VW Violet+white
Br(R) Brown 0.5YB Yellow+black
0.85W White 0.5WO White+orange
RL Red+blue 0.5PB Pink+black
G Green 0.5VR Violet+red
0.5BL Black+blue 0.5BG Black+green
0.5R Red+blue 0.5WY White+yellow
0.5Y Yellow 0.5WR White+red
0.5BR Black+red 0.5BrW Brown+white
0.5BrY Brown+yellow 0.5GO Green+orange
0.5BY Black+yellow 0.5Sb Sky blue
0.5GW Green+white 0.5OW Orange+white
0.5LO Blue+orange
PD 1.25V Violet
0.5PG Pink+green 1.25RG Red+green
0.5RY Red+yellow 1.25RW Red+orange
0.5BW Black+white 0.85GL Green+Blue
0.5LgR Light green+red
Air in cab
Out side fresh air
Receiver
Lo-pres.
side
Compressor
Hi-pres.
side
PD
Hot air
Lo-pressure portion Hi-pressure portion
ZX215-1002141
IO
4.7.4.2 Heating cycle diagram
Engine
Blower motor
Internal air
4.7.5 Compressor
3 4
1 2
16
15
14
13
PD 5
12
IO
11 10 9 8 7
ZX215-1002143
1) Stator 9) Slipper
2) Front radial bearing 10) Front cylinder block
3) Thrust bearing 11) Piston
4) Front radial bearing 12) Front cylinder head
5) Rear cylinder head 13) Shaft seal
6) Safety valve 14) Main shaft
7) Rear cylinder block 15) Hub
8) Swash plate 16) Rotor
Operating principle
Compressor type: 10S15C. This compres- back and forth and transforms the refrigerant
sor has 5 plungers in total with a piston on sucked from the evaporator from low tempera-
both sides of each plunger. The rotation of ture and low pressure gas state to high tem-
the swash plate drives the pistons to move perature and high pressure state.
Process 1 Process 2
Valve plate
Process 6
Intlet valve disc
PD Process 3
Process 5 Process 4
ZX215-1002144
4.7.6 Clutch
1) Rotor
1
2) Stator coil
2
3) Snap ring
3
4) Ball bearing 4
5) Stator
6) Center piece
● Operating principle
4.7.8 Condenser
1
4
2
1)
2)
3)
Condenser core
Bracket
Bolt with gasket
PD 4)
5)
Refrigerant inlet
Refrigerant outlet
ZX215-1002146
Function
1) Spring 2
2) Diaphragm
1
3) Probe
4) Needle valve
Operating principle
3
● Refrigerant from the receiver tank spurts
out via the orifice, turns into low-temper-
ature, low-pressure liquid (mist) after ex- 4 Compressor
panding, and enters the evaporator. Reservoir
ZX215-1002147
4.7.9 Evaporator
1) Expansion valve
2) Evaporator
Operating principle
1) Inlet 2
1
2) Outlet
3) Receiver/dehydrator
IO
4) Desiccant
Function
3
● Dehydration of refrigerant 4
ZX215-1002149
1) O-ring
Pressure
2) Mobile contact point
3) Hood
1
4) Plug and fixed contact 7
5) Spring 2
6
6) Chamber
7) Diaphragm
Function 3
5
Feature
DIFF DIFF
HI pressure ON
operating value Above 0.02 MPa 0.59±0.2 MPa
OFF
LO pressure 0.196±0.02 MPa 0.196~0.250 MPa 2.94~3.19 MPa
operating value
ON
MID pressure
operating value OFF
1.23±0.1 MPa 1.52±0.08 MPa
/KΩ
10
Resistance value
Technical specifications
8
Item Specification 6
4.7.13 Refrigerant
PD
1.6 mA (MAX)
WARNING
● Obey local material disposal regula-
tions. Never discharge refrigerant di-
rectly into the air.
IO
● Refrigerant R134 a is a harmless gas
under room temperature. It will change
into highly toxic gas when burning.
1. General property
2. Refrigerant cycle
● After evaporation in the evaporator, refrigerant turns from gas into liquid via the compressor
and the condenser, which finishes a refrigerant cycle.
lgp
Liquefaction completed Refrigerant cyclic curve
IO
Liquefaction starts
Condensing process
Liquid
Expansion throttle
Compressing
Expansion valve process Compressor
Evaporating process
Evaporator
h=u+Apv(kJ/kg)
3. Feeding of refrigerant
1) Refrigerant: HFC-134a
ZX215-1002153
PD
● Inspect the state of the refrigerant in the
A/C circulation system through the sight
glass:
Sight glass
turns clear.
4. Evacuation
Evacuating steps
Step 2: Evacuation
Lo-press. gauge
returns to 0
turn to zero.
no leakage is detected.
squeezing sound).
To compressor Fluorine cylinder
ZX215-1002157
PD
3) Add refrigerant until pressure reading on
the Lo-pressure gauge is 1kgf/cm² . Hi-
pressure valve of the gauge is open at this Valve
Lo Hi Lo-press gauge Lo Hi
time. Close the Hi-pressure valve when OFF ON
at 1kgf/cm2
OFF OFF
feeding is finished. Lo-pres. gauge
reads1kgf/cm2
● When evacuation is finished, add refrigerant into the cooling system as per the following in-
struction:
Performance testing
Evacuation starts
Evacuation ends
Add refrigerant
Air leak check
Pres. gauge
Tighten pipe joint abnormal (1) Compressor stopped, charge at hi-press end
Check leak point (2)Compressor running, add at lo-press end
S
R134a
ZX215-1002160
CAUTION
● Do not operate the compressor when
refrigerant charging is in progress.
Otherwise, refrigerant will counterflow
and cause the cylinder and hoses to
explode.
HIGH pressure:
ZX215-1002162
LOW pressure:
CAUTION
● Opening the Hi-pressure valve of the
pressure gauge will cause pressurized
gas to counterflow and cause the hoses
and the fluorine cylinder to explode, re-
sulting in serious damage.
Compressor
Water less than 40°C running
(Do not use hot water)
ZX215-1002163
Disc plate
3. Install a new cylinder onto the cylinder
valve. Refrigerant
cylinder
lowing instruction: PD
1) Tighten the valve of the fluorine cylinder,
and then, loosen it a bit.
CAUTION Valve
Lo Hi
Do not press the valve with naked hand to Loose OFF
Green
Blue
R-134a
Red
After the engine has been preheated, read the pressure value on the gauge under the following
conditions:
Gauge reading:
PD
Lo-pressure end: 0.15~0.25 Mpa (1.5~2.5 Kgf/cm²)
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
IO
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
R134a
ZX215-1002167
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
8 3
0
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
ZX215-1002168
Symptom
at the Lo-pressure
end unstable (some-
ices up at the expan-
sion valve causing
circular temporary
Cause
hydrator.
PD
● When the system is ● Moisture in the system ● Over-saturation of de- ● Replace receiver/
operating, pressure dehydrator
times vacuum, stop. When ice melts, ices up at the expan- ture in the system
sometimes normal) the system becomes sion valve and hinders through constant
normal again. the circulation of the pumping.
refrigerating system.
IO
● Add proper volume
of new refrigerant.
● Insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
ZX215-1002169
Symptom
● Pressure at both Hi- and
Ho-pressure ends very
low
● Air leaks
somewhere
in the refrig-
erating sys-
Cause
PD Analysis
● Insufficient
refrigerant in the
system
● Check for air leakage with a leak
detector. Make necessary re-
pairs.
Remedy
● Foam is continuously ob- tem ● Leak of refriger- ● Add proper amount of refriger-
served via the sight glass ant ant.
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
ZX215-1002170
Symptom
● Pressure at both
Hi- and Lo-pressure
sides very low
● Contaminant in the
Cause
04 15 2
03 05
4 15 20
3 5
1
02 06 25
2 6 10 25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
ZX215-1002171
Symptom
● Vacuum at Lo-pres-
sure side; pressure
at Hi-pressure side
extremely low
● Moisture or contami-
PD
Cause
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa
ZX215-1002172
Symptom
● Pressure at both Hi-
and Lo-pressure
sides very high
Cause
NOTE: If refrigerant is added with no evacuation operation performed, the following gauge read-
ing will appear:
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01 35
MPa MPa
Symptom
● Pressure at both Hi- and ● Air enters the re-
PDCause Analysis
● Air enters the refriger-
ZX215-1002173
Remedy
● Check if compressor
Lo-pressure ends very frigerating system ant system oil is contaminated
high or inadequate.
● Insufficient evacuation
● Lo-pressure piping feel- ● Evacuate and add
IO
ing hot new refrigerant.
● Foam is observed
through the sight glass
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
ZX215-1002174
Symptom
● Pressure at both
Hi- and Lo-pressure
ends very high
● Expansion valve de-
Cause
● Compressing error
Symptom: No refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1 5
01 07 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 - 01 35
MPa MPa
ZX215-1002175
Symptom
● Pressure at Lo-pressure
side very high
PD
● Compressor internal
leakage
Cause
● Compressing fault;
Analysis Remedy
● Repair or replace
compressor
● Leaking or damaged
● Pressure at Hi-pressure valve, loosened parts
side very low
IO
Oil shall be added into the A/C system for lubrication. Compressor oil is solved in the refrigerant
and circulates in the system. When the air conditioning system is shut down, compressor oil will
stay inside the components. If no compressor oil is added into the system when replacing compo-
nents, inadequate lubrication will result. Add compressor oil according to the chart below:
Replaced component
Compressor Condenser Evaporator
Volume (ml) See "CAUTION" below 40 40
ND8# (10P, 10PA, 10S series compressor)
Compressor oil grade
ND9#(TV series compressor)
CAUTION
● Add oil into a new compressor according to the required volume of the system. When
PD
the compressor is to be replaced, discharge the surplus oil in it.
● Over-filling of compressor oil will reduce the refrigerating capacity. Short of compres-
sor oil in the system will cause compressor abnormality.
● Protect pipe joints and O-rings from contamination when disassembling the compres-
sor.
IO
4 5
PD 6 7
9
8
1
IO
Z
ZX215-1002176
Engine startup
Lo s
(Starting signal)
S SW
Hi Hi Governor E
L B
motor Safety
When it happens, the controller checks the
s
relay
Throttle Off
P E
P
Lo B BR C
M B E
signal voltage from the fuel control dial and Throttle On P Alternator Lock
relay
(Starting signal)
sets the engine speed to the speed set by
(Potentiometer singal)
Drive signal
Shutdown Bat. relay
Shutdown
relay
Controller
(Regulating signal)
(Start switch ON signal)
ZX215-1002177
Starting relay
Start S/W
troller. Hi
Fuel ctrl dial
Hi
Lo
Governor
s
E
(Starting signal)
S
L
SW
B
motor Safety s
relay
Throttle Off
P E
P
Lo B BR C
M B E
(Starting signal)
(Potentiometer singal)
Drive signal
Shutdown
Controller
(Regulating signal)
(Start switch ON signal)
ZX215-1002178
Engine shutdown
down device to cut off the fuel supply and Fuel ctrl dial
Engine
Start motor Starting relay
Start S/W
Lo s (Starting signal) L
S SW
E
P
Lo B E
B BR C
Alternator Lock
Throttle On
relay
(Starting signal)
Shutdown
relay
Controller
(Regulating signal)
(Start switch ON signal)
ZX215-1002179
4.8.2 Components
140°
9×10°
1
Level 1
Level 10
2 25°
5
PD
6 Yellow
a 5V
IO
b Blue
VR
b
a c
Red
c 0V
ZX215-1002180
1) Knob 4) Ball
2) Dial 5) Potentiometer
3) Spring 6) Connector
Function
Dial angle
controller. The controller calculates the col-
lected signals and drives the throttle motor
via signal output and controls the volume
of the injection pump so that the engine
can run at an optimal speed.
0 0.25 1.72 4.49 4.75 5(V)
Voltage(V)
● When throttle voltage is beyond the area,
ZX215-1002181
the controller sends out alarm code and
the engine runs at low idle. The area under
the sloping line is the abnormality detection
area.
Remark: PD
The left limit is 0%; and the right limit is 100%.
IO
4.8.2.2 Controller
Controller
PD TYPE
USE FOR
NO
ZX215-1002182
........
........ ...................
...................
........ ...................
........ ...................
A2 A1 ZX215-1002183
A1 A1
Pin Input/ Pin Input/
Signal name Signal name
No. output No. output
1 Power ground 53 Rear pump pressure sensor Input
2 Power ground 54 Sensor power ground Input
3 Power ground 55 Sensor power ground Input
4 Power supply(24V constant) Input 56 Sensor power Output
5 Power supply(24V constant) Input 60 Monitor CAN Low
11 Fuel level sensor Input 61 Calibrator CAN High
15 Throttle position signal Input 62 Calibrator CAN Low
19 Engine speed signal Input 66 Coolant temp very high Input
22 RS232 ground 67 R. travel pressure sensor Input
23 RS232 receive 68 Swing pressure sensor Input
24 Enable 69 Bucket CURL pressure sensor Input
30 Coolant temperature sensor signal Input 70 Boom RAISE pressure sensor Input
31 Oil temperature sensor signal Input 71 Arm IN pressure sensor Input
33
34
38
41
42
43
Backup pilot pressure signal
Fuel dial signal
Engine speed signal ground
RS232 send
CPU mode
Enable
PD
Input
Input
72
73
74
75
76
77
Front pump pressure sensor
Sensor PWR ground
Sensor PWR
Sensor PWR
State indicator
Monitor CAN High
Input
Output
Output
Self-diagnosis function
Power ON signal
Start switch
Power supply
Preheating signal
Starting signal
Power supply
Monitor panel
R. travel signal
Network signal 2
Working mode signal L. travel signal
Signal monitor info Travel spd select signal 3
Auto-deceleration signal Boom UP signal
Signal monitor info 4
Boom DOWN signal
5
Arm IN signal
6
9
10
Starting signal
Starting motor
Heater relay Elct. intake air heater
17
PD PPC Basic pressure
13
12
PPC Lock Bucket Swing Travel
solenoid confluence priority speed
16 solenoid solenoid solenoid
valve valve valve
valve
IO
15
14 Control valve
ports
F. Pressure sensor
R. Pressure sensor
PnA2 XBp2
Proportional valve
Proportional valve
PsP
Main valve
Servo Servo
F R
Travel motor
Main pump
Remark:
The diagram above illustrates the electrical control system. For hydraulic circuit diagram, see Hy-
draulic System section.
Boom UP/DOWN
Arm IN/OUT
Bucket DIG/DUMP
Swing
MIN
F1 F2 F3 F4 F5
ESC Enter
Fuel control dial
MC Controller input
Pressure Option pressure
H/S/L/B sensor
sensor
Auto-idle cancel
KC controller
P2
P1
IO
Engine
Oil-feed
Pump adjustment
Pump proportional
pressure reduce
solenoid valve
Throttle motor
CAN path
Potentio- Motor
meter
Engine speed
Calibrator
SW LED Actual throttle position feedback
MEMORYON
H S L A/I
Control motor
LED
DOWN UP
7 RPW
LED
SW
PWR resouce DC24V H S L A/I
Fuel, coolant temp and others
(Battery)
ZX215-1002186
Function
Engine torque T
output. Four different working modes are
available: H, S, L and B. To select a work- H
S
ing mode, use the working mode selector L
switch on the machine monitor.
Specifications
H mode
Engine
speed
~1600
PD
1600~1800 1800~2250
Engine power KW
H
S
S mode
Engine
~1600 1600~2250
IO
speed Engine speed N
ZX215-1002194
Power (KW) 60 84
L mode
Engine
2250
speed
Pump delivery Q
H
Power (KW) 60
S
H mode
Engine torque T
● The matching point of H mode: rated
speed 114kW/2050rpm
Engine torque T
Mode S L B H
S
L
Power output rate 90% 80% 70%
H
PD Engine power KW S
Engine speed N
ZX215-1002194
IO
Pump delivery Q
M
P Speed
Servo Servo
sensor
(Throttle position feedback signal)
Proportional Proportional
(Control signal)
(Control signal)
Hi
(Motor drive signal)
Lo
Monitor
IO
Controller
F1 F2 F3 F4 F5
(CAN bus)
ESC Enter
Bucket DUMP signal
Boom UP signal
Arm OUT signal
R. Travel signal
L. Travel signal
Arm IN signal
Swing signal
ZX215-1002196
Pump 1
delivery
amount
Pump 1
delivery
amount
ZX215-1002197
Pump 2
delivery
amount
Pump 2
delivery
amount
Pump 2
delivery
amount
ZX215-1002198
Function
Operation
PD
● When the work equipment is operating, the
controller collects the signal of pilot pres-
sure sensor, and determines the control
discharge amount of pump 1 and pump 2
according to the pressure signal.
IO
Function
Operation
PD
● When the work equipment is working, the
controller collects the throttle gear signal,,
a constant current value is provided and
pump power control is achieved.
IO
ESS control
Function
Operation
Main valve
M
Speed
P Servo Servo
sensor
PD
(Throttle position feedback signal)
Proportional Proportional
valve valve
(Control signal)
(Control signal)
Hi
(Motor drive signal)
Lo
IO
Monitor
Controller
F1 F2 F3 F4 F5
Boom UP signal
Arm OUT signal
R. Travel signal
L. Travel signal
Arm IN signal
Swing signal
ZX215-1002200
Function
Swash plate angle
Min
Function
Operation
Operating condition
IO
● Swing pressure sensor: signal output avail-
able
Travel motor
Regulator Regulator
L. Travel pressure sensor
Engine
Injection
pump
Throttle
motor
M
P
PD F
Servo
Main pump
R
Servo
(Throttle position feedback signal)
(Control signal)
(Control signal)
Hi
Lo
Monitor
A B C
Controller
F1 F2 F3 F4 F5
ZX215-1002203
Function
Operation
Remark:
Start switch
Heat
Engine Main
Throttle motor pump
Coolant
tempe
F R
sensor
M
P Servo Servo
PD
Fuel control dial
(Throttle position feedback signal)
(Control signal)
(Control signal)
Hi
(Motor drive signal)
Lo
Monitor
A B C
IO
F1 F2 F3 F4 F5
(CAN bus) Controller
ESC Enter
ZX215-1002204
Function
● Preheating control
Operation
Operating condition
PD
● Power ON. Start key set at the HEAT posi-
tion.
● Preheating switch: ON
IO
Function
Operating condition
● Power ON.
Function
IO
● The engine controller collects signal from
the engine oil pressure sensor. When en-
gine speed exceeds 600 rpm, if oil pres-
sure is too low, alarming information will be
generated and transmitted to the machine
monitor. The alarm indicator lights up when
the monitor receives the signal.
Right joystick
Boom Bucket
DOWN
OUT
UP
IN
Engine
CURL
DUMP
controller
R
L
(Potentiometer signal)
(Motor drive signal)
Forward
Reverse
Forward
Reverse
Monitor
A B C
(Throttle signal)
(CAN bus)
PD Controller
F1 F2 F3 F4 F5
Control lever signal
ESC Enter
IO
ZX215-1002205
Function
Operation
less than 2 S
Unoperated
Less than 1 S
Operated
Time (s)
ZX215-1002206
Main valve
M
P Speed
sensor Servo Servo
PD
(Throttle position feedback signaL)
(Control signaL)
(Control signaL)
(Motor drive signaL)
Hi
Lo
IO
Monitor
A B C
Controller
(CAN bus)
F1 F2 F3 F4 F5
Bucket DUMP signal
ESC Enter
Boom DOWN signal
Calibtator
Bucket DIG signal
SW LED
Boom UP signal
Arm OUT signal
R. Travel signal
MEMORYON
L. Travel signal
Arm IN signal
Swing signal
H S L A/I
LED
DOWN UP
7 RPW
LED
SW
H S L A/I
ZX215-1002207
Function
Operation
4) Power OFF
Connection diagram
B GND
C Output
Terminal A Terminal B
Operation
Z direction
PD
Terminal C
ZX215-1002208
4. 5
(E) is shown in the right diagram.
4
IO
3
1
0. 5
(MPa)
0 10 20 30 40 50
Oil pressure (P)
ZX215-1002209
Connection diagram
B GND
C Output
Terminal A Terminal B
Terminal C
Z direction ZX215-1002208
Operation
3
IO
2
1
0. 5
(MPa)
0 1 2 3 4 5
Oil pressure (P)
ZX215-1002210
2 1
ZX215-1002211
Function
PD
● The engine revolution sensor is installed to
the ring gear of the engine flywheel. It elec-
trically calculates the number of the gear
teeth which pass in front of it and transmits
the result to the engine controller.
Operation
CAUTION
● If the engine speed sensor is not tight-
ened to the specified torque, the sen-
sor may send out no signals. Tighten
the engine speed sensor to the speci-
fied torque.
2
1
ZX215-1002212
1) Sensor
2) Connector
Function
PD
● The output resistance of the engine cool-
ant temperature sensor changes with the
coolant temperature. The controller collects
and processes coolant temperature signals
and works out the coolant temperature.
IO
Specifications
1 2 3 4
ZX215-1002246
1) Float PD 3) Casing
2) Lever 4) Coupler
IO
1 2 3
Load
Pressure
Electrical
diagram
ZX215-1002214
1)
2)
3)
O-ring
Sensor
Connector
PD
Function
Specifications
Machine monitor
A B C
S 10
CAN signal
Engine
controller
00/00/00
0000h 00m 12 00:00:00
S Lo
F1 F2 F3 F4 F5
ESC Enter
Power source
PD Sensor
IO
Battery
ZX215-1002215
● The state of the machine is monitored 1. Alert information when a machine fault is
by the sensors mounted on the machine detected.
components. The controller processes the
signals and transmits the signals to the 2. Operating condition (coolant temperature,
monitor display, informing the operator of fuel level, etc. )
the machine condition.
● The machine control system can be oper-
● Information on the monitor display includes ated using the switches and keys on the
primarily: monitor panel.
A B C
F1
ESC
F2 F3
Enter
PD
F4 F5
7
6
12
ZX215-1002216
Outline
● The monitor displays various kinds of items ● When the monitor is turned on, blinking
and is used by the operator to select a strips may appear on the LCD screen.
IO
working mode. This is normal.
● The monitor has an LCD (Liquid Crystal No. Signal name Input/output
Display) screen. 1 Digital input A Input
3 CAN high
NOTE:
4 CAN low
7 Digital input B
● The LCD may have black spots (which do
not light up) or bright spots (which stay on). 8 Trigger power source (24V)
Products having 10 or less black or bright 9 Power source (24V)
spots conform to the product specification; 10 Grounding
such condition is quite normal. 11 Digital input C
12 Grounding
● Continuous operation of the monitor may
cause the LCD to display bright blue spots
on a black background; it is quite normal.
Warning indicator
Indicators
A B C Signal indicator
C H
Screen display Page items
PDS
E
36 h 25 m 12
Lo
F
2010/07/27
15:32:48
Function icon
F1 F2 F3 F4 F5 Function keys
XP2151106001
IO
Outline
1
1. Warning indicator
2
2. Signal indicator
XP2151106002
● The signal indicators include: power indica-
tor, CAN indicator and standby indicators
which may light up under certain circum-
stances.
Screen display
PD
The LCD display is the screen display of the
monitor. Depending on the selected entry of
the user, the screen displays different page
headings, items, parameters, times and func-
tion icons. The user can use the navigation
1
3
S
Sany Hydraulic Excavator
5 2
3. Fuel level
7. Date (Y/M/D)
8. Clock (H:M:S)
Operation keys
S Lo
1. Function keys
1 F1 F2 F3 F4 F5
● Functions of the five keys (F1, F2, F3, F4
and F5) are indicated by the function icons ESC Enter
2
above them on the screen display.
F1
F2
F3
S
Lo
PD
Working mode selection
Information menu ——
F5
Return to previous page Same as ESC key
IO
Every time the system is energized, the de- Auto-idle switch
fault working state is:
● Auto-idle function is active under default
● Working mode: S condition. When neither of the joysticks are
operated for 5 seconds, the engine enters
● Full/Auto idle speed: Auto-idle the idling state automatically in order to
save fuel and reduce noise.
● High/Low travel speed: Lo
● When the controller detects movement of
the joysticks or adjustment of speed level
while the engine is idling, engine speed re-
sumes its previous or newly set speed.
Enter Enter/Confirm
Select item on upper side (Selects bottom item after top item)
Select item on lower side (Selects top item after bottom item)
Select item on left side (Selects right end item after left end item)
Select item on right side (Selects left end item after right end item)
Function
PD Sany Hydraulic Excavator
1 S 5 12
This is the normal operation display. Items on
this page include: working mode, speed level, 2
C
coolant temperature, fuel level, service hours, H
IO
clock, fault code, etc.. You can set the working
condition of the machine on the home page.
3
E F
11
Display
4 36 h 25 m 12 15:32:48 10
S Lo
1. Working mode (S, H, L and B)
5 6 7 8 9
2. Coolant temperature (°C) XP2151106003
Operation
Function
in asterisks. 1
Function
Operation
Function
Display
Coolant temp °C: 0
1. Real-time display of engine signals col-
lected by the controller. 1 Fuel level %: 0
Function
IO
This page displays the throttle signal of the
Throttle Signal
engine.
Display
Throttle gear N:12
1. Real-time display of throttle signals col-
lected by the controller. 1 Eng speed r p m : 1 2 3 4
Function
This page displays the pilot pressure signal of Pilot Pressure Signal 1
the hydraulic system.
Display
Boom UP kg: 123.4
1. Real-time display of pilot pressure signals
1 Boom DN kg: 123.4
collected by the controller.
Arm IN kg: 123.4
2. When F1 is pressed, the screen moves to
the next page “Pilot Pressure Signal -2”. Arm OUT kg: 123.4
Function
IO
This page displays the pilot pressure signal of
Pilot Pressure Signal 2
the hydraulic system.
Display
Function
IO
Main Valve Signal
This page displays the main valve signal.
Display
Function
Display
Function
Display 中文系统
1. List of system languages. 1 English Systems
Function
Display
IO
1. Current time. C ur r ent ti m e:
1 1234 ·12 · 12 12: 12:12
2. Setup time.
Function
Display
1. A 5-digit password displayed in (*). The as- Please enter the password:
terisks becomes a number when the cursor
moves on it, while the rest is still displayed
in asterisks.
1
* * * * *
2. When F1 is pressed, the number on the
cursor changes in an ascending order.
Remark:
Function
Display
Machine configuration
1. System setup list. 1 Service hour setup
Machine configuration setup
2. When F1 is pressed, the highlighter move
downward.
Operation
PD
● F1: Select the item on the system setup
2 3 4
XP2151106017
Function
Display
Please enter the password:
1. A 5-digit password displayed in (*). The as-
terisks becomes a number when the cursor
moves on it, while the rest is still displayed
1
* * * * *
in asterisks.
Operation
Function
Display
1. A 5-digit password displayed in (*). The as- Please enter the password:
terisks becomes a number when the cursor
moves on it, while the rest is still displayed
in asterisks.
1
* * * * *
2. When F1 is pressed, the number on the
cursor changes in an ascending order.
Function
Display
Current service hour
1 100 h 50 m
1. Current total service hour in the controller.
Operation
PD
● F1, ENTER: Confirm the completion of ser-
3 4
XP2151106021
Display
Remark:
System locked
NOTE:
Contact manufacturer to unlock system
● The screen displays any of the following All keys are disabled!
machine states after 5 seconds. “Lockout
PD
(Level 1)” or “Lockout (Level 2)” or “Un-
locked”. (Five seconds is the filtering time)
XP2151106025
Function
Macine model :215
This display indicates that the machine has
IO
entered lockout state (level 2), and all keys are Machine No. :11SY0216 00008
disabled. Machine state :Lockout (2)
1
Current time:12:12:11
Display
E
PPDAG
IOK
AN
BL
Standard Values
5 Standard Values
5.1 Standard Values of Engine - related Parts............................................................... 5-3
5.2 Standard Values of Chassis-related Parts ............................................................... 5-4
PD
IO
PD
IO
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
5 STANDARD VALUES
5.1 Standard Values of Engine - related Parts
Swing control ● Control lever grip at center {kgf} Max. 15.6 Max. 21.6
lever ● Pedal at tip {Max. 1.6} {Max. 2.2}
Travel control Max. 30.4 Max. 39.2
● Max. reading at stroke end
lever {Max. 3.1} {Max. 4.0}
Travel control Max. 93.1 Max. 107.8
pedal {Max. 9.5} {Max. 11}
● Hydraulic oil temp: Within operational
range
Unloaded
pressure
Boom relief
PD
● Engine running at high idle
● Working mode: H
● All control levers in neutral position
● Hydraulic pump output pressure
● Hydraulic oil temp: Within operational
0~1.0
{0~10}
34.3 ± 1.0
0~2.0
{0~20}
33.3 ~ 35.3
range {350 ± 10} {340 ~ 360}
● Operate corresponding control lever 34.3 ± 1.0 33.3 ~ 36.8
Arm relief
after engine runs at high idling speed. {350 ± 10} {340 ~ 375}
● Working mode: H
Hydraulic Pressure
Time
● Working mode: H
taken to sec. 24 ± 3.5 Max. 30
● Time required for 5 turns after making initial 1
swing
turn
● For measuring posture see Swing 1.
● Hydraulic oil temp: Within operational range
● Engine stopped
● Keeping the upper structure transverse on a
Hydraulic
IO
grade of 15°. For more information see Swing 2. mm 0 0
drift
● Notching a mating mark on inner and outer races
of the swing circle
● Mating mark misalignment amount during 5 min.
● Hydraulic oil temp: Within operational range
Motor ● Engine running at high idle ml/
Max. 5 Max. 10
leakage ● Swing lockout switch: ON min
● Leakage amount for 1 minute during swing relief
● Hydraulic oil temp: Within operational range Lo 51.3 ± 5.1 46.2 - 60.4
● Engine running at high idle
Travel
● Working mode: H
Travel
speed
● Time required for track shoes to make 5 sec.
(unload- Hi 28.0 ± 1.4 26.6 - 31.4
turns after making one initial idle turn
ed)
● For more information on measuring posture
see Travel 1.
● Working mode: H
sec.
● Level ground
● Time required for traveling 10m after 10m trial run
Hi 13 ± 2.5 11.5~15.5
● For measuring posture see Swing 2.
● Engine stopped
● Park the machine on a grade of 12°, with the sprocket
mm 0 0
in the downhill direction
● Measure the sliding distance for 5 minutes
● For measuring posture see Travel 4.
● Hydraulic oil temp: Within operational range
travel motor
Leakage of
● Engine stopped
Hydraulic drift
mm Max. 20 Max. 20
ing the falling every 5 min. immediately after initial set-
ting
● Bucket tip lower distance
Bucket cylinder
● Working mode: H
UP sec. 3.4 ± 0.4 Max. 4.8
● Time required for the bucket to raise
from the ground to its stroke end
● For measuring posture see Work
Equipment 2.
● Hydraulic oil temp: Within operation- IN sec. 3.6 ± 0.4 Max. 4.5
al range
Work Equipment Speed
● Working mode: H
Arm
● Time required from dumping stroke OUT sec. 2.9± 0.3 Max. 3.5
PD
end to digging stroke end
● For measuring posture see Work
Equipment 3.
● Hydraulic oil temp: Within operation- DIG sec. 2.9 ± 0.5 Max. 3.4
al range
● Engine running at high idle
Bucket
● Working mode: H
● Time required from dumping stroke
DUMP sec. 1.9 ± 0.3 Max. 2.3
IO
end to digging stroke end
● For measuring posture see Work
Equipment 4.
to the moment that the bucket reaches the sec. Max. 1.0 Max. 1.2
ground and begins to push the machine up-
ward, within 50mm off the ground
● For measuring posture see Work Equipment
5.
● Working mode: H
● Average time required for operating the con-
Arm
move
● For measuring posture see Work Equipment
6.
5 20
Internal Leakage
simultaneous operation of
Amount of deviation in
● Working mode: H
● Travel Speed: Low mm Max. 200 Max. 220
● Amount of deviation measured for 20 m after
traveling about 10 m on a hard level ground
● For measuring posture see Travel 2.
ZX215-1003002 ZX215-1003005
45°
IO
ZX215-1003003 ZX215-1003006
15° x
10m
ZX215-1003007
Sprocket
ZX215-1003004
12°
ZX215-1003008 ZX215-1003011
ZX215-1003010 ZX215-1003013
ZX215-1003014 ZX215-1003015
PD
IO
E
G
PPDA
IAONK
BL
E
PPDAG
IOK
AN
BL
PD
IO
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
6.1.1 Testing
Testing Items:
6.1.2 Adjusting
Testing tools
CAUTION
● Do not touch any hot parts when mount-
ing or dismounting the testing tools.
ZX215-1004003
ZX215-1004004
IO
4) When engine speed increases sud-
denly or is kept at high idle, use the
opacimeter to read the smoke value of
exhaust gas.
Special Tools
6.3.1 Testing
Pointer
ZX215-1004009
NOTE:
Cylinder 1 2 3 4 5 PD 6
INT ● ○ ● ○ ● ○
EXH ● ● ○ ● ○ ○
6.3.2 Adjusting
Service Standard
Special Tool
the crankcase.
Service Standard
Special Tool
Universal Exten-
sion Rod
PD Part Number Application
ZX215-1004011
ZX215-1004012
tion.
PD
the engine manually in the forward direc-
ZX215-1004014
6.5.2 Adjusting
B: 1 nut
A
PD ZX215-1004015
Pointer ZX215-1004016
ZX215-1004017
ZX215-1004018
IO
Service Standard
Lubricant/Sealant
Engine Oil
IO
Pressure Switch
ZX215-1004019
Adaptor
ZX215-1004020
NOTICE PD
Then engine oil pressure switch must be
installed when the engine is cold.
IO
ZXT215-1004001
Drive Pulley
ZX215-1004022
6.8.2 Adjusting
2
3. After positioning the compressor (3), tight-
en the bolts (1) and (2). 3
IO
4. Check belt tension again after adjustment. ZXT215-1004002
Reference
NOTE:
Measuring tool
CAUTION
● Park your machine on a level ground.
Lower your work equipment to the
ground.
150~200mm
is the clearance of the bearing.
6.10.1 Testing
1
NOTE: A straight angle steel bar is recom- ZX215-1004026
mended for this purpose as it has good
resistance to bending strain.
6.10.2 Adjusting
CAUTION
● Do not loosen the valve over one turn.
If the valve is loosened too much, the
grease under high pressure may cause
the valve to eject.
b
ZX215-1004027
6.11.1 Measuring
CAUTION
● Lower the work equipment to the PD
ground and stop the engine. Operate
the control levers for several times to
release the residual pressure in hydrau-
lic circuits.
2
● Plug (1): For oil circuit of rear pump
1
● Plug (2): For oil circuit of front pump
6.11.2 Adjusting
8
ZX215-1004030
6.12.1 Testing
CAUTION
● Lower the work equipment to the
ground and stop the engine. Operate
the control levers for several times to
lic circuits.
PD
release the residual pressure in hydrau-
6.12.2 Adjusting
PD
IO
Measuring tools
CAUTION
● Lower the work equipment to the
ground and stop the engine. Operate
the control levers for several times to PD
release the residual pressure in hydrau-
lic circuits.
Solenoid Valve
OFF (de-energize)
ON (energize)
Output Pressure
0 {0}
PD
3.9~4.1 MPa{39~41 kgf/cm²}
Swing priority
Measuring tools
PD
IO
Locknut:
PD
4. When the disc (3) is fixed, tighten the lock-
ZX215-1004032
PD
2) Operate the control levers so that the
boom is in the raising position and the
bucket in the digging position.
ZX215-1004033
2. Arm cylinder
[Reference]
CAUTION
● Release the residual pressure in the hy-
draulic circuit before disconnecting the
lines between the hydraulic cylinders
or between the hydraulic motor and the
control valve.
ZXT215-1004004
Bleeder:
Bleeder:
2
27.5~35.3 N·m{2.8~3.6 kgf·m}
ZXT215-1004016
PD
IO
E
G
PPDA
A IONK
BL
E
PPDAG
IOK
AN
BL
Troubleshooting
7 Troubleshooting
7.1 Points to Remember When Troubleshooting ........................................................... 7-3
7.2 Troubleshooting Procedures .................................................................................... 7-5
PD
7.3 Connector Location and Electrical Circuit Diagram ................................................. 7-8
7.4 Failure Symptoms and Troubleshooting Codes ..................................................... 7-26
7.5 Troubleshooting with an Event Code ..................................................................... 7-28
7.6 Troubleshooting of Electrical System (E - Mode)................................................... 7-63
7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode) ...................... 7-93
IO
PD
IO
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
7 TROUBLESHOOTING
● Stop the machine in a level ground, and check that lock pins, blocks, and parking brake are
securely fitted.
● When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
● If the radiator cap is removed when the engine is hot. Hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
● Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
PD
● When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
● When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
The aim of troubleshooting is to pinpoint the ● It will become impossible to find the
basic cause of the failure, to carry out repairs cause of the failure.
swiftly, and to prevent reoccurrence of the fail-
ure. It will also cause a waste of man-hours,
IO
parts, or oil or grease, and at the same
When carrying out troubleshooting, important time, will also lose the confidence of the
point is to understand the structure and func- user or operator.
tion.
For this reason, when carrying out
However, a short cut to effective troubleshoot- troubleshooting, it is necessary to carry out
ing is to ask the operator various questions thorough prior investigation and to carry
to form some idea of possible causes of the out troubleshooting in accordance with the
failure that would produce the reported symp- fixed procedure.
toms.
2. Points to ask user or operator:
1. When carrying out troubleshooting, do not
hurry to disassemble the components. 1) Have any other problems occurred apart
from the problem that has been reported?
If components are disassembled immedi-
ately any failure occurs: 2) Was there anything strange about the
machine before the failure occurred?
● Parts that have no connection with the
failure or other unnecessary parts will 3) Did the failure occur suddenly, or were
be disassembled. there problems with the machine condition
5) Other maintenance items can be checked 6. Measures to remove root cause of failure
externally, so check any item that is con-
sidered to be necessary. ● Even if the failure is repaired, if the root
cause of the failure is not repaired, the
IO
4. Confirming failure same failure will occur again. To prevent
this, always investigate why the problem
● Confirm the extent of the failure yourself, occurred. Then, remove the root cause.
and judge whether to handle it as a real
failure or as a problem with the method of
operation, etc.
If some phenomenon occurs on a machine that looks like a failure, identify the corresponding
troubleshooting No. and proceed to the explanations for diagnosis.
Follow six steps listed below to diagnose and analyze for troubleshooting, and find the causes
and work out the corresponding methods.
1. Read related technical manuals in detail. d. What kind of trouble did machine have
Have a knowledge of related system, before?
principle of operation, and structure,
function and technical specification of For example: Which parts have been
parts. repaired or replaced?
failure.
PD
Before checking, ask related person, i.e.
the operator for all information about the
—
mechanical Electrical equipment
4. Operate machine by yourself (trial run) ● Failure codes may not indicate machine
trouble. Temporary electrical failure can oc-
Confirming that the third item above is cur in controller memory, such as low bat-
normal, run startup check on the machine tery output voltage, or open circuit in switch
to determine the cause of failure. If the or sensor. Therefore, make repeated trials
failure cannot be determined, turn off the to erase the accumulated failure codes
engine and get more information from the from the controller memory and confirm
operator. whether the failure codes are displayed af-
ter repeated trials. That is to say, "reoccur-
5. Perform troubleshooting rence" of this trouble is possible.
Conduct deep analysis and determine the 6. Find out possible causes
cause of trouble according to the symp-
toms of the machine and the information Before making a conclusion, check the
displayed on the monitor. most possible causes again and try to de-
termine the root causes of troubles. Make
Remark: PD a feasible repair scheme according to your
conclusion.
● 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.
IO
Location
Connec- No. of Sensor,
Type Name of device Cab Engine
tor No. pin Layout solenoid
circuit circuit
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
Battery relay contact (out-
T-103 Terminal 1 M-2 D-1
put)
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
T-111
T-112
T-115
Terminal
Terminal
Terminal
Terminal
1
1
1
PD
Body grounding
Body grounding
Preheating resistance wire
terminal
Starting motor grounding
M-1
K-6
J-7
J-6
B-1
H-9
L-3
Body grounding (at the sides
T-119 Terminal 1 M-1 B-9
of battery)
T-201 Terminal 1 Body grounding X-6
T-202 Terminal 1 Body grounding X-6
IO
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
Location
Connec- No. of Sensor,
Type Name of device Cab Engine
tor No. pin Layout solenoid
circuit circuit
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
CN-105M
CN-113M
CN-101M
A
A
S
2
2
1
PD
Boom lamp (left)
Boom lamp (right)
Hydraulic oil temperature
sensor
Fuel level sensor
E-7
E-7
I-7
F-6
K-1
K-2
F-9
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
IO
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
Location
Connec- No. of Sensor,
Type Name of device Cab Engine
tor No. pin Layout solenoid
circuit circuit
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
Boom priority solenoid valve
CN-135F AMP 2 J-6 F-2
2
Bucket Confluence solenoid
CN-134F AMP 2 J-6 F-3
valve
Boom priority solenoid valve
CN-132F AMP 2 J-6 F-3
1 PD
CN-136F AMP 2 Pilot solenoid valve J-6 L-2
Hi/Lo speed travel solenoid
CN-131F AMP 2 J-6 F-1
valve
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
IO
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
PD
IO
5
PD
CN-102M
Z
IO
4
ZX215-1005033
A B C D E F
T-111
CN-445M
CN-800M
T-107
CN-112M
CN-124M
F-104
F-103
PD CN-125M
CN-126M
CN-128M
IO
CN-127M
CN-123M
CN-122M
CN-121M
T-108 T-109
CN-120M T-101
CN-131F T-102
CN-132F
KB
CN-133F
CN-134F T-104
CN-135F T-103
CN-136F
T-110
T-119
Z ZX215-1005034
G H I J K L M
9 CN-305M
CN-304M
CN-303M
CN-104M
8 CN-302
CN-131M
CN-301M
6
PD
5
CN-7-705
IO
4
3 CN-7-707
ZX215-1005035
N O P Q R S T
CN-1-111
CN-661F CN-161M CN-152M
CN-1-112
T-201
CN-241M T-202
K5
CN-121F
K6
K10
CN-142M K3
K7
K8
CN-613F
CN-615F
CN-616F
PD CN-412F
KH
IO
CN-204F
PF021
CN-207F
CN-107M
CN-106F
ZX215-1005036
T U V W X Y Z
PD
IO
CN-1-002M
8
CN-1-005
CN-1-001M
7
CN-1-103M
6
PD
5
CN-1-004M
IO
4
CN-1-110
2
CN-150M
ZX215-1005037
AA AB AC AD AE AF
Monitor
CANL
Ground 1
29
4 4 4
25 F5 5A
8 8 8
2 CN-1-111 22 21
(D-8) 9 9 9
3 0 10 10 10 F7 10A
1 1 26
24Vpower 4 2 2 12 12 12
CN-131M CN-302F
9
5 3 3 CN-142M F9 5A
50 (D-12) 50
(D-12)
50 (A-3) 50 28
6 1 1 1 1
8 18
19
43
1
2
1
2 2
4
2
4
CN-204F
20 (A-2) 5 5
21 9 9
10 10
22
11 11 1 3 4 5 8 9 10 11 12
23 12 12 CN-241M
24 (D-12)
1 3 4 5 8 9 10 11 12
25
26
27
28
29
30
31
32
33
Fuel control knob voltage 34
7 35
36
37
38
39
40
41
s GND
s GND
s PWR
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
00
00
50
CAN-
PD 28
70
X-1
X-2
59 CAN+
60
61
62
CN-132F
63
5
(D-12)
64 1
65 2
1
33 X-3
2
66 3 3 24 X-4
67 4 4 25 X-5
68 5 5
69
37 X-6
70 12 12
IO
71
36 X-7
72
00
s GND 73
s PWR 74
50 35 L X-8
50
s PWR 75
72 X-9
76 CAN+
CAN-
CAN+ 77
35 H X-10
4 CAN- 78
79
23 X-11
80
81
X-12
CN-615F
82 X-13
83
84
85 X-14
86
87
88
89
90
23 31
3 91
92 Top lamp switch 21
20
93 Horn switch
94 CN-104M
95 70 72
96
97 CN-307M
98
99 TERMINAL
B BRACCR1 R2 C
100 Work lamp switch HEAT
101
OFF Start switch
ON
102 START
2 103
104
24 33 22 13
105 CN-303M
106
107 Washer switch
22 11
108 11
109 Stabilized voltage diode 25 37 13 13
110 9 9
CN-152M CN-153M
111 1 2 1 2 CN-332M
CN-305M
112 S-6
113
0 0 42 0 42 Wiper switch
Ground 114
0
Ground 115
36
116 25
117
35 L 1 2 3 4 5
118
1 2
42
24V power supply 119
1 35 H 1 2 3 4 5
42
24V power supply 120 KB
121
122
CN-304M Battery relay + - + -
Chassis GND
ZX215-1005038
A B C D E F
★ This circuit diagram has been compiled by extracting the wiper system and each switch control system
from the overall electrical circuit diagram.
Access lamp
28
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
31 0 23 32 33 0 24 34 72 0 70 71 0
8
CN-1-110
(D-6) Wiper
0
1 1
X-1 25
2 2
36 3
M
CN-161F 3
X-2 (S-16)
35H 4 4
1 1 7
3 3
4 4
5 5 35 L
6 6 5 5
X-3
X-4
X-5
X-6
X-7
X-8
X-9
7
8
7
8
PD CN-112M
(A-2)
1
2
Washer motor
1
2
0
37 M
6
X-10
Right top lamp
X-11
1 1
0
71
5
X-12 2 2
CN-150M
(S-8) F-104
R+
1 1
R+
(W-1)
R- R- Horn
L+
2
3
2
3 L+ 1 1 4
CN-661F
L- 4 4 L-
(S-12)
0
5 5 0 32 F-103
3 3
71
6 6
71
34 (W-1)
4 4
0 7 7 0
1 1
26 8 8 26
F6
21 20 b CN-102M Rotating stage
(A-2) work lamp
F8
0
1 1
0 3
21 38 34 34
2 2
ZX215-1005039
G H I J K L
3 - + - + 2 2 10
8
22 13 16 11
4 42 20 20
F1 20A22
Controller power supply 5 9 9 F2 5A10
21 21
6 11 11
PF021
7
9 8
CN-152M CN-153M
9
10 1 2 1 2
11
12 0 42 0 42
13
14 506
Throttle position feedback 15
16
17
18
19
20 X-1
21 21
22
8 23
24
25
26 X-2
27 10
28
29
30 X-3
31 21
32
33
34
35 13 X-4
36
37
7 38
39
40 X-5
41 18
42
43
44
45 X-6
5V power supply
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
00
00
50
PD 22
12
606
X-7
X-8
X-9
62 X-10
63 50
64
65
5 66 507 X-11
67
68 X-12
69 MT+
70
71 X-13
72 00 00
73 50
5V power supply74 X-14
MT-
IO
50
5V power supply75
76
77 F16 CN-221M
78
79 1 1
4 80
81
CN-615F
CN-161F
82 27
83 12 12 105
84
85 14 14
Pilot switch
86
87
88
89
90
91
92
3 93
94
95
96
97
98
99
100
101
102
103
104 MT+
Throttle motor output signal+ 105
106
2
107
108
109
110
111
112 MT- 7 7
113
Grounding 114
0
Grounding 115
0 CN-331F
116
117 21
0 105 11 12
118 CN-241F F11 21
24V power supply
42 T-102 T-101 T-103 T-104
1 2 3 4 5 Preheat switch 1 2 3 4 5
119 4
24V power supply120 42 1 2
1 2 3 4 5
K3 1
1 2 3 4 5 2 3 4 5
121
1
1 2 3 4 5
122 KB 16 18
Battery relay
Pilot valve relay CN-306M Locking relay
ZX215-1005040
A B C D E F G
★ This circuit diagram has been compiled by extracting the engine preheat system, startup system and
governor system from the overall electrical circuit diagram.
T-112
17
Preheat relay Parking relay
KH
1 2 3 4 5 K7 1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
F13 160A
T-108 T-109
0 18 16 17 0 13 64 63 65 9
7 7 17 Preheater
9 9
14
CN-661M 12 12
(S-16)
10 10
Preheater indicator
15 15
CN-442F
(D-12) 17
1 1
0 2 2
CN-121F
CN-661F
CN-801F
22
64 B
8
(D-12) (H-6) 63 A
65 P2
(S-16)
X-1 21 5 5 606 22 P1
1 1 1 1 E
64
65
2 2 Parking motor
X-2 10 6 6 63 0
12 3 3
0
X-3 7 7 4 4
21 65
63
9 9 6 6
X-4 13 64
10 10
18
X-5
7
X-6 22
X-7 12
X-8
X-9
X-10
X-11
X-12
0
606
50
507
MT-
PD 12 a
14
10
47
0
1
2
3
4
6
CN-613F
1
2
3
4
6
12a
14
10
47
S
L Safety relay
R
P
0
6
X-13 00
5
X-14 MT+ 10
14 R
21 L
47 B
P
E
0
IO
Generator
Body ground
CN-112M
1 2
12 a 12
CN-111F
1 1
12
2 2
12 a
21
E
0
Starting motor
3
A3 Body ground
F-311
2 2
Connector 282080-1 CN-316F
(AMP-2)
1 2
606
1 1
2
2 2
Pilot solenoid valve
M13
(S-6)
50
1 1
507
2 2 1
2 Throttle motor
3
MT-
3 3 5 AC-2000
6
00
MT+
5 5 1
6 6
ZX215-1005041
G H I J K L M
7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit)
CN-101M
509 (S-1)
CN-616F 1 1 Fuel level sensor
CN-448M
1 (S-2)
Grounding 2 108A 1 1
3 108B Engine speed sensor
4 2 2
22
CN-121M
23 (DF-3)
24 50 A A
25 0 Right travel pilot
26 B B
27 201 C C
pressure sensor
28 CN-120M
29 50 (DF-3)
Coolant temp. sensor 30 A A
Hydraulic oil temp. sensor 31 0 B B Left travel pilot
32 200 C C
pressure sensor
33 CN-123M
34 (DF-3)
50
7 35
36 0
A A
Swing pilot
B
37 208
B
pressure sensor
Pulse input 38 C C
39 CN-124M
40 (DF-3)
41
50 A A
42 PD 0 B B
Bucket curl pilot
43 205 C C
pressure sensor
44
45 CN-127M
(DF-3)
46 50 A
47 0
A
CN-125M
Boom lower sensor 51 (DF-3)
Arm out sensor 52 50 A A
Rear pump main pressure sensor 53
0 B B Boom lower pilot
s GND 54 207 C pressure sensor
s GND 55 C
s PWR 56 CN-126M
57 (DF-3)
58
50 A A
59 0 B B
Boom raise pilot
60 206 C C
pressure sensor
61 CN-128M
62 (DF-3)
63 50
5 64 0
A
B
A
B Arm in pilot
65 203 C
pressure sensor
66 C
76 0 B B
Front pump
77 501 C C
pressure sensor
4 78
79
CN-116M
(DF-3)
80 50 A A
81 0 B B
Rear pump
CN-615F 502 C C
pressure sensor
Hi/Lo speed travel
CN-133F
82 608 (AMP-2)
1 Swing priority-A4
83 0
1
proportional
84 2 2
solenoid valve
85
86 CN-134F
87 604 1 1
(AMP-2) Bucket confluent-A5
Front pump solenoid proportional valve 88 0 2 2 proportional
Rear pump solenoid proportional valve 89 solenoid valve
90
3 91 602
CN-132F
(AMP-2)
Boom priority 1-A4
92 1 1
93 0 2 2 proportional
solenoid valve
94 CN-135F
95 (AMP-2)
96 603 1 1 Boom priority 2-A4
97 0 2 2 proportional
Swing priority solenoid valve 98 solenoid valve
Bucket confluent valve 99
Boom priority 1 100
Boom priority 2 101
102
103
104
105
2 106
107
108
109
110 CN-113F
(AMP-2)
111
112 702 1 1 Front pump
113 0 2 2 proportional
Grounding 114 CN-114F
solenoid valve
Grounding 115 (AMP-2)
116 703 1 Rear pump
117 0
1
proportional
118 2 2
solenoid valve
24V power supply 119 CN-131F
ZX215-1005042
A B C D E F G
7222-1424-40
PD 7123-1424-40 (No. of pin: 2)
IO
7222-7464-40 7123-7464-40 (No. of pin: 6)
282105-1
PD 282087-1 (No. of pin: 3)
IO
174354-2 174352-2 (No. of pin: 2)
A
A B B
C C
1 6 PD 6 1
2 5 5 2
3 4 4 3
8 5 8
5
IO
1 4 4 1
12 7 7 12
1 6 6 1
Troubleshooting
No. Symptom
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
Display Service Code in electrical system after checking According
2
failure history to displayed
Display Failure Code in mechanical system after checking code
3
failure history
Engine-related failure
Engine does not start up easily. (It always takes some
4 S-1
time to start up the engine)
5 Engine misfires. E-1 S-2
6 Color of exhaust gas is too dark.(Incomplete combustion) S-3
7
8
9
Engine pickup is poor.
Engine runs rough or is unstable.
PD
Engine is short of output, or lacks power
10 Auto Idle fails.
E-2
E-4
H-2
H-5
S-4
S-5
S-6
Troubleshooting
No. Symptom
Code E mode H mode (Engine)
Other work equipment moves, when specific work equip-
27 H-12
ment is relieved
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 difficult 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
39
PD Swing-related failure
H-21
2 <Inclusion>
● Standard value under normal condition can be used to judge pos-
3 PD sible causes
Possible causes ● Reference for passing the above "Good" or "No Good" judgement
4
of trouble (Given
<Symptom of Wiring Harness Failure>
numbers are ref-
● Open circuit
erence numbers,
Faulty contact with connector or open circuit in wiring harness
which do not indi-
cate priority)
5 ● Faulty grounding
An ungrounded wiring is grounded.
IO
● Short circuit
A wiring has mistaken contact with a 24 V electric circuit.
This is part of the circuit diagram which shows the portion where the failure occurred.
1 Internal failure No troubleshooting can be done for failure occurs in the inner of controller. (If
of controller this failure occurs, replace the controller.)
2
normal state
5
PD
IO
User Code Service Code Throttle motor loading circuit is abnormal and the
Trouble
E212 12 engine acceleration fails.
When the power is on, magnitude of throttle motor coil current is out of the
Failure description
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.
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of throt-
1 form troubleshooting.
tle motor coil
Between CN-445M ③ and ⑥ Resistance 12.2 Ω
● Turn engine start switch to OFF position. Keep it at OFF position to per-
2 Open circuit of form troubleshooting.
3
harness
Short circuit
of harness
PD
Unplug the controller and measure the resistance
between pin 113 and pin 105.
form troubleshooting.
Unplug the connector CN-445M and measure the
resistance between motor ③ ( ⑥ ) and the hous-
Resistance 12.2 Ω
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Resistance ≥2M Ω
(grounded)
ing.
No troubleshooting can be done for failure occurs in the inner of controller.
Internal failure
4 (Except for the above reasons, the controller must be replaced in case of
of controller
failure.)
IO
5
CONTROLLER
CN-445M THROTTLE MOTOR
50# GREEN
SENSOR 5V 75 1 1
507# WHITE
THRTL FEEDBACK VOLT. 55 2 2
MT- 3 RED
MT- 113 3 M
4 4
GND WIRE 55
0#
5 5 YELLOW
MT+ 105
MT+ BLUE
6 6
ZX215-1005071
User Code Service Code Operation of throttle motor suspends and engine
Trouble
E213 13 acceleration fails.
The controller monitoring accuracy deviates by over 5%, which is normally
Failure description
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.
1 form troubleshooting.
motor coil Between CN-445M ③ and ⑥ Resistance 12.2 Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
Failure of 5V
2 perform troubleshooting.
power supply Between CN-445M ① and ⑤ Voltage About 5V
3
Open circuit of
harness
Failure of throttle
PD
● 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 Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
4 perform troubleshooting.
position sensor Between CN-445M ② and ground Voltage 0.8V~3.5V
Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
5 of harness Unplug the connector CN-445M and measure the
Resistance ≥2M Ω
IO
(grounded) resistance between motor ③ ( ⑥ ) and the housing.
No troubleshooting can be done for failure occurs in the inner of controller.
Internal failure of
6 (Except for the above reasons, the controller must be replaced in case of
controller
failure.)
CONTROLLER
CN-445M THROTTLE MOTOR
50# GREEN
SENSOR 5V 75 1 1
507# WHITE
THRTL FEEDBACK VOLT. 55 2 2
MT- 3 RED
MT- 113 3 M
4 4
GND WIRE 55
0#
5 5 YELLOW
MT+ 105
MT+ BLUE
6 6
User Code Service Code Throttle motor working range is abnormal and the
Trouble
E214 14 engine returns to auto idle.
The voltage is below 0.8V at the minimal stroke or above 4.2V at the maximal
Failure description
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.
3
Open circuit of
harness
Failure of
PD
● 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 Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
4 throttle position perform troubleshooting.
sensor Between CN-445M ② and ground Voltage 0.8V—3.5V
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Short circuit form troubleshooting.
5 of harness Unplug the connector CN-445M and measure the
IO
(grounded) resistance between motor ③ ( ⑥ ) and the hous- Resistance ≥2M Ω
ing.
No troubleshooting can be done for failure occurs in the inner of controller.
Internal failure
6 (Except for the above reasons, the controller must be replaced in case of
of controller
failure.)
CONTROLLER
CN-445M THROTTLE MOTOR
50# GREEN
SENSOR 5V 75 1 1
507# WHITE
THRTL FEEDBACK VOLT. 55 2 2
MT- 3 RED
MT- 113 3 M
4 4
GND WIRE 55
0#
5 5 YELLOW
MT+ 105
MT+ BLUE
6 6
ZX215-1005071
Failure of ● Turn engine start switch to OFF position. Keep it at OFF position to perform
1 power sup- troubleshooting.
ply Measure battery voltage Voltage ≤25V
● Turn engine start switch to OFF position. And Then, keep the engine running
normal state
1 2 F-107
CN-800M
G
R
L P
B E
0
ALTERNATOR
- + - +
BATTERY RELAY
0
ZX215-1005072
Internal
No troubleshooting can be done for failure occurs in the inner of controller. (If this
1 failure of
failure occurs, replace the controller.)
controller
2
mal state
4
PD
5
IO
Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to perform
troubleshooting.
1 in harness Measure the resistance between pin 56, pin 75, pin 74 of
(grounded) controller KC-MB and the ground. Resistance ≥2M Ω
Internal
No troubleshooting can be done for failure occurs in the inner of controller. (Except
2 failure of
for the above reasons, the controller must be replaced in case of failure.)
PD
state
controller
5
IO
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of CAN
1 form troubleshooting.
resistance Between CN-7-709 ① and ② Resistance 60 Ω
● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
Open circuit of Unplug the controller and measure the resistance
2 PD ≤1 Ω
state
CN-7-709
IO
CANH
1 1
120Ω RESISTANCE
2 2
CANL
CONTROLLER CN-7-705
CANH 3 3 3
MONITOR
CANL 4 4 4
29 8 8 8
22
CANH 60 CN-1-111 9 9 9
0 10 10 10
1 1
CN-441 2 2 12 12 12
CANL 78 3 3 3 3
1 1 F1 20A
22
F10 5A
29
20
21
PWR PWR
ZX215-1005073
User Code Service Code Front pump output pressure is abnormal. Only output
Trouble
E320 20 alarm is enabled. .
A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec
Failure description
when the power is on.
Response from controller Only output alarm is enabled.
Symptom of machine —
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of 5V form troubleshooting.
1
power supply Between CN-115M A and B Voltage About 5V
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
2
3
Short circuit
of signal wire
(grounded)
● Turn engine
PD
signal wire Between CN-115M C and pin 72 of controller
Between CN-115M B and ground
start switch
form troubleshooting.
to OFF position.
it at OFF
Resistance
≤1 Ω
≤1 Ω
position to per-
≥2M Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
Failure of sen-
4 perform troubleshooting.
sor Between CN-115M C and ground Voltage 0.5±0.2V
5
IO
CONTROLLER CN-115 FRONT PUMP
PRESS. SENSOR
501#
FRONT PUMP PRESSUSRE 72 C SIGNAL
SIGNAL COLLECTING PORT
00#
54 B GND WIRE
GND WIRE
50#
5V PWR SUPPLY 56 A 5V
ZX215-1005074
User Code Service Code Reading of rear pump output pressure is abnormal.
Trouble
E321 21 Only output alarm is enabled. .
A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec
Failure description
when the power is on.
Response from controller Only output alarm is enabled.
Symptom of machine —
5
IO
CONTROLLER CN-116 REAR PUMP
PRESS. SENSOR
REAR PUMP PRESSURE
502#
53 C SIGNAL
SIGNAL COLLECT PORT
00#
GND WIRE 54 B GND WIRE
50#
5V PWR SUPPLY 56 A 5V
ZX215-1005075
User Code Service Code Arm-in pilot pressure is abnormal. Only output alarm
Trouble
E322 22 is enabled. .
A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec
Failure description
when the power is on.
Response from controller Only output alarm is enabled.
Symptom of machine The arm in motion is slow.
5
IO
CONTROLLER CN-128M ARM-IN PILOT
PRESS. SENSOR
203#
ARM-IN PILOT PRESSURE 71 C SIGNAL
SIGNAL COLLECTING PORT
00#
GND WIRE 54 B GND WIRE
50#
5V PWR SUPPLY 56 A 5V
ZX215-1005076
User Code Service Code Reading of arm-out pilot pressure is abnormal. Only
Trouble
E323 23 output alarm is enabled.
A pressure feedback voltage other than 0.25 – 4.75V keeps more than
Failure description
200msec when the power is on.
Response from controller Only output alarm is enabled.
Symptom of machine Arm-out motion is slow.
5
IO
CONTROLLER CN-122M ARM-OUT PILOT
PRESS. SENSOR
ARM-OUT PILOT PRESSURE
202#
SIGNAL COLLECTING PORT
52 C SIGNAL
00#
54 B GND WIRE
GND WIRE
50#
5V PWR SUPPLY 56 A 5V
ZX215-1005077
5
IO
CONTROLLER CN-126M BOOM-RAISE PILOT
PRESS. SENSOR
BOOM-RAISE PILOT PRESS. 206#
SIGNAL COLLECTING PORT
70 C SIGNAL
00#
54 B GND WIRE
GND WIRE
50#
56 A 5V
5V PWR SUPPLY
ZX215-1005078
5
IO
CONTROLLER CN-125M BOOM-LOWER PILOT
PRESSURE SENSOR
207#
BOOM-LOWER PILOT PRESS 51 C SIGNAL
SIGNAL COLLECTING PORT
00#
GND WIRE 54 B GND WIRE
50# 5V
5V PWR SUPPLY 56 A
ZX215-1005079
5
IO
CONTROLLER CN-124M BUCKET-DIG PILOT
PRESSURE SENSOR
205#
BUCKET-DIG PILOT PRESS.
69 C SIGNAL
SIGNAL COLLECTING PORT
00#
54 B GND WIRE
GND WIRE
50#
5V PWR SUPPLY 56 A 5V
ZX215-1005080
5
IO
CONTROLLER BUCKET-DUMP PILOT
CN-128M
PRESSURE SENSOR
204#
BUCKET-DUMP PILOT PRESS.
SIGNAL COLLECTING PORT
50 C SIGNAL
00#
GND WIRE 54 B GND WIRE
50#
5V PWR SUPPLY 56 A 5V
ZX215-1005081
User Code Service Code Reading of swing pilot pressure is abnormal. Only
Trouble
E328 28 output alarm is enabled. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than
Failure description
200msec when the power is on.
Response from controller Only output alarm is enabled.
Symptom of machine Swinging motion is slow.
5
IO
CONTROLLER CN-123M SWING PILOT
PRESS. SENSOR
208#
SWING PILOT PRESSURE
SIGNAL COLLECTING PORT
68 C SIGNAL
00#
GND WIRE 54 B GND WIRE
50#
5V PWR SUPPLY 56 A 5V
ZX215-1005082
User Code Service Code Reading of left travel pilot pressure is abnormal.
Trouble
E329 29 Only output alarm is enabled. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than
Failure description
200msec when the power is on.
Response from controller Only output alarm is enabled.
Symptom of machine Left travel speed is low. Travel deviates.
5
IO
CONTROLLER CN-120M L. TRAVEL PILOT
PRESS. SENSOR
L. TRAVEL PILOT PRESSURE
200#
SIGNAL COLLECTING PORT
49 C SIGNAL
00#
GND WIRE 54 B GND WIRE
50#
5V PWR SUPPLY 56 A 5V
ZX215-1005083
User Code Service Code Reading of right travel pilot pressure is abnormal.
Trouble
E330 30 Only output alarm is enabled. .
A pressure feedback voltage other than 0.25 – 4.75V keeps more than
Failure description
200msec when the power is on.
Response from controller Only output alarm is enabled.
Symptom of machine Right travel speed is low. Travel deviates.
5
IO
CONTROLLER CN-121M R. TRAVEL PILOT
PRESS. SENSOR
201#
R. TRAVEL PILOT PRESSURE 67 C SIGNAL
SIGNAL COLLECTING PORT
00#
GND WIRE 54 B GND WIRE
50#
5V PWR SUPPLY 56 A 5V
ZX215-1005084
User Code Service Code Voltage setting of fuel control dial is abnormal. En-
Trouble
E231 31 gine returns to auto idle.
The voltage of fuel control dial other than 0.25 – 4.75V keeps more than
Failure description
200msec when the power is on.
Response from controller The throttle is switched to idle position.
Symptom of machine Engine returns to auto idle speed.
4
Short circuit
of signal wire
(grounded)
Short circuit
of signal wire
PD
● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
Between CN-302F ② and ground Resistance ≥2M Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
perform troubleshooting.
(contact with Between CN-302F ② and ground Voltage ≤5V
power supply)
● Turn engine start switch to OFF position. Keep it at OFF position to per-
5 Defective form troubleshooting.
Unplug the connector CN-302F, and measure the
IO
knob Resistance 5K±15% Ω
resistance between dial ① and ③
CAB
ZX215-1005085
User Code Service Code Hydraulic oil temperature is abnormal. Only output
Trouble
E237 37 alarm is enabled.
A voltage other than 0.2 – 4.75V, transformed from hydraulic oil temperature
Failure description
that is detected by controller, keeps more than 200msec.
Only output alarm is enabled. The alarm resets automatically when conditions
Response from controller
become normal.
Symptom of machine —
● Turn engine start switch to OFF position. Then, keep it at OFF position to
Failure of sen-
1 perform troubleshooting.
sor Between CN-113M ① and ground Voltage 0.2~4.75V
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of
2 form troubleshooting.
PD
wire harness Between CN-113M ① and pin 31 of controller Resistance ≤1 Ω
state
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
3 wire harness form troubleshooting.
(grounded) Between CN-113M ① and ground Resistance ≥1M Ω
● Turn engine start switch to OFF position. Keep it at ON position to perform
Failure of 24V
4 troubleshooting.
power supply Between CN-113M ② and ground Voltage About 24V
5
IO
CN-152M
0#
1 1
CONTROLLER 240Ω
2 2
HYDRAULIC OIL
CN-113M TEMP SENSOR
HYDRAULIC OIL SIGNAL
TEMP SENSOR 31 1 1
2 2 24V PWR
SUPPLY
24V PWR SUPPLY
ZX215-1005086
User Code Service Code Engine speed is abnormal. Only output alarm is en-
Trouble
41 E541 abled.
Failure description CPU detects out that engine speed is too low (below 100 rpm).
Only output alarm is enabled. The alarm resets automatically when conditions
Response from controller
become normal.
Symptom of machine —
5
IO
CONTROLLER
108A
ENGINE SPEED
1 SIGNAL
38
PROBING
108B
GND WIRE 19 2 GND WIRE
ZX215-1005087
User Code Service Code Front pump proportional solenoid coil current is ab-
Trouble
E450 50 normal. The system operates slowly.
Abnormality occurs in loaded circuit of proportional solenoid coil. Current above
Failure description
1.8A lasts for 1 second. Differential current occurs in drive protection loop.
Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.
Symptom of machine System operates slowly.
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
1 Between CN-113F ① and pin 88 of controller ≤1 Ω
wire harness Resistance
Between CN-113F ② and ground ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
2 wire harness form troubleshooting.
PD
(grounded) Between CN-113F ① and wire 0# Resistance ≥1M Ω
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
3 portional valve Unplug the connector CN-113F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ②
No troubleshooting can be done for failure occurs in the inner of controller.
Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
5
IO
CONTROLLER
SOLENOID VALVE
CN-113F (FRONT PUMP)
FRONT PUMP 702#
SOLENOID VALVE 88 1 SIGNAL
SIGNAL OUTPUT PORT
0#
GND WIRE 55 2 GND WIRE
ZX215-1005088
User Code Service Code Front pump proportional solenoid coil current is ab-
Trouble
E450 50 normal. The system operates slowly.
Abnormality occurs in loaded circuit of proportional solenoid coil. Current above
Failure description
0.1 A lasts for 1 second. Differential current occurs in drive protection loop.
Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.
Symptom of machine System operates slowly.
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
1 Between CN-113F ① and pin 88 of controller ≤1 Ω
wire harness Resistance
Between CN-113F ② and ground ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
2
3
wire harness
(grounded)
PD
form troubleshooting.
Between CN-113F ① and wire 0# Resistance ≥1M Ω
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
portional valve Unplug the connector CN-113F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ② .
No troubleshooting can be done for failure occurs in the inner of controller.
Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-113F (FRONT PUMP)
FRONT PUMP 702#
SOLENOID VALVE 88 1 SIGNAL
SIGNAL OUTPUT PORT
0#
GND WIRE 55 2 GND WIRE
ZX215-1005088
User Code Service Code Rear pump proportional solenoid coil current is ab-
Trouble
E451 51 normal. The system operates slowly.
Abnormality occurs in loaded circuit of proportional solenoid coil. Current above
Failure description
1.8 A lasts for 1 second. Differential current occurs in drive protection loop.
Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.
Symptom of machine System operates slowly.
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
1 Between CN-114F ① and pin 89 of controller ≤1 Ω
wire harness Resistance
Between CN-114F ② and ground ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
2 wire harness form troubleshooting.
PD
(grounded) Between CN-114F ① and wire 0# Resistance ≥1M Ω
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
3 portional valve Unplug the connector CN-114F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ② .
No troubleshooting can be done for failure occurs in the inner of controller.
Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
5
IO
CONTROLLER
SOLENOID VALVE
CN-114F (REAR PUMP)
REAR PUMP
702#
SOLENOID VALVE 89 1 SIGNAL
SIGNAL OUTPUT PORT
0#
GND WIRE 55 2 GND WIRE
ZX215-1005089
User Code Service Code Rear pump proportional solenoid coil current is abnor-
Trouble
E451 51 mal. The system operates slowly.
Abnormality occurs in loaded circuit of proportional solenoid coil. Current above
Failure description
0.1 A lasts for 1 second. Differential current occurs in drive protection loop.
Response from controller Stop the solenoid coil when failure is detected. Power supply must be restored.
Symptom of machine System operates slowly.
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
1 Between CN-114F ① and pin 89 of controller ≤1 Ω
wire harness Resistance
Between CN-114F ② and ground ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
2 wire harness form troubleshooting.
PD
(grounded) Between CN-114F ① and wire 0# Resistance ≥1M Ω
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
3 portional valve Unplug the connector CN-114F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ②
No troubleshooting can be done for failure occurs in the inner of controller.
Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
5
IO
CONTROLLER
SOLENOID VALVE
CN-114F (REAR PUMP)
REAR PUMP
702#
SOLENOID VALVE 89 1 SIGNAL
SIGNAL OUTPUT PORT
0#
GND WIRE 55 2 GND WIRE
ZX215-1005089
User Code Service Code Current through the proportional solenoid coil for
Trouble
E452 52 swing priority is abnormal.
Abnormality occurs in loaded circuit of proportional solenoid coil. Current above
Failure description
1.8A lasts for 1 second. Differential current occurs in drive protection loop.
Operation of solenoid coil is stopped when failure is detected. Power supply
Response from controller
must be restored.
Symptom of machine —
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
1 Between CN-133F ① and pin 98 of controller ≤1 Ω
wire harness Resistance
Between CN-133F ② and ground ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
PD
2 wire harness form troubleshooting.
(grounded) Between CN-133F ① and wire 0# Resistance ≥1M Ω
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
3 portional valve Unplug the connector CN-133F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ②
No troubleshooting can be done for failure occurs in the inner of controller.
Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-133F (SWING PRIORITY)
SWING PRIORITY 608#
88 1 SIGNAL
SOLENOID VALVE
SIGNAL OUTPUT PORT
0#
GND WIRE 55 2 GND WIRE
ZX215-1005090
User Code Service Code Current through the proportional solenoid coil for
Trouble
E452 52 swing priority is abnormal.
Abnormality occurs in loaded circuit of proportional solenoid coil. Current above
Failure description
0.1A lasts for 1 second. Differential current occurs in drive protection loop.
Operation of solenoid coil is stopped when failure is detected. Power supply
Response from controller
must be restored.
Symptom of machine —
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
1 Between CN-133F ① and pin 98 of controller ≤1 Ω
wire harness Resistance
Between CN-133F ② and ground ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
PD
2 wire harness form troubleshooting.
(grounded) Between CN-133F ① and wire 0# Resistance ≥1M Ω
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
3 portional valve Unplug the connector CN-133F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ②
No troubleshooting can be done for failure occurs in the inner of controller.
Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-133F (SWING PRIORITY)
SWING PRIORITY 608#
88 1 SIGNAL
SOLENOID VALVE
SIGNAL OUTPUT PORT
0#
GND WIRE 55 2 GND WIRE
ZX215-1005090
User Code Service Code Current through the proportional solenoid coil for bucket
Trouble
E453 53 confluence is abnormal. Motion of bucket is slow.
Abnormality occurs in loaded circuit of proportional solenoid coil. Current above
Failure description
1.8 A lasts for 1 second. Differential current occurs in drive protection loop.
Operation of solenoid coil is stopped when failure is detected. Power supply
Response from controller
must be restored.
Symptom of machine Motion of bucket is slow.
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
1 Between CN-134F ① and 99 pin of controller ≤1 Ω
wire harness Resistance
Between CN-134F ② and ground ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
PD
2 wire harness form troubleshooting.
(grounded) Between CN-134F ① and wire 0# Resistance ≥1M Ω
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
3 portional valve Unplug the connector CN-134F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ②
No troubleshooting can be done for failure occurs in the inner of controller.
Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-134F (BUCKET CONFLUENCE)
BUCKET CONFLUENCE 604#
SOLENOID VALVE 88 1 SIGNAL
SIGNAL OUTPUT PORT
0#
GND WIRE 55 2 GND WIRE
ZX215-1005091
User Code Service Code Current through the proportional solenoid coil for bucket
Trouble
E453 53 confluence is abnormal. Motion of bucket is slow.
Abnormality occurs in loaded circuit of proportional solenoid coil. Current above
Failure description
0.1A lasts for 1 second. Differential current occurs in drive protection loop.
Operation of solenoid coil is stopped when failure is detected. Power supply
Response from controller
must be restored.
Symptom of machine Motion of bucket is slow.
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
1 Between CN-134F ① and pin 99 of controller ≤1 Ω
wire harness Resistance
Between CN-134F ② and ground ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
PD
2 wire harness form troubleshooting.
(grounded) Between CN-134F ① and wire 0# Resistance ≥1M Ω
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
3 portional valve Unplug the connector CN-134F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ②
No troubleshooting can be done for failure occurs in the inner of controller.
Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-134F (BUCKET CONFLUENCE)
BUCKET CONFLUENCE 604#
SOLENOID VALVE 88 1 SIGNAL
SIGNAL OUTPUT PORT
0#
GND WIRE 55 2 GND WIRE
ZX215-1005091
User Code Service Code Current through the proportional solenoid coil for
Trouble
E455 55 boom priority is abnormal.
Abnormality occurs in loaded circuit of proportional solenoid coil. Current above
Failure description
1.8 A lasts for 1 second. Differential current occurs in drive protection loop.
Operation of solenoid coil is stopped when failure is detected. Power supply
Response from controller
must be restored.
Symptom of machine —
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
1 Between CN-135F ① and pin 101 of controller ≤1 Ω
wire harness Resistance
Between CN-135F ② and ground ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
PD
2 wire harness form troubleshooting.
(grounded) Between CN-135F ① and wire 0# Resistance ≥1M Ω
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
3 portional valve Unplug the connector CN-135F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ②
No troubleshooting can be done for failure occurs in the inner of controller.
Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-135F (BOOM PRIORITY 2 )
BOOM PRIORITY 2 603#
SOLENOID VALVE 101 1 SIGNAL
SIGNAL OUTPUT PORT
GND WIRE 0#
55 2 GND WIRE
ZX215-1005093
User Code Service Code Current through the proportional solenoid coil for
Trouble
E455 55 boom priority is abnormal.
Abnormality occurs in loaded circuit of proportional solenoid coil. Current above
Failure description
0.1A lasts for 1 second. Differential current occurs in drive protection loop.
Operation of solenoid coil is stopped when failure is detected. Power supply
Response from controller
must be restored.
Symptom of machine —
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
1 Between CN-135F ① and pin 101 of controller ≤1 Ω
wire harness Resistance
Between CN-135F ② and ground ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
PD
2 wire harness form troubleshooting.
(grounded) Between CN-135F ① and wire 0# Resistance ≥1M Ω
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
3 portional valve Unplug the connector CN-135F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ②
No troubleshooting can be done for failure occurs in the inner of controller.
Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
IO
5
CONTROLLER
SOLENOID VALVE
CN-135F (BOOM PRIORITY 2 )
BOOM PRIORITY 2 603#
SOLENOID VALVE 101 1 SIGNAL
SIGNAL OUTPUT PORT
GND WIRE 0#
55 2 GND WIRE
ZX215-1005093
User Code Service Code Connection of the solenoid coil for dual speed travel is
Trouble
60 E460 abnormal. High speed travel is not functioning.
Failure description Abnormality, open circuit or short circuit occurs in the proportional solenoid coil.
Response from controller Only output alarm is enabled.
Symptom of machine High speed travel is not functioning.
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
1 Between CN-132F ① and pin 100 of controller ≤1 Ω
wire harness Resistance
Between CN-132F ② and ground ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
2 wire harness form troubleshooting.
(grounded)
PD
Between CN-132F ① and wire 0# Resistance ≥1M Ω
Failure of pro- ● Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
3 portional valve Unplug the connector CN-132F, and measure the
coil Resistance 17.5 Ω
resistance between solenoid valve's ① and ②
No troubleshooting can be done for failure occurs in the inner of controller.
Failure of con-
4 (Except for the above reasons, the controller must be replaced in case of this
troller
failure.)
5
IO
CONTROLLER
SOLENOID VALVE
CN-132F (DUAL-SPEED TRAVEL)
DUAL SPEED TRAVEL 602#
SOLENOID VALVE 100 1 SIGNAL
SIGNAL OUTPUT PORT
0#
GND WIRE 55 2 GND WIRE
● The following information is contained in the troubleshooting table and related electric circuit
diagrams. Fully understand these information before carrying out troubleshooting.
4 PD
Possible causes of
< Description >
trouble (Given num-
bers are reference
● Standard value in normal state, which is used to judge possible
numbers, which do
causes that might be OK or N/G.
not indicate priority)
● A reference value is used to determine OK or N/G.
5
IO
This is part of the circuit diagram which shows the portion where the failure occurred.
shooting. (When all power supplies, grounding, signal and engine inputs are nor-
mal except engine output, it is the failure of start motor)
4 Failure of Engine start motor Start switch Voltage
start motor Power supply: Terminal B and ground 20~30V
Start
Between engine input terminal S and ground 20~30V
● Turn engine start switch to OFF position. Then, keep it at OFF position to perform
Open circuit troubleshooting.
5 of wire har- Wire 21# and start motor terminal B ≤1 Ω
IO
ness Wire 12# and start relay terminal SW Resistance ≤1 Ω
Start relay terminal L and safety relay terminal S ≤1 Ω
Failure of
6 Battery terminal "+" (wire 20#) and control dial wire 22# Resistance ≤1 Ω
fuse F1
Short cir- ● Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
cuit of wire bleshooting.
7
harness Start relay terminal SW and ground ≥1 M Ω
Resistance
(grounded) Engine input terminal S and ground ≥1 M Ω
Internal ● Turn engine start switch to OFF position. Then, keep it at ON position to perform
8 failure of troubleshooting.
alternator Alternator terminal P and ground Voltage ≤1V
● Turn engine start switch to OFF position. Move it to START position when per-
forming troubleshooting.
9 Start relay Terminal SW and ground App. 24V
Voltage
Terminal S and ground App. 24V
● Turn engine start switch to OFF position. Then, keep it at ON position to perform
Failure of troubleshooting.
10 ≤1 Ω
parking unit Between CN-801F 2 and 3
Resistance
Unplug connector CN-801F; measure resistance of motor coil. App 63 Ω
START SWITCH
TERMINAL B BR ACC R1 R2 C
F1 20A 22 HEAT
20 OFF
CN-241F 21
F2 5A 10 ON
BATTERY (D-12)
START
20 22 22 13 11
1 1
10
2 2
9 9
12 12
BATTERY RELAY
21
PILOT SWITCH
1 2 3 4 5
1 2 3 4 5
F16 10A 105
0
LOCK RELAY
PD 0
1
1
2
2
3 4 5
3 4 5
22 PARK RELAY
CN-661F PARK MOTOR
(S-16)
64
CN-801F 64 A
10 10
9 9
63 (H-6) 22
65
B
P1
6 6 65 63
CN-161F 1 2 3 4 5
1 1
P2
E
(S-16)
2 2
IO
0
10 10 1 2 3 4 5 0
15 15
13 3 3
6 6
12a
12
14
HLR CHARGE 47
CN-613F
4
3
2
1
INDICATOR
(L-6)
4 47
3 10
2 14
1
21
12a
10
10
12a
47
14
10
SW
R
P
S
L
R
P
B
L
B
0
S
E
E
0
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Open circuit of form troubleshooting.
1 Unplug the connector controller, and measure
wire harness Resistance 2.3±0.2 K Ω
the resistance between pin 19 and pin 38.
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Internal failure
2 form troubleshooting.
in sensor Between CN-448M A and B Resistance 2.3±0.2 K Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
3 wire harness form troubleshooting.
(grounded) Between CN-448M B and ground Resistance ≥1M Ω
Internal failure No troubleshooting can be done due to internal failure. (Failure lies in the con-
PD
4
of controller troller if the reasons above are ruled out)
CONTROLLER
CN-448M
IO
(S-2) SPEED SENSOR
SPEED SENSOR 38 A SIGNAL
INPUT SIGNAL
GND 19 B GND
ZX215-1005096
1 relay contact is heard, the battery is normal. Turn the start switch
tery relay
OFF→ON→OFF.
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Breakdown of form troubleshooting.
2
surge diode Between battery relay wire 20# and wire 21# Resistance ≥1M Ω
4
PD
5
IO
START SWITCH
TERMINAL B BR ACC R1 R2 C
F1 20A 22 HEAT
20 OFF
CN-241F 21
F2 5A 10 ON
BATTERY (D-12)
START
20 22 22 13 11
1 1
10
2 2
9 9
12 12
BATTERY RELAY
21
PILOT SWITCH
1 2 3 4 5
1 2 3 4 5
F16 10A 105
0
LOCK RELAY
PD 0
1
1
2
2
3 4 5
3 4 5
22 PARK RELAY
CN-661F PARK MOTOR
(S-16)
64
CN-801F 64 A
10 10
9 9
63 (H-6) 22
65
B
P1
6 6 65 63
CN-161F 1 2 3 4 5
1 1
P2
E
(S-16)
IO
0 2 2
10 10 1 2 3 4 5 0
15 15
13 3 3
6 6
12a
12
14
HLR CHARGE 47
CN-613F
4
3
2
1
INDICATOR
(L-6)
4 47
3 10
2 14
1
21
12a
10
10
12a
47
14
10
SW
R
P
S
L
R
P
B
L
B
0
S
E
E
0
● Turn engine start switch to OFF position. Keep it at OFF position to perform
Failure of pre-
1 troubleshooting.
heat fuse Between wire 21# and preheat relay pin 3# (contact) Resistance ≤1 Ω
When the preheating function is activated, if operation of the preheat relay
Failure of pre-
2 contact is heard, the relay is normal. The preheat switch is to be switched
heat relay
OFF→ON→OFF.
● Turn engine start switch to OFF position. Keep it at OFF position to perform
troubleshooting.
Failure of pre- Turn off the preheat switch and measure the resistance
3 ≥1M Ω
heat switch between wire 16# and wire 18#. Resistance
Turn on the preheat switch and measure the resistance
PD ≤1 Ω
between wire 16# and wire 18#
Short circuit ● Turn engine start switch to OFF position. Keep it at OFF position to perform
of wire har- troubleshooting.
4
ness (ground- Between preheat relay pin 3# (contact) and ground Resistance ≥1M Ω
ed)
5
START SWITCH
IO
TERMINAL B BR ACC R1 R2 C
HEAT
OFF
ON
_ _ (D-12)
+ + 22
1 1
20 F1 20A 22
9 9 16
BATTERY RELAY
1 2 3 45
PREHEAT PREHEAT RELAY
1 2 3 45
21 21
F13 160A
SWITCH CN-131M CN-142M
0
1 2 345
(D-12) (D-12) 1 2 345
18 GR-1 GLOW PLUG
7 7 6 6 17
PREHEATER
ZX215-1005097
● Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.
Failure of lockout Item Lockout control lever Resistance
1
switch LOCK ≤1 Ω
Between wire 105# and wire 27#
FREE ≥1M Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to per-
state
1 1
CN-161F
IO
(S-16)
2 2
10 10
12 12
0 105 27 606 CN-661F CN-136F
1 2 3 45 (S-16) (AMP-2)
1 2 3 45
1 1 1 1
8 8 2 2
ZX215-1005098
Short circuit
troubleshooting.
2 of harness Between harness ( from controller pin 70 to CN-126M
(grounded) Resistance ≥1M Ω
A) and ground
● Turn engine start switch to OFF position. Keep it at OFF position to perform
Open circuit of PD
3 troubleshooting.
harness Between controller pin 54 and CN-126M B Resistance ≤1 Ω
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the con-
4
troller troller if the reasons above are ruled out)
CONTROLLER
CN-126M BOOM UP
(DF-3) PRESS. SENSOR
BOOM UP 70 A
PRESSURE SENSOR SIGNAL
IO
54 B GND WIRE
SENSOR GND WIRE
SENSOR 5V 56 C 5V
ZX215-1005099
ARM-OUT
IO
CN-122M
(DF-3) PRESS. SENSOR
A SIGNAL
B GND WIRE
C 5V
CONTROLLER
ARM-OUT ARM-IN
CN-128M
PRESS SENSOR 52 (DF-3) PRESS. SENSOR
ARM-IN
PRESS SENSOR 71 A SIGNAL
SENOSR 5V 56 C 5V
ZX215-1005119
CN-127M BUCKET-DUMP
PRESS. SENSOR
(DF-3)
A SIGNAL
B GND WIRE
C 5V
CONTROLLER
5V
SENOSR 5V 56 C
BUCKET PD
CONFLUENCE SIGNAL 99
1 SIGNAL
2 GND WIRE
IO
CAB CHASSIS HARNESS
ZX215-1005100
● Turn engine start switch to OFF position. Start the engine and keep it run-
ning to perform troubleshooting.
Failure of sen- Levers in NEUTRAL, left and right travel pressure
1 0 KG
sor signals
Pressure
Levers in operation, left and right travel pressure
0~39 KG
signals
● Turn engine start switch to OFF position. Keep it at OFF position to perform
troubleshooting.
Short circuit Between harness (from controller pin 49 to CN-
2 of harness 120M A) and ground
(grounded) Between harness (from controller pin 67 to CN- Resistance ≥1M Ω
3
Open circuit of
harness
PD
121M A) and ground
● Turn engine start switch to OFF position. Keep it at OFF position to perform
troubleshooting.
Between controller pin 54 and CN-120M B Be-
tween controller pin 54 and CN-121M B
Resistance ≤1 Ω
Failure of con- No troubleshooting can be done due to internal failure. (Failure lies in the con-
4
troller troller if the reasons above are ruled out)
A SIGNAL
B GND WIRE
C 5V
CONTROLLER
ZX215-1005101
Short circuit of
3 wire harness
PD
● Turn engine start switch to OFF position. Keep it at OFF position to perform
troubleshooting.
Between harness (from CN-7-705 pin 8 to CN-241
pin 3) and ground
(grounded) Between harness (from CN-7-705 pin 9 to CN-241
pin 1) and ground
Resistance
≥1M Ω
≥1M Ω
Failure of No troubleshooting can be done for it is internal failure. (If it is not caused by
4
monitor one of the factors listed above, it should be the failure of monitor.)
CN-1-112
(D-3)
CANH
1 1
IO
120Ω RESISTANCE
2 2
CANL CN-7-705
CONTROLLER (D-12)
CANH 3
3 3
CANL
MONITOR
4 4 4
CN-1-111 29 8 8 8
CANH 60 (D-6) 22 9 9 9
0 10 10 10
1 1
2 2 12 12 12
CANL 78 3 3 3 3
1 1 CN-241F F1 20A
(D-12) 22
F10 5A
29
20
21
PWR PWR
ZX215-1005102
CN-1-112
(D-3)
CANH
1 1
IO
120Ω RESISTANCE
2 2
CANL CN-7-705
CONTROLLER (D-12)
CANH 3
3 3
CANL
MONITOR
4 4 4
CN-1-111 29 8 8 8
CANH 60 (D-6) 22 9 9 9
0 10 10 10
1 1
2 2 12 12 12
CANL 78 3 3 3 3
1 1 CN-241F F1 20A
(D-12) 22
F10 5A
29
20
21
PWR PWR
ZX215-1005103
Failure of dual ● Turn engine start switch to OFF position. Keep it at OFF position to perform
1 speed travel troubleshooting.
solenoid valve Between CN-131F A and B Resistance About 17.5 Ω
● Turn engine start switch to OFF position. Keep it at OFF position to perform
normal state
CONTROLLER
CN-132F HIGH SPEED TRAVEL
(AMP-2) SOLENOID VALVE
ZX215-1005104
COOLANT TEMP
510
30
SENSOR
ZX215-1005105
Trouble Engine fuel level sensor cannot correctly reflect current fuel level.
Related information Fuel level can be checked on the monitor.
● Turn engine start switch to OFF position. Keep it at OFF position to perform
troubleshooting.
Fuel level sen- Pin Fuel level Resistance
1
sor error Between wire 509# and ground FULL (Upper limit) Approx. 10 Ω
EMPTY (Lower limit) 85-95 Ω
● Turn engine start switch to OFF position. Keep it at OFF position to perform
state
Open circuit of
2 troubleshooting.
lead Between wire 509# and controller pin 11 Resistance ≤1 Ω
Short circuit of ● Turn engine start switch to OFF position. Keep it at OFF position to perform
3 lead (ground- troubleshooting.
PD
ed) Between wire 509# and ground Resistance ≥1M Ω
● Turn engine start switch to OFF position. Keep it at OFF position to perform
Lead short to
4 troubleshooting.
24V Wire 509# grounded Voltage ≤1V
CONTROLLER
IO
FUEL LEVEL 509
SENSOR 11
ZX215-1005106
Internal Fail- ● Turn engine start switch to OFF position. Keep it at OFF position to perform
1 ure of wiper troubleshooting.
motor Between wiper wire 25# and ground Resistance >10 Ω
● Turn engine start switch to OFF position. Keep it at OFF position to perform
troubleshooting.
2
Open circuit of Between CN-241F 1 and CN-1-110 (2) ≤1 Ω
lead
state
WIPER SWITCH
CN-121F CN-132F CN-1-110 25
(D-12) (D-12) CN-131M (D-6)
1 1 (D-12)
F5 5A 36 2 2 36
IO
11 3 3 35L 35L M
25 25 4 3 3
35H 35H
4 4 4 4
CN-241F
(D-12) 5 5
1
21
PWR
CAB
ZX215-1005107
5
Failure of sen-
sor
PD
● Turn engine start switch to OFF position. Then, keep it at ON position to
perform troubleshooting.
Between CN-128M ② and ground Voltage 0.5V~ 4.5V
CONTROLLER
CN-128M ARM IN
(DF-3) PRESS SENSOR
IO
ARM IN 71 2 SIGNAL
PRESS SENSOR
SENSOR GND WIRE 55 3 GND WIRE
SENSOR 5V 75 1 5V
ZX215-1005108
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Short circuit of
3 form troubleshooting.
signal wire Between CN-122M ② and ground Resistance ≥2M Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
4
5
Failure of sen-
sor
PD
perform troubleshooting.
Between CN-122M ② and ground Voltage 0.5V~ 4.5V
CONTROLLER
CN-122M ARM OUT
(DF-3) PRESS SENSOR
ARM OUT
IO
52 2 SIGNAL
PRESS SENSOR
SENSOR GND WIRE 55 3 GND WIRE
SENSOR 5V 75 1 5V
ZX215-1005109
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Short circuit of
3 form troubleshooting.
signal wire Between CN-126M ② and ground Resistance ≥2M Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
4
5
Failure of sen-
sor
PD
perform troubleshooting.
Between CN-126M ② and ground Voltage 0.5V~ 4.5V
CONTROLLER
CN-126M BOOM UP
(DF-3) PRESS SENSOR
BOOM UP
IO
70 2 SIGNAL
PRESS SENSOR
SENSOR GND WIRE 55 3 GND WIRE
SENSOR 5V 75 1 5V
ZX215-1005110
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Short circuit of
3 form troubleshooting.
signal wire Between CN-125M ② and ground Resistance ≥2M Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
4
5
Failure of sen-
sor
PD
perform troubleshooting.
Between CN-125M ② and ground Voltage 0.5V~ 4.5V
CONTROLLER
CN-125M
BOOM DOWN
(DF-3)
PRESS SENSOR
BOOM DOWN 51 2 SIGNAL
IO
PRESS SENSOR
55 3 GND WIRE
SENSOR GND WIRE
SENSOR 5V 75 1 5V
ZX215-1005111
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Short circuit of
3 form troubleshooting.
signal wire Between CN-124M ② and ground Resistance ≥2M Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
4
5
Failure of sen-
sor
PD
perform troubleshooting.
Between CN-124M ② and ground Voltage 0.5V~ 4.5V
CONTROLLER
CN-124M BUCKET CURL
(DF-3) PRESS SENSOR
BUCKET CURL SIGNAL
69 2
IO
PRESS SENSOR
SENSOR GND WIRE 55 3 GND WIRE
SENSOR 5V 75 1 5V
ZX215-1005112
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Short circuit of
3 form troubleshooting.
signal wire Between CN-127M ② and ground Resistance ≥2M Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
4
5
Failure of sensor
PD
perform troubleshooting.
Between CN-127M ② and ground Voltage 0.5V~ 4.5V
CONTROLLER
CN-127M BUCKET DUMP
(DF-3) PRESS SENSOR
SENSOR 5V 75 1 5V
ZX215-1005113
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Short circuit of
3 form troubleshooting.
signal wire Between CN-123M ② and ground Resistance ≥2M Ω
● Turn engine start switch to OFF position. Then, keep it at ON position
4
5
Failure of sensor
PD
to perform troubleshooting.
Between CN-123M ② and ground Voltage 0.5V~ 4.5V
CONTROLLER
CN-123M SWING PILOT
(DF-3) PRESS SENSOR
SWING PILOT
IO
68 2 SIGNAL
PRESS SENSOR
SENSOR GND WIRE 55 3 GND WIRE
SENSOR 5V 75 1 5V
ZX215-1005114
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Short circuit of
3 form troubleshooting.
signal wire Between CN-120M ② and ground Resistance ≥2M Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
4
5
Failure of sensor
PD
perform troubleshooting.
Between CN-120M ② and ground Voltage 0.5V~ 4.5V
CONTROLLER
CN-120M LEFT TRAVEL PILOT
(DF-3) PRESSURE SENSOR
SENSOR 5V 75 1 5V
ZX215-1005115
● Turn engine start switch to OFF position. Keep it at OFF position to per-
Short circuit of
3 form troubleshooting.
signal wire Between CN-121M ② and ground Resistance ≥2M Ω
● Turn engine start switch to OFF position. Then, keep it at ON position to
4
5
Failure of sen-
sor
PD
perform troubleshooting.
Between CN-121M ② and ground Voltage 0.5V~ 4.5V
CONTROLLER
CN-121M RIGHT TRAVEL PILOT
(DF-3) PRESSURE SENSOR
IO
RIGHT TRAVEL PILOT 67 2
PRESSURE SENSOR SIGNAL
ZX215-1005116
LOWER
RAISE
RIGHT
BWD
OUT
DUMP
BWD
FWD
LEFT
CURL
FWD
IN
LOCK
(PILOT VALVE )
16
BOOM PRIORITY
1 2 3 4 15
5 6 7 8 9 10 11 12 BUCKET CONFLUENCE
14
SWING PRIORITY
13
VARIABLE SPEED
(TRAVEL)
ACCUMULATOR
PD 1
2
19 20
IO
17 18
REGULATOR REGULATOR
SERVO SERVO
MECHANISM MECHANISM
P1 P2
M
FRONT REAR
ZX225-1105039
● The system schematic is a simplified hydraulic circuit schematic, which can be used as a ref-
erence to the hydraulic system and the mechanical system.
1 BACKUP VALVE
CONFLUENCE
BUCKET
CONFLUENCE 15
ARM HOLD
REG. VALVE
1 ARM 2 VALVE
2
14
BUCKET
CYLINDER
ANTISWING ANTISWING
BOOM 9 S&S
BOOM
S&S 10
BOOM 2
9
Su
PD
VALVE
VALVE
CYLINDER SWING
Sa
MOTOR
Su
VALVE
13
5 Su l. TRAVEL
VALVE
Su 6 3 SWING
VALVE 4
13
BALANCE VALVE
Sa
MECHANISM
SERVO
BALANCE VALVE
R. TRAVEL
STRT. TRAVEL 7 Su VALVE Su 8
Sa
VALVE
Sa
MECHANISM
SERVO
Sa
TRAVEL
MOTOR (L)
TRAVEL
IO
MOTOR (R)
1
2
3
ZX225-1105040
● The following information is contained in the troubleshooting table and related electric circuit diagrams.
Fully understand these information before carrying out troubleshooting.
4
Possible causes of
trouble (Given numbers
are reference numbers,
which do not indicate
priority)
PD
< Description >
● Standard value in normal state, which is used to judge possible
causes that might be OK or N/G.
● A reference value is used to determine OK or N/G.
5
IO
H-1 Work equipment speed slow, or swing and travel speeds slow
2
Malfunction
of pilot relief
valve
PD
ure of main relief valve or internal defect. Check the valve directly.
● Stop the engine. Perform troubleshooting while the engine is running at
high idle.
Control levers Pilot control pressure
3.9~4.1 MPa
All levers in "NEUTRAL"
{40~42 kg/cm²}
Malfunction of
3 The regulator possibly fails. Check the servo mechanism of the regulator.
regulator
Malfunction of If the trouble is caused by other factors, it might be the main pump that has
IO
4
main pump performance deterioration, malfunction or internal defect.
2 Malfunction of regulator Regulator may have malfunction. Check its servo mechanism.
Clogging of oil filter ele-
3 Oil filter element may be clogged. Check the element directly.
mal state
ment
Carbon buildup at fuel
4 Carbon built up at fuel injection nozzle. Check it directly.
injection nozzle
5 Clogging of air cleaner Air cleaner may be clogged. Check it directly.
Trouble ● Whole work equipment, swing, and travel systems do not work.
● Set working mode to (S) and fuel control dial at position (10) to
Related information
carry out troubleshooting.
Low level of
1 Make a visual check.
hydraulic oil
Inferior hydrau-
2 Hydraulic oil probably contains air. Make a visual check.
lic oil
Clogging of It is probably the clogging of the vent on top of the hydraulic tank that
state
3 vent on top of causes negative pressure in the hydraulic tank. Press the release button of
hydraulic tank the breather valve to eliminate air. Check again if the noise disappears.
Clogging of
It is probably the clogging of hydraulic tank strainer that causes negative
4 hydraulic tank PD
pressure in the oil suction line. Make a visual check.
strainer
Failure of main
5 The main pump may have internal defect. Check the main pump.
pump
IO
● Stop the engine. Perform troubleshooting while the engine is running at high
idle.
Malfunction Control levers Pilot valve output pressure
1 "NEUTRAL" 0 {0}
of sensor
3.5~4.1MPa
Operation
{36~42 kg/cm²}
● Stop the engine. Perform troubleshooting while the engine is running at high
idle.
2
Malfunction
of pilot valve
Failure of
PD
Control levers
"NEUTRAL"
Operation
Pilot valve output pressure
0 {0}
3.5~4.1MPa
{36~42 kg/cm²}
4
Malfunction of arm control
valve (spool)
PD
Check the pressure sensor by replacing it with a new one.
Malfunction of arm control Regeneration valve of arm control valve may have malfunction.
valve (regeneration valve) Check it directly.
Malfunction or defective
seal of arm control valve The relief valve or makeup valve inside the arm control valve may
5
(Relief valve and makeup have malfunction or defective seal. Check the valves directly.
valve)
IO
● Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Cut off the oil passage to the high-pressure side of the cylinder.
Disconnect the cylinder from the main valve. Measure the displace-
6 Failure of arm cylinder ment of piston for 15 minutes after the cylinder becomes stable. If
the measured value is greater than 10 mm, it is deemed that cyl-
inder has a defective seal. For more information on the measuring
procedure refer to "Testing and Adjusting", "Hydraulic Drift (Work
Equipment) - Test".
3
sensor
Malfunction of
PD
Check the pressure sensor by replacing it with a new one.
bucket control valve Spool of bucket control valve may have malfunction. Check it directly.
(spool)
Malfunction or
defective seal of
Relief valve and makeup valve in bucket control valve may have mal-
4 bucket control valve
function or defective seal. Check the valves directly.
(relief valve and
makeup valve)
IO
● Stop the engine. Perform troubleshooting while the engine is running
at high idle.
Charge the bucket with a load of approximate 1260 kg. Cut off the oil
passage to the high-pressure side of the cylinder. Disconnect the cylin-
Failure of bucket
5 der from the main valve. Measure the displacement of piston for 15 min-
cylinder
utes after the cylinder becomes stable. If the measured value is greater
than 10 mm, it is deemed that cylinder has a defective seal. For more
information on the measuring procedure refer to "Testing and Adjusting",
"Hydraulic Drift (Work Equipment) - Test".
DIG or DUMP
PD {36 kg/cm²}
● Stop the engine. Perform troubleshooting while the engine is
Failure of pressure sen-
2 running at high idle.
sor
Check the pressure sensor by replacing it with a new one.
Malfunction of control
3 Spool of control valve may have malfunction. Check it directly.
valve (spool)
IO
Seal of relief valve or makeup valve of bucket control valve may be defec-
Defective seal
tive. Check it directly.
of bucket control
2 ● The performance of seal can be judged by replacing it with another
valve (relief valve
relief valve or makeup valve. (Do not replace it with the boom-down
and makeup valve)
relief valve or makeup valve as their pressures are set differently.)
Defective seal
3 of bucket control Seal of bucket control valve spool may be defective. Check it directly.
valve (spool)
Malfunction of arm
1 Regeneration valve of arm may have malfunction. Check it directly.
regeneration valve
in normal state
H-12 Other work equipment moves while single oil circuit is relieved
● Other work equipment moves while single oil circuit of certain work equip-
Trouble
ment is relieved.
Related information ● Set the working mode to (S) in order to perform troubleshooting.
IO
Possible causes and standard value in
Defective seal of
1 Seal of control valve may be defective. Check it directly.
control valve
Failure of straight The straight travel valve gives no response. Check the spool and the
1
travel valve logic oil circuit drain port.
PD
IO
3.5~3.9 MPa
All levers in "NEUTRAL"
{ 36~40 kg/cm²}
3 Failure of regulator Check the regulator by swapping the front and back regulators.
● Stop the engine. Perform troubleshooting while the engine is
Sluggishness of proportion- running at high idle.
4 Travel control lever Proportional valve output pressure
al solenoid valve
Operate both control levers ≤0.1 MPa
Sluggishness of travel con-
IO
5 Check the valve spool to see whether it works well.
trol valve (spool)
Internal leakage of central
6 Check it by swapping the lines.
swivel joint
● Stop the engine. Perform troubleshooting while the engine is
running at high idle.
7 Malfunction of travel motor Travel control lever Leakage of travel motor
Travel relief 27.2 ml/min
Final drive may have internal defect. Check it directly.
● Internal defect of the final drive can be determined through
8 Failure of final drive
abnormal noise, abnormal heat, and metal powder or debris
contained in the oil drained.
● Stop the engine. Perform troubleshooting while the engine is
running at high idle.
Travel control lever Pilot valve output pressure
Failure of travel pilot pres- Forward 3.5~3.9MPa
9
sure sensor Reverse { 36~40 kg/cm²}
Difference occurs between
0.4 MPa {4 kg/cm²}
left and right output
Check the sensor by swapping it with another one.
{ 36~40 kg/cm²}
● Stop the engine. Perform troubleshooting while the engine is
running at high idle.
PD Travel control lever Solenoid valve output pressure
Malfunction of travel pilot
2 3.5~3.9 MPa
pressure sensor Both sides operated
{ 36~40 kg/cm²}
3.5~3.9 MPa
Either side operated
{ 36~40 kg/cm²}
Malfunction of travel Spool of travel control valve may have malfunction. Check it direct-
3
control valve (spool) ly.
Malfunction of travel
The makeup valve in travel control valve may have malfunction.
4 control valve (makeup
IO
Check it directly.
valve)
Seal of relief valve in travel motor may be defective. Check it di-
Failure of travel motor rectly.
5
(relief valve) ● The failure of seal can be determined by swapping the front
and back motors or the left and right motors.
Seal of check valve in travel motor may be defective. Check it di-
Failure of travel motor rectly.
6
(check valve) ● The failure of seal can be determined by swapping the front
and back motors or the left and right motors.
2
speed change)
PD
Failure of travel motor (in Speed shifting assembly of travel motor may have malfunction.
Check it directly.
IO
2
motor (relief valve) Check it directly.
Defective seat of travel
Seat of check valve in travel motor valve may have malfunction.
3 motor valve (makeup
Check it directly.
valve)
4
Speed of travel motor
drops.
PD
● Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Travel control lever
Travel relief
Leakage from travel motor
27.2 ml/min
Final drive may have internal defect. Check it directly.
● Internal defect of final drive can be determined with abnormal
5 Failure of final drive
noise, overheat, and metal powder or debris contained in the oil
drained.
● Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
IO
Travel control lever Pilot valve output pressure
Defective pilot pressure Forward 3.5~3.9MPa
6
sensor Reverse { 36~40 kg/cm²}
Difference occurs between left and
0.4 MPa {4 kg/cm²}
right output
Check it with swapping method.
Malfunction of swing
Possible causes and standard value in normal state
"NEUTRAL" 0 {0}
Swing ≥3.5MPa {≥36 kg/cm²}
Malfunction of swing
2 Spool of swing control valve may have malfunction. Check it directly.
control valve (spool)
Defective seal of Seal of makeup valve in swing motor may have defect. Check it directly.
3 swing motor (makeup ● Failure of the seal can be determined by swapping the right and left
valve) PD
makeup valves and check for any changes.
IO
Malfunction of swing
1 Parking brake of swing motor may have malfunction. Check it directly.
motor (parking brake)
● Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Improper adjustment Swing control lever Swing relief valve
or malfunction of 25.5~28.5 MPa
2 Swing relief
swing motor (relief {260~291 kg/cm²}
valve) If oil pressure does not become normal after adjustment, swing motor
3
Failure of swing mo-
tor
PD
relief valve may have malfunction or internal defect. Check the relief
valve directly.
● Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
Swing control lever Leakage from swing motor
Swing relief ≤10 ml/min
Clogging of brake
4 Disassemble, clean and check.
control lines
IO
{260~291 kg/cm²}
motor (relief valve)
If oil pressure does not become normal after adjustment, swing motor
relief valve may have malfunction or internal defect. Check the relief
valve directly.
PD
● Stop the engine. Perform troubleshooting while the engine is run-
ning at high idle.
2 Failure of swing motor Control lever Leakage from swing motor
Swing relief ≤10 ml/min
Trouble (2) ● Swing acceleration is only poor on one side, or swing speed is low.
● Set the working mode at gear (10) of power mode (S) to perform
Related information
troubleshooting.
IO
Possible causes and standard value in nor-
Left swing
≥3.5MPa {≥36 kg/cm²}
Right swing
Malfunction of swing con- Spool of swing control valve may have malfunction. Check it direct-
2
trol valve (spool) ly.
Seal of makeup valve in swing motor may be defective. Check it
Malfunction or defec-
directly.
3 tive seal of swing motor
● Swap the left and right makeup valves and observe the result
(makeup valve)
in order to determine whether the seal fails.
Failure of swing hold- Swing holding brake control lines and holding brake pilot valve may be
in normal state
1
ing brake control lines defective. Check them directly.
2
Malfunction of swing
motor (parking brake)
PD
Parking brake of swing motor may have malfunction. Check it directly.
Malfunction or defec-
Swing control valve spool may have malfunction or defective seal.
1 tive seal of swing
Check it directly.
in normal state
Failure of swing motor Seal of makeup valve in swing motor may be defective. Check it di-
3
(makeup valve) rectly.
E
PPDAG
IOK
AN
BL
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
Removal
● The "Removal" section contains procedure, precautions and the amount of oil or water to be
discharged.
Installation
● Unless specified otherwise, installation of a part is a reverse procedure of removing the part.
Disassembly
PD
8.1.2 Disassembling and assembling an assembly
● The "Disassembly" section contains procedure, precautions and the amount of oil or water to
be discharged.
Assembly
IO
● The "Assembly " section contains operating procedure, precautions, technical specification
and the amount of oil or water to be added.
● Necessary characteristics of the tools are noted in the list of special tools.
● : Very useful tools, which can be replaced with commercially available ones.
This section uses some symbols and icons that are not used elsewhere in this manual. They in-
clude:
● Dispose the engine coolant properly if antifreeze is contained in the engine coolant.
IO
● After disconnecting a hose or tube, cover or plug must be used to prevent invasion of dirt
or dust.
● A suitable container must be prepared to collect oil when draining the oil.
● Matching mark must be made at where is necessary before removing in order to avoid
mistake during reinstallation.
● Do not pull the wire and avoid the wire coming off. To avoid excessive force imposing on
the wire, hold the connector when disconnecting a wire.
● Tag the wires and the hoses in order to ensure their connecting positions. By doing so,
mistakes can be avoided during reinstallation.
● Count and check the number and thickness of the shims, and keep them in a safe place.
● When raising or lifting components, be sure to use proper lifting equipment of ample
strength and safety.
● When forcing screws are used to remove any components, tighten the screws evenly in
turn.
● The surrounding area must be cleaned before removing a unit. Cover the unit after remov-
al in order to prevent invasion of dirt or dust.
A: Thread-connected hoses
● Tighten all the screws and nuts (sleeve nuts) to specified torques.
● Replace the gaskets, O-rings, cotter pins and lock plates with new parts.
● Before applying the sealant to the gasket, clean the gasket surface of oil and dust. Check
the gasket for contamination or damage. Apply the gasket sealant evenly.
● Clean all parts, and correct any damage, dents, burrs, or rust.
● Before connecting the wiring connector, clean the wiring connector of oil, dirt or water.
Make sure that the wiring connector is connected securely.
● Before using an eyebolt, check the eyebolt for deformation or deterioration. Screw on the
eyebolt as far as possible and align it to the direction of the hook.
● Before tightening the split flange, tighten it evenly in turn in order to prevent over tighten-
ing on one side.
NOTE: After reassembling the hydraulic cylinder, main pump or other hydraulic equipment
that has been disassembled and repaired, it is necessary to bleed the air from the hydraulic
cylinder prior to initial operation of the cylinder. The purging procedure is performed as the
following:
2) Operate the work equipment control lever in order to cycle the movement of the hydraulic
cylinder 4 or 5 times. Hold the cylinder at where it is 100 mm from its stroke end.
4) You can run the engine at normal speed after this operation.
NOTE: This procedure is to be performed before using your machine for the first time after
repair or long storage.
● Completely discharge the engine coolant, tighten the drain valve, and add coolant to the
specified level. Run the engine to circulate the coolant through the system. Check the
coolant level again. PD
● Add hydraulic oil to the specified level after disassembly and reinstallation of a hydraulic
unit. Run the engine to circulate the hydraulic oil through the system. Check the oil level
again.
● Bleed the air from the system after removing and repairing the lines or hydraulic unit and
reassembling the parts.
For more information, see “Air in Each Component - Bleed” on page 6-45.
IO
● Add the specified amount of grease (molybdenum disulphide) to the work equipment re-
lated parts.
8.3.1 Removal
CAUTION
● Before removing the start motor assem-
bly, disconnect the cable from the nega-
tive (-) post of the battery, and insulate
between the cable and the negative post
with insulation tape.
Terminal S
Starter relay
IO
ZX215-1006001
8.3.2 Installation
1 2 3 4 6
● Installation is to be performed in the re-
verse order of removal.
8.4.1 Removal
CAUTION
● Disconnect the negative (-) post of the
battery.
ZX215T-1006003
PD
2. Disconnect the air intake hose (1).
1
IO
ZX215T-1006004
4 ZX215T-1006005
ZX215T-1006006
PD
ZX215T-1006007
IO
6. Disconnect the air hose (8).
10
ZX215T-1006008
ZX215-1006009
8.4.2 Installation
Relief valve:
IO
20~29 N·m {2.1~3.0 kgf·m}
ZX215-1006009
● Air bleeding
PD
Bleed the air from the fuel injection system.
IO
8.5.1 Removal
3
2. Remove the engine fan (1), the belt (2) and 1
the pulley (3).
ZX215-1006010
PD
3. Remove the mounting nut (4) and replace
the cone (5) and the O-ring (6). Remove
the crankshaft belt pulley (7).
6
Ta 4
IO
7
5 ZX215-1006011
8
8.5.2 Installation
ZX215-1006012
8.6.1 Removal
ZX215-1006013
8.6.2 Installation
Bolt:
8.7.1 Removal
CAUTION
● Disconnect the negative (-) post of the
battery.
Coolant: 22.5 L
ZX215T-1006017
ZX215T-1006018
ZX215T-1006019
8
ZX215T-1006021
11
12
ZX215-1006022
15
ZX215T-1006024
16
ZX215T-1006025
ZX215-1006026
8.7.2 Installation
Unit: mm
Notch
NOTICE
The amount of piston projection must be
ZX215-1006027
measured as the amount of piston projec-
tion may vary when replacing a piston or
connecting rod.
Engine oil
Tappet circumference:
Engine oil
F o r m o r e i n f o r m a t i o n , s e e “ Va l v e
Clearance - Adjust” on page 6-7.
● Adding coolant
IO
Add engine coolant to the specified level.
Start the engine to circulate the coolant in
order to release all foams. Check the cool-
ant level again.
8.8.1 Removal
ZX215T-1006028
ZX215T-1006030
7 ZX215T-1006031
ZX215T-1006032
IO
11. Remove the radiator fan guard (11).
11
ZX215T-1006033
12
ZX215T-1006034
14
ZX215T-1006035
IO
8.8.2 Installation
NOTE:
8.9.1 Removal
CAUTION
● Lower the work equipment to the
ground. Stop the engine. Disconnect
the cable from the battery negative (-)
post.
3
2
ZX215T-1006036
8
ZX215T-1006037
10
IO
12
ZX215T-1006038
16
ZX215T-1006039
19
ZX215T-1006040
22
23 ZX215T-1006041
IO
13. Disconnect the air intake hose (25).
25
ZX215T-1006042
26 27
ZX215T-1006043
ZX215T-1006044
IO
18. Disconnect the cables (31) and (32), and
remove the hose clamp (33).
33
32
31
ZX215T-1006045
34
ZX215T-1006046
36
ZX215T-1006047
IO
22. Disconnect the oil return hose (38).
39
ZX215T-1006048
40
ZX215T-1006049
640 kg
41
41
ZX215T-1006050
IO
8.9.2 Installation
● Air bleeding
IO
For more information, see “Air in Each
Component - Bleed” on page 6-45.
8.10.1 Removal
CAUTION
● Lower the work equipment to the
ground. Stop the engine. Operate the
breather valve to release internal pres-
sure.
1
ZX215-1006051
IO
3. Disconnect the four hoses (2) of the travel
motor and the corresponding hose connec- 2
tors.
ZX215T-1006052
NOTICE
● Be careful not to damage the surface
of mounting seal installed on the hose
base. ZX215-1006053
8.10.2 Installation PD
● Installation is to be performed in the re-
verse order of removal.
● Air bleeding
8.11.1 Disassembly
1. Oil draining
2. Cover
①
Remove the bolts. Use eyebolts ① to the
cover (1).
PD 1
ZX215-1006054
IO
3. Spacer
2
ZX215-1006055
ZX215-1006056
ZX215-1006058
6. Thrust washer 13 14
ZX215-1006059
21
16
23
ZX215-1006060
3) Remove the screw (21) to take the
IO
planetary carrier assembly (22) and the
shim (23) from the body.
9. Hub assembly
②
24
ZX215-1006061
PD 29
30
ZX215-1006063
IO
8.11.2 Assembly
1. Hub assembly
PD 25 28
ZX215-1006062
30
ZX215-1006063
24
ZX215-1006061
ZX215-1006065
IO
2) Measurement of raised thickness
Apply 3000 Kg load to the bearing and
measure the value (H) of the raised
part of the bearing.
加负荷3000Kg
● Turn the hub 2-3 times before applying
h
a pushing force.
ZX215-1006066
● Do not push or strike the resin retainer.
Screw-locking adhesive:
(Kesaixin 1277)
ZX215-1006067
Screw (21):
Screw (15):
4. Thrust washer 13 14
ZX215-1006059
ZX215-1006056
8. Spacer
2
9. Cover
PD
Use eyebolts ① to assemble the cover (1).
Use a torque spanner to tighten the bolts.
Bolts: ZX215-1006055
IO
73.4±3.63 N·m {7.5±0.4 kgf·m}
ZX215-1006068
8.12.1 Removal
CAUTION
● Lower the work equipment to the
ground. Stop the engine. Press the re-
lease button of the breather valve to re-
lease residual pressure in the hydraulic
tank. Place the hydraulic lockout con-
trol in the LOCK position.
8.12.2 Installation
● Air bleeding
PD
For more information, see “Air in Each
Component - Bleed” on page 6-45.
IO
8.13.1 Disassembly
1. Draining of oil
ZX225-1006077
IO
3. No.1 sun gear
2
ZX215-1006072
ZX215-1006073
PD
2) Disassemble the carrier assembly.
ZX215-1006074
IO
5. Ring gear
10
ZX215-1006075
ZX215-1006076
ZX215-1006077
17
NOTE: Pull out the pin (13) after
removal of the shaft. 14
8. Snap ring
ZX215-1006080
23
24
ZX215-1006081
10. Bearing
PD
Remove the bearing (25) and the oil seal
26
27
25 ZX215-1006082
8.13.2 Assembly
1. Bearing 23
2. Oil seal
PD
Press the oil seal (26) into the housing (27). 27
27
26
ZX215-1006083
3. Housing assembly
24
28
ZX215-1006085
4. Bearing 22 25
ZX215-1006086
14
13
ZX215-1006078
3) Assemble the gear (17) in the carrier
assembly (19). Put the bearing (18)
on the shaft (14). Slightly tap the pin
(15) into the bore after alignment. Use
IO
a rubber hammer to tap the pin. Make
sure that the pin (15) must not higher
than the bearing (18).
ZX215-1006087
Mating surface:
ZX215-1006073
ZX215-1006072
Contact surface:
8.14.1 Disassembly
(2). 8
6
13
12
2. Remove the float seals (3) from the sup- 10
5
port (2) and the idler (4).
6 7
ZX215-1006091
7 8
ZX215-1006092
8.14.2 Assembly
ZX215-1006093
7 8
ZX215-1006092
IO
3. Install the float seals (6) to the idler (4),
shaft (5) and support (7) assembly.
6
● Float seals
ZX215-1006095
PD
ZX215-1006096
IO
PD ZX215-1006098
Oil: approx.
4
2 ZX215-1006090
8.15.1 Removal
Sprocket: 58 kg
PD ZX215-1006099
8.15.2 Installation
Bolts (sprocket):
Special tools
8.16.1 Removal
1
WARNIN G
● The adjustment cylinder is under ex- ZX215T-1006100
IO
tremely high pressure. Never loosen the
grease fitting by more than one turn.
3. Pull out the master pin (2) with the tool (M).
ZX215-1006101
ZX215-1006102
PD
IO
8.16.2 Installation
ZX215-1006104
8.17.1 Removal
PD 1
ZX215T-1006105
ZX215T-1006106
8.17.2 Installation
Step 1:
Step 2: PD
Torque to: 549±59 N·m {56±6kgf·m}
Swing bearing:
8.18.1 Removal
CAUTION
● Fully extend the arm and the bucket.
Lower the work equipment to the
ground and move the hydraulic lockout
control lever to the LOCK position.
ZX215T-1006109
ZX215T-1006110
7
7. Disconnect the six hoses above the swivel
ZX215T-1006111
joint assembly.
IO
● Central swivel joint (port A) - Left travel
control valve (port BTL)
NOTICE
● Be careful not to impact the central
PD
swivel joint while removing the swing
platform assembly.
Swing Platform 15
Assembly
Only (Ref.)
SY195C9 8,427 kg 1,689 kg
IO
SY205C9 8,382 kg 1,689 kg
SY215C9 8,427 kg 1,689 kg
ZX215T-1006113
8.18.2 Installation
● Air bleeding
8.19.1 Removal
WARNIN G
● Release residual pressure in the hy-
draulic circuit before disconnecting the
hydraulic hoses.
16
IO
ZX215T-1006116
Transition plate
16
17 ZX215-1006117
8.19.2 Installation
8.20.1 Disassembly
13
ZX215-1006119
ZX215-1006120
8.20.2 Assembly
8.21.1 Removal
PD
5. Remove the screen (6) and the partition
frame mounting bolt (7) on the hydraulic
tank side.
6 7
10
ZX215T-1006124
NOTE:
ZX215T-1006127
8.21.2 Installation
Bolt:
● Air bleeding
8.22.1 Removal
WARNIN G
● Lower the work equipment to the
1
ground. Stop the engine. Press the re-
lease button of the breather valve to re-
lease residual pressure in the hydraulic 2
tank. Place the hydraulic lockout con-
trol in the LOCK position.
ZXT225-1106010
26
27 ZXT225-1106014
30
29
28 31
ZXT225-1106015
ZXT225-1106016
IO
12. Remove pipe (36) (main valve to radiator).
36
ZXT225-1106017
37
ZXT225-1106018
ZXT225-1106019
IO
15. Remove hoses (40) to (44) on the solenoid
valve and tag them properly.
45
45
46
ZXT225-1106021
8.22.2 Installation
PD
● Installation is to be performed in the re-
verse order of removal.
● Air bleeding
8.23.1 Removal
WARNIN G
● Lower the work equipment to the
ground and stop the engine. Press the
release button of the breather valve to
release residual pressure in the hydrau-
lic tank.
PD
NOTE: Tag each line so as to ensure correc-
tion installation.
Oil stopper
NOTE: If no oil stopper is used, remove
the drain plug and drain the oil from the
hydraulic tank and from circuits.
IO
ZX215-1006144
Hydraulic tank: Approx. 225 L
ZX215T-1006145
2
ZX215T-1006146
5 6
ZX215T-1006148
7
ZX215T-1006149
9
ZX215T-1006150
IO
9. Disconnect the oil drain hose (10) and seal
10
the openings properly.
16 18 19 17
ZX215T-1006152
20
IO
ZX215T-1006153
8.23.2 Installation
● Air bleeding
8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install
8.24.1 Removal
8.24.2 Installation
PD
● Installation is to be performed in the re-
verse order of removal.
4
Seal lip:
IO
Grease (No.1 Calcium base grease)
Seal circumference:
NOTE: This section discusses only the precautions when reassembling the work equipment pilot
valve assembly.
8 9
1 2 3 4 5 6 7 10
ZX215T-1006156
8.25.1 Assembly
valve assembly
PD
● Reassembly of the work equipment pilot Plug (5) circumference:
2. Insert the spring (7) into the spool hole in Thread adhesive (Tonsun 1277)
the valve body (8). Put the spool (6) in the
spring. Install the plunger (5) on the spool.
Push the plug (5) to the spool hole.
● A p p l y t h e t h r e a d a d h e s i v e ( To n -
sun 1277) to two points on the inner 5~7 mm
threads. The amount of application is
approximately 0.02 g.
U-joint (3):
specified torque.
NOTE: This section discusses only the precautions when reassembling the travel pilot valve as-
sembly.
Plunger
9 8 7
PD 6
5
4 3 2 1
ZX215T-1006158
8.26.1 Assembly
2. Install the cover (4) after aligning the holes. Tighten the socket bolts (1).
3. Install the dust ring (3) on the plunger. Install the cover (2) and fix the cover (2) with the cam-
shaft (5).
Special tools
Pulling out/pushing
■ 1
in the bushing
ZX215-1006159
ZX215-1006163
8.27.1 Disassembly
ZX215-1006165
piston rod.
ZX215-1006167
IO
ZX215-1006170
20
17 16 19
ZX215-1006173
8.27.2 Assembly
21
2) Install the dust ring (22) with the help of
a suitable cushion block. ZX215-1006175
Surface 19
under pressure
IO
ZX215-1006176
2) Use the press to push in dust ring (18).
NOTE:
Setscrew (3):
ZX215-1006183
NOTE:
12 5
Bolt: 267 N·m {27.2 kgf·m}
10 3
2 7
Tightening sequence
ZX215-1006185
8.28.1 Removal
WARNIN G
● Fully extend the arm and the bucket.
Lower the work equipment to the
ground. Move the hydraulic lockout
control to the LOCK position.
4
3. Remove the plate (4) and then the pin (5).
9
ZX215T-1006188
SY195C9
Work equipment assembly:
Model Weight
3450 kg
PD
SY205C9 3418 kg
SY215C9 3451 kg ZX215T-1006189
IO
8.28.2 Installation
CAUTION
● Do not put your finger in the pin bore
while aligning the pin bore.
plate (4).
● Air bleeding
Special tools
8.29.1 Removal
CAUTION
● Disconnect the cable from the negative
(-) post of the battery.
ZX215T-1006192
ZX215T-1006193
盖
ZXT225-1006202
3 6
4
SY195, SY205 ZXT225-1006203
IO
4
3
SY215 6 ZX215T-1006196
ZXT225-1006205
13
12
11
IO
ZXT225-1006206
14
15 18 ZXT225-1006207
ZX215T-1006200
8.29.2 Installation
NOTICE
● Keep the hoses free from contamination
by dirt, dust or water while installing the
return hose of the air conditioner.
● Refrigerant charging
8.30.1 Removal
1
1. Remove the cover (1) from the counter-
weight. Install eyebolts to the counter-
weight. Hold the counterweight.
ZX225-1106004
2
IO
ZX225-1106005
Counterweight assembly:
3901 kg
3
ZX225-1106006
8.30.2 Installation
Counterweight adjustment
10±5 mm(L&R)
b: max. 5 mm
a: 10±4
c: max. 5 mm
8.31.1 Removal
CAUTION
● Disconnect first the cable connecting to
the negative (-) post of the battery.
ZX215T-1006206
PD
2. Remove the fuse box (2) and storage box
(3).
3
2
SY215 5 ZX215T-1006001
ZXT225-1006216
PD
10
ZXT225-1006217
IO
8. Disconnect the external air duct (11).
11
ZX215T-1006210
12
ZX215T-1006211
14
ZX215T-1006212
IO
12. Remove the window washer reservoir (15).
15
ZX215T-1006213
16
ZX215T-1006214
ZX215T-1006215
IO
15. Remove the four mounting nuts (18) and
the five mounting bolts (19).
18
19
ZXT335-1006995
20
Cab assembly: 450 kg
ZX215T-1006217
8.31.2 Installation
10 10
9
8
1
10
2 7
10 11
PD 10
6
4 5
12
IO
3 10
ZX225-1006226
● Cab window glasses (1), (2), (5), (7) and (9) are adhered to the window frame.
● When replacing front window glass (2), disassemble front window assembly (12). (If the cab
is install with a front window assembly, do not only replace the front window glass.) For more
information about front window replacement, see “Front Window AS - Disassemble and As-
semble” on page 8-136.
8.32.1 Removal
CAUTION
● Removing shattered or cracked window
glass may cause finger cuts.
ZX225-1006227
IO
2. Removal of glass (4) and (6)
4
ZX225-1006228
Frame
Sealing
ZX225-1006229
Cab side
Retainer
A A
Cab
ZX225-1006231
ZX225-1006232
Adhesive
ZX225-1006233
IO
3) Pull a piece of piano string (or steel
wire) through the hole as illustrated.
Piano string
(or steel wire)
ZX225-1006234
PD
IO
8.32.2 Installation
ZXT225-1006238
unsealed.
10
ZX225-1006241
IO
● Besides the above locations, apply
primer also onto the right window glass
and the cab door lower window glass.
b
● Additional priming area on the right
window glass: (b)
ZX225-1006242b
glass (9). PD
Glass primer:
ed.
PD
window frame, do not overlap the two
ends of the seal. A 5 mm gap between
the two ends of the seal is recommend-
ZXT225-1006246
IO
(f): 50 mm h
(g): 90 mm
(h): 250 mm g
ZXT225-1006247
ZXT225-1006248
ZXT225-1006249
IO
● Adhere additional rubber seal (6b) onto
the lower cab door window frame as il- j
lustrated.
6b
Position of additional rubber seal:
m
(j): 110 mm
(k): 90 mm
ZX225-1006251
8
3) Cut the tapes across the glass (9) and
ZXT225-1006253
the cab (8) and remove the glass.
[6]
[6]
8 [6]
ZX225-1006254
ZX225-1006255
IO
6. Adhesive
13
Adhesive: PD
Sunrise MSI SR sealant U90 4463876
(r): 5 mm q
IO
ZX225-1006257
ZX225-1006258
ZX225-1006259
Dimension of (s): 10 mm PD 6
Dimension of (t): 15 mm t
15
● Adhesive (15) shall be thicker that the
rubber seal (6).
evenly.
IO
ZX225-1006261
6b 15
PD
ZX225-1006262
9
● Install the glass properly within 5 min-
utes after adhesive has been applied.
Dimension of (u): 5 mm t
4
● Use a rubber spatula to cover the edge
of the glass and trim the adhesive.
Glass primer:
Adhesive:
PD
Sunrise MSI Primer 35
A-A
16
ZX225-1006264
a
ZXT225-1006265
NOTICE
● Before removing the front window as-
sembly, lower the work equipment onto
the ground and shut down the engine.
8.33.1 Disassemble
6 5
ZX225-1006268
NOTICE 7
ZX225-1006269
● A return load of 58.8 N {6 kg} is applied
onto the rear of the cab. Be very care-
ful when removing pin (7) to disconnect
pull rod (9).
PD 9 8
ZX225-1006270
IO
7. Pull out the front window assembly (10)
10
from the opened part of the guide rail and
lower the assembly gradually.
ZX225-1006271
ZX225-1006272
10
ZX225-1006274
8.33.2 Assemble
ZX225-1006277
ZX225-1006279
16 19
ZX225-1006281
to the roof.
PD
front window assembly is adjusted in
Step 6 and Step 7, raise the assembly
ZX225-1006285
IO
8) Turn the left/right rubber stopper (18) to
the left by one and a half round.
18
● When front window assembly is "un-
locked", it must move the left/right rub-
ber stopper (18) by 1.5 – 3.0 mm. ZX225-1006286
Adhesive(LT-2)
ZX225-1006290
8.34.1 Removal
CAUTION
● Disconnect first the cable connecting to
the negative (-) post of the battery.
8.34.2 Installation
8.35.1 Removal
CAUTION
● Disconnect first the cable connecting to
the negative (-) post of the battery.
8.35.2 Installation 6
5
ZX215-1006283
● Installation is to be performed in the re-
verse order of removal.
1. Main structure
8.36.1 Structure
RED — L. SOUND TRACK INPUT
AUDIO INPUT
BLACK — GROUND
RADIO ANTENNA
PD
ZX215-1006285
ZX215-1006284
SY195-205-215C9 Crawler Hydraulic Excavator
SY195-205-215C9 Crawler Hydraulic Excavator Disassembly and Assembly
8.36.2 Removal
NOTICE
● Disconnect the power supply prior to
removal.
PD
2. Remove the radio connector CN-003F.
Radio
ZX215-1006286
IO
Radio
Mounting bracket Washer
Screw
ZX215-1006288
8.36.3 Installation
1 2 3
1 2 3 20b R+ L+
4 5 6 7 0 20b R- L-
8.37 Battery
8.37.1 Structure
A
2 B
10 J
C
11
6 E
D
PD G
I
F
8 7 5 9 4 3 1
IO
ZX215-1006290
8.37.2 Removal
NOTICE
● Turn the start switch to the OFF posi-
tion before removal.
CAUTION
● Battery gas can cause explosion. No
sparks or flames are allowed near the
battery.
PD Battery
MAINTE
免 维 护
蓄 电 池
FREE BA
NANGE-
TTERY
ZX215-1006291
VARTA
TA
VAR
Battery box
Bolt Wahser
ZX215-1006293
8.37.3 Installation
8.37.4 Replacement
NOTICE
PD
● During installation, apply vaseline to
battery terminals in order to prevent
corrosion.
IO
8.38.1 Structure
23 22 20 18 17 15 13 12,11 28 6 10,9,8,7
PD
25,24 21 1 14 19 16 26 5 4,3,2
IO
27
4 5 6
1 2 3
ZX215-1006294
8.38.2 Removal
NOTICE
● Disconnect the power supply of the
start switch before removal.
X
T MA
STAR
ON
OFF
1. Remove the setscrew to remove the con-
CK
LO
MIN
sole cover.
PD
2. Remove both setscrews in order to remove Set screw Console cover
the mounting plate and the start switch
from the console cover.
IO
Mounting plate Start switch
ZX215-1006296
1. Working principle
ON/OFF
Key Position Preheat Plug
Battery (B) Battery Relay (BR) Accessory Start Relay (C)
(R1) (R2)
HEAT
OFF
ON
START
2. Wiring
1 B BR ACC
PD
3 1 22 13 3
4 R1 R2 C 6 4 16 11 6
8.39.1 Removal
Cover
1. Remove the cover.
ZX215-1006300
2. Remove the bolts and take off the back Back cover Fuse box cover
cover along with the fuse box.
PD
Bolt
IO
ZX215-1006301
Back cover
ZX215-1006302
8.40 Wiper
8.40.1 Structure
Blade
Rotating mechanism
Arm
Wiper motor
Connector
PD Mounting bracket
ZX215-1006303
YELLOW (RESET)
M
BLUE (HIGH SPEED)
RED (POWER+)
BLACK (POWER-)
ZX215-1006304
8.40.3 Removal
Inner decor
ZX215-1006305
Moving
mechanism
Wiper motor
IO
Bolt
ZX215-1006306
Cap
Locknut
Cab
ZX215-1006307
8.40.5 Installation
ZX215-1006308
IO
8.41 Relay
S
B 1 SW(-) SW L
AA2A
2 L(-)
ZX215-1006309
3 4
Batter (+) terminal
3 4
IO
1(+)
2(-)
ZX215-1006310
3. Heater relay
5(-)
● Check the conduction and action. Replace
the relay in case of any failure.
1
5 1 2 3 4
(-) (+)
2 4(+)
Fuse 3
ZX215-1006311
4. Safety relay
Relay harness
Headlight relay
Starter control relay PD
Work lamp relay
IO
Mounting plate
ZX215-1006313
2. Removal
3. Installation
ZX215-1006314
PD
IO
1 4 2
0
HORN
K5
32
31
WORK LAMP
0
K6
34
33 0
PD
PILOT CONTROL
K10
606 105
STARTER CONTROL
0
K3
12
105
PARKING
0
K7
65
63 13
HEADLIGHT
K8
0
70
72
23 24 27 11 64 71
8.42 Sensor
50±0.2°C 80±10Ω
60°C 56.3Ω(ref.)
Standard
Value
80°C
100°C
106±0.3°C
120°C
PD
29.5Ω(ref.)
16.5Ω(ref.)
14.3±1.0Ω
10Ω(ref.)
NOTICE
● Insufficient tightening of the engine
speed sensor may cause signal output
failure. Tighten the sensor to specified
torque.
Terminal C ZX215-1006318
8.43.1 Insertion
ZX215-1006320
ZX215-1006322
8.43.2 Removal
ZX215-1006323
ZX215-1006324
IO
3. Pull out the tool to remove the wire with
terminal.
ZX215-1006325
E
G
PPDA
A IONK
BL
E
PPDAG
IOK
AN
BL
Engine
9 Engine
9.1 General .................................................................................................................... 9-3
9.2 Engine Assembly ..................................................................................................... 9-6
PD
9.3 Lubricating System ................................................................................................ 9-88
9.4 Fuel Supply and Engine Control ...........................................................................9-119
9.5 Cooling System.................................................................................................... 9-161
9.6 Air Intake and Exhaust System ............................................................................ 9-185
9.7 Electrical System ................................................................................................. 9-201
IO
PD
IO
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
9 ENGINE
9.1 General
2. Inspection standard PD
● The inspection procedures of undercar-
riage parts and components focus primarily
on the removal, installation, disassembling,
assembling, inspection of parts and com-
6. Standard value
3. Inspection 7. Limit
IO
● All items labeled "Acceptable” or “Unac- ● When a certain value of a part exceeds
ceptable" as per the inspection standard this limit, this part can not be used any
shall be specified. more in terms of performance and strength
and must be replaced or repaired.
● Some routine visual inspection and clean-
ing of repeatedly used parts may not be 8. Tightening torque
specified, but they shall be performed dur-
ing inspection. ● It specifies the standard tightening value of
bolts and nuts.
4. Caution
● Refer to the standard tightening torque
● Procedures which, if not observed, will table if not otherwise specified. (The stan-
result in major injury, or even death and dard tightening torque depends on the size
damage to the machine and inspection in- and material of the thread)
struments, are specified.
● "WET" shall be marked where wet type
5. Terms and units tightening is applicable. Otherwise, dry
type tightening is applicable and refer to
● Front and rear the specified tightening value.
9. Unit
FD215-1007001
FD215-1007002
IO
9.2.1 Specifications
Item Specification
Valve spring
Rocker arm
Flywheel
Plunger
Intake valve
Tappet
Camshaft gear
PD
Idle gear
Exhaust valve
Connecting rod
Injection pump gear FD215-1007035
Valve cap
Rocker arm Valve retainer lock
Stem Upper seat
seal
Adjusting screw External valve spring
Internal valve spring
Valve guide
Plunger Valve
PD
Tappet
Camshaft
FD215-1007036
IO
● A valve lever seal is placed inside the
valve, which controls the grease amount
on the sliding surface between the valve
and the valve guide.
Size mark
1.3mm 1.35mm 1.4mm
FD215-1007037
FD215-1007038
Bushing
Connecting rod
Bolt
Cap
9.2.2.6 Piston
PD FD215-1007039
Part No.
Weight
IO
Oversize mark
Front mark
FD215-1007040
Idle gear
Oil orifice
Camshaft gear
Idle gear shaft
Thrust plate
2
2
2
Idle gear
1
PD 3
3
1
3
1
9.2.3 Troubleshooting
Abnormal
Symptom Low output Reference
Cause noise
Incorrect valve clearance ○ ○
Defective cylinder head gasket ○ ○
Abrasion and carbon build-up on valve
○ ○
Cylinder head, and valve seat
valve mechanism Valve spring elastic fatigue ○ ○
Defective rocker arm and bracket ○
Rocker arm bracket greasing defect ○
Tappet abrasion ○
Gear engagement clearance defect ○
Timing gear Timing gear perimeter and idle gear
○
greasing defect PD
Excessive camshaft end play ○
Camshaft
Camshaft abrasion ○
Piston ring groove abrasion/damage ○ ○
Piston, connecting Piston ring abrasion, damage ○ ○
rod Abrasion of piston pin and connecting
○
rod small end
Excessive crankshaft end play ○
IO
Crankshaft defective assembling ○
Inspection standard
Special tools
Unit: mm
Location Tool name and shape Part No. Use
Compression gauge
A
connector
PD MH061460
Measuring compres-
sion pressure
M14×1.5 A
with rags.
CAUTION
● When coolant and engine oil are ad-
hered on the rag, they may spurt out of
the mounting hole under high tempera-
ture when the engine is running. Do not
touch or watch the injector mounting
hole when the engine is running.
Gasket
sion gauge.
Inspection standard
Special tool
Adjusting valve
Grooved screw
MH060008 clearance
driver
(Loaded condition)
PD
Valve clearance shall be adjusted when the
engine is cool according to the following pro-
cedure:
[Inspection]
Cylinder No. 1 2 3 4 5 6
Valve sequence IN EX IN EX IN EX IN EX IN EX IN EX
No.1 Compression TDC ○ ○
PD ○ – – ○ ○ – – ○ – –
No.6 Compression TDC – – – ○ ○ – – ○ ○ – ○ ○
FD215-1007049
Ta
3
1
4
7 Tb
Tb 7
6
PD 8
9
IO
10
*a
FD215-1007050
Disassembling sequence
1) Oiler cap 8) Cylinder head
2) Insulator 9) Cylinder head gasket
3) Rocker cover 10) Tappet
4) Rocker cover gasket *a: Crankcase
5) Rocker arm and bracket P : Position pin
6) Plunger : Non-reusable parts
7) Cylinder head bolt
NOTICE
● Heating plug and injector project un-
der the cylinder head. Be careful not
to damage these parts when placing
them.
Assembling sequence
PD
Reverse the disassembling sequence.
NOTICE
● Cylinder head bolt is fastened onto
plastic area. Replace the bolt if it has
IO
been tightened for 3 times.
Inspection standard
Unit: mm
Location Check item Standard value Limit Remedy
T Tightening torque
Unit: N·m{kgf·m}
Symbol Tightened parts Tightening torque Remark
PD Wet type
Tb Cylinder head bolt 147{15}+90°
Reusable for 3 times
Special tools
Valve spring
Tappet
FD215-1007055
FD215-1007056
NOTICE
“UP”
● Piston projection may change when
changing pistons and connecting rods.
Piston projection must be measured.
Unit: mm
NOTICE
PD
● Before installing the cylinder head,
check the number of punch marks on
Punch mark
the bolt head. (Usable when no more
than 2 marks are available)
FD215-1007061
NOTICE
● Cylinder head bolts are tightened in the
plastic area. No further tightening is re-
quired once the angle is fixed.
4 5
7
1 10
9
8
6
2 FD215-1007063
Disassembling sequence
1)
2)
Set bolt
Rocker shaft bracket
PD 6)
7)
Rocker shaft spring
Adjusting screw
3) Adjusting screw 8) Rocker arm bushing
4) Rocker arm bushing 9) Air outlet rocker arm
5) Air intake rocker arm 10) Rocker shaft
IO
: Non-reusable parts
Assembling sequence
Inspection standard
Unit: mm
Location Check item Standard value Limit Remedy
Rocker arm
Removing and installa-
bushing remover
A MH061378 tion of rocker arm bush-
A B
ing
φ19 φ21 B
IO
C
FD215-1007065
[Remove]
Bushing
FD215-1007066
[Install]
Bushing turning
(joint)
Tc
13
1
10
2
Ta
3
11
Tb 14
4 9
12
5
6
PD
8
15
16
20
19
IO
21
18
17
FD215-1007069
Disassembling sequence
Assembling sequence
NOTICE
● Replace the stem seal when replacing
the intake valve and exhaust valve.
Inspection standard
Unit: mm
Location Check item Standard value Limit valve Remedy
Free length 60.84 57.8
Outer valve Assembling load (assembling
4 24.5±1.2kg 20.8kg Replace
spring length 47.25)
5
Inner valve
spring
Verticality
Free length
length 40.3)
Verticality
PD
Assembling load (Assembling
–
55.07
9.5±0.45kg
–
2.5
52.1
8.1kg
2
Replace
T Tightening torque
Unit: N·m{kgf·m}
Special tool
Unit: mm
Valve tappet
A MH061668
φ42
A
Removing and instal-
lation of valve retainer
lock
c
tool
A
φ28
B
φ9
PD
A B MH061293
Installation of stem
seal
A
IO
Valve guide remover
Removing of valve
e A B MH061066
guide
φ28 φ9
A
Valve seat
angle Valve edge thickness
FD215-1007079
Modification of valve
10
[Remove]
IO
Valve guide
FD215-1007082
[Install]
Valve – Grind
NOTICE
● Make sure no grinding paste is adhered
onto the valve rod. Valve rod
Dent depth
FD215-1007089
● Grind the valve seat with a valve seat cut- Dent depth Valve seat
ter or a wheel head. surface angle
NOTICE
● Make sure the thickness of the valve
deflection does not exceed the speci-
IO
fied limit during grinding operation.
[Install]
A B
● Replace cylinder head in case of abnor-
mality. FD215-1007092
NOTICE
PD
● When working on a cool valve seat, be
careful with low temperature.
阀座seat
Valve
set the chamfer of tool h on the cylinder
head.
FD215-1007093
● Grind the valve after the valve seat has
IO
been installed.
NOTICE
● Make sure the valve deflection thick-
ness does not exceed the specific limit
during grinding operation.
FD215-1007095
NOTICE
● After the seal is driven in, check if the Cylinder head
spring of the stem seal is deformed or
IO
FD215-1007096
damaged. Replace it with a new one in
case of abnormality.
5
3
2
P
PD Ta
FD215-1007097
Disassembling sequence
NOTICE
● The connecting rod is fastened in the
plastic area. Replace the bolt of con-
necting rod if it has been tightened for
3 times.
Assembling sequence
Inspection standard
Unit: mm
T Tightening torque
Symbol
Ta
PD
Tightened parts
29{3}+90°±5°
Unit: N·m{kgf·m}
Remark
Wet type
Reusable for 3 times
Special tools
Unit: mm
Socket wrench
c MH061560
d
Cylinder bushing
installation tool
A
φ103
PD ME062228
Installation of cyliner
bushing
NOTICE
● The projection of piston influences en-
gine performance. It must be inspected.
PD B
FD215-1007101
NOTICE
● Do not expand the bearing by hand.
NOTICE FD215-1007105
NOTICE
● To avoid cylinder deformation due to
PD
the heat generated by the boring, bore
the cylinders in the following order.
No.1→No.5→No.3→No.6→No.2→No.4
[Remove]
[Inspect]
183mm
IO
99mm Crankcase
● Check if the cylinder bushing mounting 15mm
hole of the crankcase if scratched.
B
D1 A
● Measure the inner diameter of the crank- D2
case, the outer diameter of the upper and
lower parts of the cylinder bushing and ra- D3
dial direction.
15mm
B
D2 A
D3
FD215-1007107
Install
FD215-1007108
bearings.
FD215-1007109
IO
Install: Piston and connecting rod
● Piston perimeter
● Inside of tool
crankcase
PD
● Inside of the cylinder portion of the
FD215-1007111
Loop bar
Socket seat
Loop bar
(for connection)
FD215-1007113
● Piston projection
8
4
7
6
PD
FD215-1007115
Disassembling sequence
IO
1) 1st compression ring 6) Connecting rod bushing
2) 2nd compression ring 7) Connecting rod
3) Oil ring 8) Piston
4) Snap ring : Non-reusable parts
5) Piston pin
NOTICE
● Do not remove the connecting rod bolt
unless it is deemed abnormal.
Assembling sequence
Inspection standard
Unit: mm
Lubricant and/sealant
Special tools
Unit: mm
FD215-1007118
FD215-1007119
FD215-1007122
FD215-1007123
Nut Base
● Fix the connecting rod onto the base and Press
secure it properly with the bracket and
Remover
base plate.
Base
FD215-1007124
[Install]
FD215-1007126
9.2.10 Flywheel
P
4
*a
Ta
1
PD 6
FD215-1007129
Disassembling sequence
Assembling sequence
Inspection standard
Unit: mm
Tightening torque
Unit: N·m{kgf·m}
Special tools
Flywheel installation
FD215-1007132
CAUTION
● Do not touch the heated area to avoid
IO
burns.
CAUTION
● Do not touch the heated area.
Chamfered side
Install: Flywheel a
Socket
below.
Loop bar
(for connection)
● Turn the socket of tool to the left and
strain the spring inside the socket.
FD215-1007135
10
*c
4
*d
5 *b
*a
PD
Tb
8
11
2 *a
IO
9
3 13
12
1
Chamfer
Ta 10
FD215-1007137
Disassembling sequence
NOTICE
● Do not remove the front oil seal unless
deemed abnormal.
Assembling sequence
Inspection standard
Unit: mm
Location Check item Standard value Limit Remedy
Between crankshaft gear and oil pump gear 0.10 – 0.18 0.3
Clearance
Between idle gear and crankshaft gear 0.07 – 0.15 0.3
– between Replace
Between idle gear and camshaft gear
PD 0.07 – 0.17 0.3
the gears
Between idle gear and injection pump gear 0.07 – 0.17 0.3
– Idle gear axial clearance 0.05 – 0.15 0.3 Replace
9, 11 Clearance between idle gear bushing and idle gear shaft 0.03 – 0.06 0.1 Replace
Tightening torque
Unit: N·m{kgf·m}
Special tools
Unit: mm
Symbol Tool name and shape Part No. Use
C
Idle gear bushing
Removal and installa-
remover
B MH062224 tion of idle gear bush-
A B C
A ing
φ44.5 φ49 φ45
Cone remover
b A A MH062496 Removal of cone
M44×1.5
FD215-1007141
FD215-1007142
9.2.11.2 Inspecting method
[Inspect]
FD215-1007143
Bushing
FD215-1007144
[Install]
FD215-1007145
● Bore the bushing if measured value is be-
low the standard value.
center position.
NOTICE
Front cover
● Do not start the engine within 1 hour
IO
after the timing gear box is installed.
FD215-1007147
9.2.12 Camshaft
“F”
PD
3
Ta 1 FD215-1007148
IO
Disassembling sequence
NOTICE
● Do not disassemble the camshaft gear
unless confirmed abnormal.
Assembling sequence
Inspection standard
Unit: mm
Location Check item Standard value Limit Remedy
Tightening torque
Symbol
Ta
PD
Tightened parts
180{18}
Unit: N·m{kgf·m}
Remark
FD215-1007149
NOTICE
● Be careful not to damage the camshaft
FD215-1007150
bushing when removing the camshaft.
IO
Remove: Camshaft gear
NOTICE
● Do not strike the camshaft gear with a
hammer. Use a press machine.
FD215-1007151
FD215-1007152
Inspect: Camshaft
FD215-1007155
rotation. PD 2
Camshaft gear
Install: Camshaft
Camshaft gear
● Set piston No. 1 and No. 4 at the top dead
center position. Align the match marks on
the camshaft gear and idle gear "2".
FD215-1007157
16
15
P
Tb 14
13
PD12
1
11 b
IO
4
3 b
8
2
Ta 5
P
10 6
FD215-1007158
Disassembling sequence
Assembling sequence
NOTICE
● The main fastening bolt is tightened
onto the plastic area. Replace the bolt
if it has been tightened for 3 times.
PD
● If the check valve is tightened to a
torque larger than specified, the engine
may seize up. Be very careful in this re-
IO
gard.
Inspection standard
Unit: mm
Tightening torque
Symbol
Ta
PD
Tightened parts
59{6}+90°
Unit: N·m{kgf·m}
Remark
Wet type
Reusable 3 times (max.)
Tb Check valve 38{3.9} Wet type
Special tools
Unit: mm
Removing of crank-
c Gear remover MH061326
shaft gear
NOTICE
PD
● Do not strike the crankshaft gear in
order to remove it. Otherwise, the gear
may get damaged.
NOTICE
● Do not expand the bearing by hand.
Inspect: Crankshaft
FD215-1007166
1. Deflection
NOTICE
FD215-1007167
● When the deflection of the crankshaft
makes the crankshaft turn for one
round, half the reading on the dial
gauge.
Inspect: Crankshaft
Crankshaft – Modify
NOTICE
● If the crankshaft shall be modified by
grinding, replace the main bearing with
one of a smaller size.
C: 41+0.2 mm
D: R4±0.2mm
Sub-size grade
0.25 0.50 0.75 1.00
Journal outer machining diameter 77.68 – 77.70 77.43 – 77.45 77.18 – 77.20 76.93 – 76.95
Pin portion outer machining diameter 64.69 – 64.71 64.44 – 64.46 64.19 – 64.21 63.94 – 63.96
Roundness Below 0.01
Cylindricity Below 0.006
FD215-1007171
IO
Install: Rear oil seal oil-catch ring Rear oil seal oil-catch ring
NOTICE
● The main bearing shall be replaced
with one of a smaller size if the crank-
shaft shall be modified by grinding.
Punch mark
NOTICE
● Check the punch marks on the bolt
head before installing the main fasten-
IO
ing bolt. (If no more than 2 marks are
available, the bolt is usable. )
F F F F F F F
FD215-1007177
Loop bar
● Turn the socket seat of tool leftward
(for connection)
and activate the internal spring.
FD215-1007178
NOTICE
● Since the bolt is tightened in the plastic
area, no further tightening is required
after angle tightening.
FD215-1007180
NOTICE
● Do not start the engine within 1 hour φ 2mm
after the installation of rear oil seal.
4
*a 5
3
1
Disassembling sequence
PD FD215-1007183
NOTICE
● Do not remove the camshaft unless
confirmed abnormal.
Assembling sequence
Inspection standard
Unit: mm
Special tools
Symbol
PD
Tool name and shape Part No. Use
Unit: mm
Loop bar
Camshaft bushing as- Removing and
sembling and removing MH061276 installation of cam-
Guide
tools shaft bushing
IO
Connector
FD215-1007185
Jig
f30mm
IO
f17.5mm 50mm
200mm
FD215-1007186
Disassembling
Bushing
No.3 Bushing
No.1 Bushing
FD215-1007188
FD215-1007189
No.5 Bushing
Seal cover
FD215-1007190
[Install] PD
● Install the bushing in combination with the
corresponding connector and guide on the
loop bar.
Loop bar
Unit: mm
Guide
Correspond- Correspond- Connector
Bushing
ing connector ing guide
IO
O.D. A B C D
A C
Bushing
No.1 φ58.5 φ54.5 41.5 φ58.5 φ58.5
No.3 φ58 φ54.5 26.5 φ58 φ58 B
No.4 φ57.75 φ54.5 26.5 φ57.5 φ57.5
D
No.5 φ57 φ53 30.5 φ57 φ57 FD215-1007191
as illustrated.
Oil orifice
FD215-1007192
Loop bar
● Install bushing No.5 onto the crankcase
from the engine rear by striking as illus- No.5 Bushing
trated.
IO
Seal cover
FD215-1007193
lustrated
Bushing A C
D
FD215-1007194
Loop bar
Guide
● Install bushing No. 1 onto the crank- Jig No.4 Bushing
case from the engine front by striking
as illustrated
IO
Oil orifice
FD215-1007195
9.2.14.3 Assembling method
2.5mm
FD215-1007196
9.3.1 Specifications
Item Specification
Lubricating method Oil pump type
Engine oil filter type Paper core, spiral type
Engine oil cooler type Shell type (multi-plate type)
Type API rating CD, CD/SF, CE, CE/SF, CF-4
Engine oil Oil pan 18{18}
Volume dm³{L}
Engine oil filter 1{1}
Pressure regulating valve opening valve kPa{kgf/cm²} 440±29{4.5±0.3}
Bypass valve opening pressure kPa{kgf/cm²} 390±29{4.0±0.3}
Reducing valve opening pressure MPa{kgf/cm²} 1.1±0.1{11±1.0}
PD
IO
2 3
14 19 25
4
5 6 7
15 17
26 27
8
23
11
9 10
12
PD 16 18
20
21
24
A
22
13
IO
28
FD215-1007197
Oil pump
To oil cooler
Bolt Connector
Gasket
Gasket
Connector
PD
Oil filter element
Gasket
Seal
Oil cooler
FD215-1007199
IO
(a) Bypass valve
To oil cooler
● High oil viscosity due to low temperature or
clogged oil cooler may increase the resis-
Bypass valve
tance of oil flow. Under this circumstance,
the bypass valve on the oil cooler will open
so that engine oil flows directly back to the
oil filter without flowing into the oil cooler.
Oil filter
FD215-1007200
Oil filter
FD215-1007201
sure.
FD215-1007202
IO
(d) Engine oil bypass alarm switch
To oil pan
PD Bypass valve
Full flow filter element
FD215-1007204
Idle gear
Camshaft gear
Bearing Timing gear box
Vacuum pump Idle gear shaft Oil injection tube
FD215-1007206
PD
● Engine oil lubricates all the gears via the
inside of camshaft and idle gear shaft.
Beside, an oil spray tube for the forced lu-
brication of oil pump gear is installed in the
timing gear box. This oil spray tube lubri-
cates the injection pump gear continuously.
IO
Cylinder head
Oil circuit
PD Plunger
Camshaft
FD215-1007207
(e) Turbocharger
Bearing bushing
Snap ring
From main
oil duct
To oil
Piston ring
PD pan
Bearing
Piston ring
FD215-1007209
Oil pipe
Automatic advance
Injection pump
FD215-1007210
9.3.3 Troubleshooting
Symptom
Overheating
Defective installation of oil cooler filter element ○ ○ ○
Damaged gasket ○ ○ ○
Damaged o-ring ○ ○ ○
Oil cooler PD
Oil cooler filter element clogged
Oil cooler filter element damaged
Bypass valve sprig low elasticity
Pressure regulating spring low elasticity
○
○
○
○
○
○
○
Special tools
Unit: mm
NOTICE
IO
● Spilled engine oil may pose a fire haz-
ard. Wipe off spilled oil if observed.
[Remove]
Oil filter
Drain plug
FD215-1007212
PD FD215-1007213
[Install]
Tightening torque
Unit: N·m{kgf·m}
CAUTION
● Spilled engine oil may pose a fire haz-
ard. Wipe off spilled oil if observed.
PD
● When adding oil into the engine, make
sure no oil is spilled on the belt. Belt
contaminated with oil may slip and re-
duce the cooling effect.
IO
[Drain]
● Remove the drain plug and drain the oil. Oil filter
[Fill]
Drain plug
● Tighten the drain plug to the specified
Filler cap
torque. Add new engine oil to specified
level.
Drain plug
FD215-1007215
Inspection standard
Unit: mm
49kPa
At min. unloaded speed 145kPa{1.5kgf/cm²}
Oil pressure (at {0.5kgf/cm²}
– Inspect
70-90°C)
295~490kPa 195kPa
At max. unloaded peed
{3~5kgf/cm²} {2kgf/cm²}
Tightening torque
Unit: N·m{kgf·m}
Symbol
–
Tightened part
PD
Engine oil pressure switch
Tightening torque
7.8~12{0.8~1.2}
Remark
Sealant
When engine is cool
FD215-1007216
FD215-1007217
NOTICE
● Engine oil pressure switch must be in-
stalled while the engine is cool.
1 Ta
Tb
PD 5
3
4
IO
FD215-1007218
Disassembling sequence
Assembling sequence
NOTICE
● Over-tightening of the check valve may
cause engine failure. Tighten the check
valve to specified torque.
Tightening torque
Unit: N·m{kgf·m}
NOTICE
● Do not start the engine within one hour
after the oil pan is installed. Apply new
sealant when the mounting bolt of the
oil pan is loosened or removed again
after installation.
FD215-1007219
*b
4
PD *a
6
3
IO
1 7
FD215-1007220
Disassembling sequence
Assembling sequence
Inspection standard
Unit: mm
Driven gear
FD215-1007222
Gear housing
FD215-1007224
IO
● Insert bolts in the remaining mounting Oil pump gear
holes and tighten the bolts to specified
torque. Pin
4 1
a 5
Ta 13 6
7
14
a
15
12
10
a
9
Tb
PD
11
FD215-1007226
Disassembling sequence
IO
1) Hose 9) Bypass alarm switch
2) Connector 10) O-ring
3) Cap 11) Plug
4) Hose 12) Oil filter seat
5) Connector 13) O-ring
6) Plug 14) O-ring
7) Drain plug 15) Filter attachment
8) Oil filter : Non-reusable parts
Assembling sequence
CAUTION
● Spilled oil may pose a fire hazard. Wipe
off spilled oil once observed.
NOTICE
● Do not spill engine oil on the belt. Oil
can make the belt slippery and reduce
cooling effect.
Tightening torque
Symbol
Ta
Tb
PD
Tightened parts
Drain plug
Engine oil pressure switch
Tightening torque
7.8±2.0{0.8±0.2}
49±4.9{5.0±0.5}
Unit: N·m{kgf·m}
Remark
–
–
26
b
Tc 18
22 17 Tb
21
24
25 23
Tb 19 Ta
PD 20 13 Ta
15 14
4 16
2
12
3
Ta 1
6
10
Tb 5 11
9
8
IO
7 Ta
FD215-1007227
NOTICE
● Spilled oil may pose a fire hazard. Wipe
off spilled oil once observed.
Disassembling sequence
Assembling sequence
Unit: mm
IO
Location Check item Standard value Limit Remedy
Mounting load of bypass valve spring
3 49N {5kgf} – Replace
(Mounting length: 64)
Mounting load of pressure regulating
9, 15 49N {5kgf} – Replace
valve spring(Mounting length: 64)
Air leak in oil cooler filter
21 (at air pressure of 980kPa{10kgf/cm²} 0cm³{ 0mL} – Replace
and hold for 15 seconds)
Tightening torque
Unit: N·m{kgf·m}
Symbol Tightened parts Tightening torque Remark
Nut (for installation of engine oil cooler filter element)
Ta Plug (for installation of pressure regulating valve spring) 19.5±5{2.0±0.5} –
Plug (for installation of bypass valve spring)
Tb Plug 34.5±5{3.5±0.5} –
Tc Engine oil pressure switch 7.8-12{0.8-1.2} Sealant
5 Ta
17
6
Tb
3 13 7
4
11 12
10 Ta
Te 1
PD 9
Ta 14
Tc
16 15
Td
FD215-1007229
IO
Disassembling sequence
Assembling sequence
CAUTION
● Spilled oil may pose a fire hazard. Wipe
off spilled oil once observed.
Inspection standard
Unit: mm
Tightening torque
Unit: N·m{kgf·m}
Special tools
Unit: mm
Gasket
● Tighten the oil filter by hand until the gas-
ket contacts the oil cooler. Further tighten
the filter by 3/4 round. FD215-1007233
ity.
PD
● Re-install the oil filter in case of abnormal-
9.4.1 Specifications
Item Specification
Producer Bosch
Type A
Type RSV
Injection pump Governor
Form Mechanical variable speed governor
Advance unit type SCDM
Feed pump type KS
Producer Bosch
Fuel injector
Type Hole-type spring
Fuel filter TypePD Filter paper
IO
Fuel injector
Injection pump
Relief valve
Fuel tank
FD215-1007234
IO
● Fuel in the tank is primed by the fuel feed ● Residual fuel in the injector enters the re-
pump which is driven by the shaft of the turn hose and returns to the tank via the
injection pump. Impurities in the fuel is fil- fuel return pipe.
tered by the fuel filter.
● If fuel in the injection pump is over-pressur-
● Filtered fuel becomes pressurized when it ized, the relief valve opens and fuel returns
passes the injection pump and is sprayed to the tank.
into the combustion chamber by the fuel
injector.
5
11
10
13
12
PD
7
6
9
IO
8
20
16
转台
2
19
17
18 3 15
4 14
FD215-1007235
CAUTION
● Keep the fuel tank away from fire
sources to avoid fire and explosion.
8
9 7
10
Primary filter
To Engine
12
FuelTank Secondary filter To Engine
12 10
PD 6
11 2
5 1
3 31
13
34
27 5
27 26
4
26
25 5
15
33 2
20
32 28
21
18 16
IO
5 23
19 17
3 24 14 30
29
22
6
5 22
1
4
FD215-1007236
NOTICE
● Check the hoses for damages and cor-
rosion after disassembling. Make nec-
essary replacements. PD
● Pay attention to leak-proofness when
re-installing the assembly to prevent oil
leakage.
IO
From tank
Fuel filter
PD FD215-1007237
Delivery valve
Piston bushing
Control pinion
Control rod
Control socket
Piston spring
PD Piston rod
Camshaft
FD215-1007238
1. Fuel feeding
When the piston rises, the spiral chute Fuel suction hole
meets the fuel at the fuel suction hole and Spiral chute
Piston sleeve
fuel flows out via the inlet/outlet hole at the
Piston
center of the piston. Surplus fuel cannot
be conducted via the rising of the piston.
Tappet
Besides, the piston stroke which is used to
feed fuel is called the effective stroke. Camshaft
Pressure Pressure
Suction feed ends
feed starts
FD215-1007239
Piston FD215-1007240
IO
2. Injection adjusting structure
3. Delivery valve
Spring
finishes. The delivery valve returns to its
original position through the action of the
delivery valve spring. Fuel path is cut off
Delivery
in this way to prevent fuel counterflow.
valve
Besides, during this downward suction
stroke, the delivery valve sucks fuel and Pressure feed Injection Pressure feed Suction
starts ends ends
the residual fuel pressure between the (Suction starts)
delivery valve and fuel injector drops FD215-1007242
4. Relief valve
PD
When fuel pressure in the injection pump
rises to a certain level, the steel ball is
pushed upward, and fuel flows back to the
Steel ball
9.4.2.6 Governor
Tension rod
Starting spring
Control rod
Shackle
Rotating rod
Cover
Camshaft
Floating rod
Governor spring
Control spring
Regulating lever
Position lever
Fly block
Retaining bolt
FD215-1007244
IO
● Using the centrifugal force of the fly block,
the governor not only controls the maxi-
mum and minimum rotation speed of the
full speed regulator, but automatically
controls the rotation of the random speed
area.
Priming pump
To fuel filter
Pump housing
PD Mesh filter
FD215-1007245
Suction
FD215-1007246
Pressure feed
Fuel suction chamber Inlet check valve
When the camshaft cannot push the cam up
after rotation, the force of the piston spring
can be applied to push the piston back. Fuel is Piston spring
conducted to the filter via the pressure cham-
PD Outlet check valve Piston
ber. Camshaft
Pressure chamber
At the same time, outlet check valve shuts and
inlet check valve opens. Fuel is sucked into
FD215-1007247
the suction chamber.
When stopped
FD215-1007248
Housing
PD Fly block seat
Fly block
IO
Flange
FD215-1007249
Spring
PD Injection nozzle
Needle valve
FD215-1007250
IO
9.4.3 Troubleshooting
Engine - knock
Cause
Fuel
Needle valve - fixation
Opening pressure - low
Fuel orifice - clogged
Air-proofness - defect
PD ○
○
○
○
○
○
○
○
○
○
○
○
○
Opening pressure - high ○
injector
Spring - broken ○ ○
Needle valve slide - defect ○
Opening pressure - defect ○
IO
Spring elasticity- low ○
Fuel filter - clogged ○ ○ ○ ○
Fuel tank - no fuel ○
Fuel hose - clogged or joint leaks ○
Fuel system -air/water inside ○ ○ ○ ○
Fuel quality - low ○ ○ ○ ○
Accelerator pedal check bolt
○ ○
adjustment defect
Accelerator control bracing
○
Engine cable installation defect
control Accelerator control bracing
○
cable sliding defect
Accelerator position sensor
○
defect
Fuel pipe/hose - crack ○
Lubricating
Oil viscosity -unqualified ○ ○
system
Engine - knock
Cause
Inspection standard
T Tightening torque
Unit: N·m{kgf·m}
Special tools
Unit: mm
[Inspect]
Injection pipe
NOTICE
● Put removed parts in light oil to prevent
dust buildup on the parts.
PD FD215-1007252
FD215-1007253
NOTICE
● The engine position lever on the gov-
Engine position lever
ernor must be set at the engine start Priming pump
position. FD215-1007254
FD215-1007255
[Adjust]
PD
● Loosen the mounting bolts of the injection
pump A
B
B: 1 location
IO
● Take the pointer as the target and activate
the pump to adjust injection timing. Injection pump
Pointer FD215-1007257
FD215-1007258
FD215-1007259
IO
T Tightening torque
Unit: N·m{kgf·m}
CAUTION
● Use of improper fuel filter may cause
fuel leakage and fire. Use genuine
parts.
<Revolving type>
4 Tb
Ta
1
2
PD 2
3
1 Ta
FD215-1007264
IO
Disassembling sequence
Assembling sequence
T Tightening torque
Unit: N·m{kgf·m}
Special tools
Symbol
Filter wrench
PD
Tool name and shape
A
Part No. Use
Unit: mm
FD215-1007266
CAUTION
Contact surface
● Use of improper fuel filter may cause of fuel filter cover
fuel leakage and fire. Use genuine parts
4
PD
2
3
1
FD215-1007268
Disassembling sequence
IO
1) Drain valve 5) Filter element
2) Vent plug 6) Seal
3) Bowl assembly 7) Filter base
4) Seal
Assembling sequence
CAUTION
● Spilled fuel may cause a fire. Wipe off
spilled fuel once observed.
Tightening torque
Unit: N·m{kgf·m}
PD
IO
10
8
9
PD 5
1
FD215-1007269
IO
Disassembling sequence
Assembling sequence
CAUTION
● Spilled fuel may cause a fire. Wipe off
spilled fuel once observed.
Tightening torque
Unit: N·m{kgf·m}
Te
7
16
Td 8
14
10 9 Ta
11
15
13
12 Ta
17 1 Ta
PD 4
6 Tc
5
*a
3 Tb
IO
FD215-1007270
Disassembling sequence
Assembling sequence
CAUTION
● Fuel is extremely flammable. Keep fuel
away from naked fire and heat sources.
NOTICE
● Particulate matters entering the injec-
tion pump may decrease the perfor-
mance of the engine. Always cover the
mounting portions once pipes or hoses
are removed. Clean bolts, gasket and
other parts with light oil. Be very care-
ful not to let foreign matters entering
PD
the assembly.
Inspection standard
Unit: mm
T Tightening torque
Unit: N·m{kgf·m}
Unit: mm
Socket wrench
Removal and installation
A A 31391-14100
of injection pump
12
shaft by 360°.
Notch
Match mark
FD215-1007274
Position pin
FD215-1007276
fixing.
FD215-1007277
12
1 Ta
11
13
10
14 Ta
9
5
3 6
7
8
Disassembling sequence
PD 4 Tb
FD215-1007278
Assembling sequence
CAUTION
● Fuel is extremely flammable. Keep fuel
away from naked fire and heat sources.
NOTICE
● The injector shall be disassembled,
assembled and adjusted when carbon
buildup on it has been removed. Check
the spray pressure, spray condition
and check for fuel leakage before dis-
assembling. Do not disassemble the
injector in case of abnormality.
Inspection standard
PD Unit: mm
T Tightening torque
Unit: N·m{kgf·m}
IO
Symbol Tightened parts Tightening torque Remark
Injection pipe connecting nut
Ta 25{2.5} –
Bolt (for installation of spray nozzle cap)
Tb Holding nut 34±5{3.5±0.5} –
Special tools
Unit: mm
NOTICE
● Operate the lever of the tester before
inspection. Spray 2~3 times and re-
move the air tap.
CAUTION
IO
● Do not contact the spray the injector.
2. Inspection of spray
CAUTION
● Never contact the spray from the injec-
tor.
NOTICE
● Do not touch the sliding part of the nee-
dle valve. In case of it being touched,
wash it with cleaning fluid (e.g. light
oil).
Clean: Injector PD
● After washing the needle valve and spray
nozzle with cleaning fluid (light oil), remove
the carbon buildup on them with tool as
Cleaning bar
FD215-1007284
FD215-1007285
Inspect: Injector
NOTICE
● When replacing the spray nozzle, use a
full set of spare parts including spray
nozzle, cylindrical pin, needle valve and
seals.
Adjust: Injector
NOTICE
● Never touch the sliding part of the nee-
dle valve.
CAUTION
PD
● Never contact the spray out of the in-
jector.
FD215-1007287
9.5.1 Specifications
Item Specification
Cooling method Forced water circulation cooling type
Pump type Belt driven, spiral type
Thermostat type Paraffin core, bottom bypass type(with jump valve)
Cooler capacity (Engine body) dm³{L} 9.5 {9.5}
Radiator
PD
Cylinder head
Water pump
FD215-1007289
9.5.2.2 Thermostat
To radiator
Cover
Thermostat
Casing
PD From cylinder head
To water pump
FD215-1007290
Casing
Bearing
Flange
Group seal
Pump shaft
Snap ring
PD
Spacer ring
Drain hole
Vane wheel
FD215-1007291
9.5.3 Troubleshooting
Inadequate engine
adequate cooling)
Over heating (in-
Abnormal noise
Symptom
output power
consumption
Over-cooling
Fast coolant
Reference
Cause
Loose or rupture ○ ○
Belt Over-tight ○
Oil/grease on belt ○
Defective installation ○ ○
Defective gasket ○ ○
Defective bearing ○ ○
Water pump Defective impeller
Defective group seals
PD
Loose contact between pump shaft
and flange or impeller
Housing installation defect
○
○
○
○
○
○
Defective gasket ○ ○
Opening temperature too high, valve
○
Thermostat always closes.
IO
Opening temperature too low, valve
○
always opens
Coolant temp sensor water leakage ○ ○
Core clogged ○
Radiator
Core broken or weld comes loose ○ ○
Defective installation of engine oil
○ ○ Lubricating
Oil cooler cooler
system
Defective gasket ○ ○
Defective installation of cylinder head ○ ○
Cylinder head Engine
Defective gasket ○ ○
Defective pressure cap ○
Coolant insufficient or contaminated ○
Coolant circuit contaminated or clogged. ○
Defective installation of hoses ○ ○
Low ambient temperature ○
Inter-cooler Foreign matters built up on the core ○
NOTICE
● Keep the belt free of grease or oil.
Grease or oil may cause the belt to slip
and reduce the cooling effect.
Inspection standard
Unit: mm
Special tools
Measurement of belt
Belt tensiometer MH062345
tension
IO
[Inspect]
O-ring (large)
PD
FD215-1007294
FD215-1007295
[Adjust]
Adjusting bolt
Nut FD215-1007296
Belt
FD215-1007297
IO
Wrinkle
T Tightening torque
Unit: N·m{kgf·m}
Drain coolant
PD
● Loosen the pressure cap to relieve the
pressure in the cooling system before
draining the coolant. Also drain the coolant
in the reservoir.
CAUTION
● Drain the coolant after it has complete-
ly cooled down to avoid burns.
IO
Crankcase drain valve
Pressure cap
● Loosening the pressure cap while the
coolant is still hot may cause the cool-
ant to spurt out. When loosening the
pressure cap, put a rag on it and turn
slowly to relieve the internal pressure.
FD215-1007298
Cleaning procedure
NOTICE
● Do not use hard water for the cleaning.
Use soft water with the following nature
to prevent scaling and rusting.
NOTICE
•When cleaning liquid is added, if the engine
keeps running for more than 1 hour, cooling
system may be damaged.
Observe the cleaning procedure.
Drain coolant
PD
Add tap water (hot) into the reservoir
NOTICE
•When the cooling system has been cleaned,
add coolant as soon as possible.
•To prevent freezing of coolant and corrosion
in the cooling system,add long-acting coolant
properly. (refer to the instruction manual)
CAUTION
● Diesel engine long-acting coolant is
flammable. Keep it away from heat
sources and naked fire.
CAUTION
● In case long-acting coolant contacts
your eyes, flush with plenty of water
and seek medical attention immediate-
ly.
CAUTION
IO
● Make sure the coolant has cooled down
before loosening the pressure cap. Hot
coolant may spurt out.
10
11
7
6
5
3
PD 9 4
IO
FD215-1007300
Disassembling sequence
Assembling sequence
Inspection standard
Cap
● Replace the engine oil cooler if air leak is
observed.
FD215-1007302
● Install hoses, radiator cap tester, and plugs Radiator cap tester
onto the reservoir of the radiator.
Plug Hose
● Opening pressure PD
● Replace the pressure cap if measured
value exceeds the standard value.
Pressure cap
FD215-1007304
IO
*a
5
2
1
PD 4
FD215-1007305
IO
Disassembling sequence
Assembling sequence
NOTICE
● Always replace the belt in pairs to
avoid belt tension difference.
8
7
6
5
4 Tb
1
10
11
3 9
2 12
PD FD215-1007306
Disassembling sequence
Assembling sequence
12→8→7→6→5→4→11→3→9→10
Inspection standard
Unit: mm
T Tightening torque
Unit: N·m{kgf·m}
Symbol
Grease fitting
Applicable location
PD 12.3±2.4{1.3±0.25}
Type
–
Quantity
Bearing stuffing MoS2 grease As required
Grease fitting [NLGI No.2(hectorite)] 60g
b Group seal perimeter ThreeBond 1102 As required
IO
Special tools
Unit: mm
Socket wrench
Removal of impeller
A B MH061417
clamp
φ48 φ10 A
Remove: Impeller
FD215-1007307
Remove: Flange
Gear clamp
PD
FD215-1007308
NOTICE
● Even if the measurement meets the Water pump shaft
standard value, do no install more than
FD215-1007309
twice.
NOTICE Flange
Above Φ20mm Clamp
● Even if the measurement meets the
standard value, do not install more Φ40mm
FD215-1007310
than twice.
Install: Flange
NOTICE PD
● Before installing the flange, check the
punch marks on the flange, as illus-
trated. One mark shows the flange is
usable. Punch a mark to record the cur-
rent disassembling and installation.
NOTICE
● The pump housing may be damaged if
no jigs are used during installation. Punch mark
FD215-1007312
Install: Impeller
NOTICE
● Before installing the impeller, check
the punch marks on the impeller as il-
lustrated. One mark shows the wheel
is still usable. Punch a new mark to
record the current disassembling and
installation.
Punch mark
● The punch marks on the wheel record
FD215-1007313
the past disassembling and installation.
If two marks are available, (showing
two disassembling and installations),
the impeller must be replaced.
PD
● Use the flange side surface of the pump
shaft as the load bearing surface.
FD215-1007315
9.5.8 Thermostat
密封胶
Ta 4
10
7
PD 11
8
5 Ta
6 Ta
FD215-1007316
Disassembling sequence
1) Thermostat cover 8) Gasket
IO
2) Gasket 9) O-ring
3) Thermostat 10) Bypass pipe
4) Coolant temperature sensor 11) O-ring
5) Coolant temperature sensor P : Position pin
6) Screw plug : Non-reusable parts
7) Thermostat housing
Assembling sequence
NOTICE
● Keep the o-ring free of engine oil. Oil
on the o-ring may cause it to expand
and result in water leak.
Inspection standard
Unit: mm
T Tightening torque
Unit: N·m{kgf·m}
Symbol
b
PD
Applicable location
O-ring
Coolant temperature sensor
Type
Soap water
Loctite 575
Quantity
As required
As required
Screw plug
IO
2. Valve lift
IO
● Keep water temperature a bit higher than
the valve opening temperature. Hold on for
5 minutes when the valve has been com-
pletely open and measure the valve lift.
9.6.1 Specifications
Item Specification
Air filter element type Paper filter element
Dust indicator type Electrical
Type TE06
Turbocharger
Producer MITSUBISHI
FD215-1007318
● When engine speed is below the specified speed, the vacuum pump vibrates due to load
change and drain the internal water and dust automatically.
9.6.2.2 Turbocharger
Bearing bushing
Liner Thrust bearing Thrust ring Piston ring
Rear plate
FD215-1007319
9.6.3 Troubleshooting
Cause
Turbo-
and housing
Shaft deflection
○
○
○
○
○
○
○
○
○ ○ ○
charger bly wheel and housing
Air compressor wheel damaged ○ ○ ○
Part sliding failure due to clogged
○ ○ ○
greasing pipe and connecting bolt
IO
Oil seal damaged due to clogged oil
○ ○
return hose
Defective installation of air compressor casing ○ ○ ○ ○
Defective installation turbine housing ○ ○
Deformation of exhaust pipe and muffler ○ ○
Defective installation of exhaust pipe and muffler ○ ○
Wrong valve clearance ○
Damaged cylinder head gasket ○
Abrasion and carbon buildup on valve and valve seat ○
Engine
Decreased valve spring elasticity ○
Abrasion or damage of piston ring ○ ○
Abrasion or damage of piston ring groove ○ ○
Function defection of cooling assembly ○ Cooling system
Excessive engine oil ○ Lubricating system
Main mobile parts seized ○ ○ Engine
Nonuniform or excessive spray ○ Fuel system
1 7
6
2
Disassembling sequence
1) Dust indicator
PD 6) Inner filter element
3
FD215-1007320
2) Connector 7) O-ring
3) Vacuum valve 8) Body
4) Cover : Non-reusable parts
5) Outer filter element
IO
NOTICE
● Do not disassemble the inner filter ele-
ment unless it needs to be replaced.
Assembling sequence
Inspection standard
Unit: mm
NOTICE
● Read the instruction manual when air- FD215-1007321
blowing the filter element. Frequent
cleaning may cause damage to the
filter element and cause dusts and for-
eign objects to enter the engine.
PD
● Do not remove dusts by tapping the fil-
ter element or striking it against other
objects.
9.6.5 Turbocharger
Ta
Tb
11 5
3
1
*a
13
PD 6
7
9
Tc
14
Ta
15
12 8
IO
Tb
10
FD215-1007324
Disassembling sequence
1) Air hose 10) O-ring
2) Intake pipe 11) Connecting bolt
3) Air hose 12) Connecting bolt
4) Turbocharger cover 13) Oil duct pipe
5) Spacer ring 14) Turbocharger
6) Exhaust pipe 15) Gasket
7) Gasket *a: Air suction pipe
8) Oil return pipe : Non-reusable parts
9) Gasket
Assembling sequence
T Tightening torque
Unit: N·m{kgf·m}
Install: Turbocharger
PD
● Before installing the turbocharger, apply
Orifice Turbocharger
Turbocharger
Ta
1
Disassembling sequence
PD 5
FD215-1007326
Assembling sequence
NOTICE
● The turbocharger can not be disassem-
bled. Replace it when the turbine wheel
and the air compressor wheel is dam-
aged, or when rotation is not smooth.
Inspection standard
Unit: mm
Turbocharger Clearance in the Turbine wheel side 0.40 – 0.53 0.58 Replace
6 direction per-
assembly
pendicular to the Air compressor
0.55 – 0.66 0.72 Replace
rotation axis wheel side
T Tightening torque
Unit: N·m{kgf·m}
Match mark
Match mark
● Imprint match marks on shaft coupling, tur-
bine housing, air compressor casing and Air compressor casing
turbocharger assembly. Turbocharger
assembly
Turbine housing
Shaft coupling FD215-1007327
NOTICE
● The blades of the turbocharger assem-
bly bend easily. Be careful not to strike FD215-1007328
the turbine housing.
PD
● Strike the outside of the air compressor
casing with a rubber hammer. Be careful
not to damage it.
NOTICE
● The blades of the turbocharger assem-
bly bend easily. Be careful not to strike
FD215-1007329
the air compressor casing.
IO
9.6.5.4 Post-disassembling work
Clean
NOTICE
● Do not immerse the turbocharger as-
sembly into the fluid. Otherwise, o-rings
in the assembly will expand and cause
damage to the turbocharger.
FD215-1007332
FD215-1007333
Snap ring
CAUTION
● Press the snap ring with you hand in
case it ejects. Air compressor casing FD215-1007334
FD215-1007335
IO
Ta
4 2
PD Ta
FD215-1007336
IO
Disassembling sequence
Assembling sequence
T Tightening torque
Unit: N·m{kgf·m}
Ta
PD
Folded portion
FD215-1007337
Disassembling sequence
IO
1) Exhaust manifold : Non-reusable parts
2) Gasket
Assembling sequence
T Tightening torque
Unit: N·m{kgf·m}
5
6
1
4
3
*a
2
PD 7
FD215-1007338
IO
Disassembling sequence
1) Insulator 6) Muffler
2) Exhaust pipe 7) Muffler bracket
3) Gasket *a: Turbocharger
4) Clamp : Non-reusable parts
5) Muffler clamp
Assembling sequence
9.7.1 Specifications
Alternator
Item Specification
Producer MITSUBISHI
Type Built-in regulator type alternator
Model A4TU7686
Output V-A 24-50
Start motor
Producer
Model
Output
PD
Item
V-kW
Specification
MITSUBISHI
M008T87171
24 – 5.0
Reduction gear mechanism Planetary gear
Solenoid switch operating voltage V 16 or below
Model U001T37072
Exciting current V-A 24 – 2.3
IO
Starter relay Connecting voltage V 16 or below
Disconnecting voltage V 4 or below
Admissible interrupting current A 200
Model Sheath type
Heating plug
Rated voltage/current V-A 11-130
Model U001T31383
Exciting current V-A 24-2.3
Heating plug Connecting voltage V 16 or below
relay Disconnecting voltage V 4 or below
Admissible interrupting current A 200
Temperature fuse capacity A 127
Solenoid switch
Steel ball Lever
Terminal S Starter relay Brush spring
Terminal B Front bracket
Brush
Rear bracket
Pinion stopper
Rear bearing
Terminal SW
PD Armature
Yoke
Cap
E-ring
Gasket
Pinion
Front bearing
Overdrive clutch
Rubber seal
Gear shaft
Terminal L Planetary gear
Internal gear
FD215-1007339
IO
● This starter uses planetary gears as the re-
duction gear mechanism.
Planetary gear
FD215-1007340
9.7.2.2 Alternator
Terminal E
Terminal P
Terminal B
Neutral diode
PD
Terminal R Terminal L
Rectifier
Rotor
Stator
Fan
Belt roller
Rear bearing
IO
Front bearing
Regulator
Rear bracket Field coil Front bracket
FD215-1007341
Terminal P
Terminal B
Neutral diode
Neutral point
Stator coil
Terminal L
Terminal R
Field coil
Terminal E
Neutral diode
PD IC Regulator
FD215-1007342
1. Features
● This alternator is the same as general alternators except that neutral diodes are installed.
IO
● These neutral diodes helps to generate more DC output when the alternator is rotating at a
high speed than a alternator without neutral diodes.
28 Output voltage
0 Ground potential
Voltage
Rotating angle
FD215-1007343
● The potential at the neutral point changes with the DC voltage (half of output voltage) at the
neutral point.
● When the alternator is rotating at high speed, voltage at the neutral point can rise above out-
put voltage (28V) and drops to below grounding voltage (0V). To regulate the over-voltage
and under-voltage (dashed area), over-voltage is taken out by the neutral diode and added
into the DC output.
● When the voltage at the neutral point is between 0~28 V, 6 of the diodes are working. The
neutral diodes do not work.
PD
Positive diode (+)
Terminal P
Terminal B
Terminal L
Terminal R
Field coil
Terminal E
IO
IC Regulator
FD215-1007344
● The positive diode (+) increases the extra DC output to all electrical equipment.
Terminal P
Terminal B
Terminal L
Terminal R
Field coil
Terminal E
PD
Negative diode(-)
IC Regulator
FD215-1007345
IO
● The negative diode (-) supplies output from the neutral point via the rest 3 diodes.
Starter
Oil press s/w
M Alternator
M
B E B P
L R Oil bypass alarm s/w
S
S
B
Starter relay
L
SW
PD Indicator
Indicator
+
-
Battery
+
-
Heating plug
FD215-1007346
9.7.4 Troubleshooting
charge excessive
charge excessive
Cause
Battery overheat
○
○
○
○
○
○
Cooling system
Belt damaged ○ ○
Battery fault ○ ○
Disconnection in stator coil ○
Stator coil and core short circuit ○
IO
Disconnection in field coil ○
Alternator
Rectifier fault ○
Regulator fault ○ ○ ○
Wiring error ○
Gauge combination fault ○
Starter works
but engine does
not start
9.7.5 Switches
FD215-1007347
● Replace the switch if measured value ex-
ceeds the standard value.
PD
9.7.5.2 Inspection of engine oil pressure switch
Standard value
50±10kPa{0.5±0.1kgf/cm²}
(work pressure)
Starter
Terminal B
PD Terminal S
Starter relay
IO
FD215-1007351
CAUTION
● Before removing the start motor, dis-
connect the cable with the negative
terminal of the battery and insulate the
cable and the negative terminal.
b 24
b 25
26 21
22
28
23
27 18
d 19
20 7
b
8
29
30 5
31 10
6
11
1
2
3
4
PD 17
b
15
14
9
12
b 16 13
5
Terminal S
IO
28
27
28 d
FD215-1007352
Disassembling sequence
Assembling sequence
Inspection standard
Unit: mm
Match mark
Yoke
9.7.7.2 Disassembling method FD215-1007353
Pinion
Cable
FD215-1007355
FD215-1007356
FD215-1007360
-A
IO
Front bearing
FD215-1007362
9.7.7.3 Inspecting method
Terminal M
● Check if terminal S and terminal M are in-
terconnected.
FD215-1007363
Terminal M
FD215-1007364
FD215-1007365
Terminal M
FD215-1007366
Brush FD215-1007367
1. Brush length
Inspect: Yoke
Brush (+)
2. Earth test
● Check if the yoke and the (+) brush are Brush (+)
disconnected.
NOTICE
PD
earthed. Inspect the insulation. Replace
the yoke and the (+) brush if the insula-
FD215-1007371
● Metal particle buildup due to brush or
armature abrasion may interconnect
the coil with the yoke and become
earthed.
IO
Inspect: Brush (+)
1. Brush length
Inspect: Armature
2. Earth test
case.
PD
ture (or shaft) are disconnected.
FD215-1007374
FD215-1007375
FD215-1007377
IO
● Modify or replace the armature accord-
ing to the abrasion condition of the de-
pression section.
○: OK
×: N/G
FD215-1007378
-B
FD215-1007380
IO
● Use the claw on tool -A to rivet the
front bearing after pressing. Dynamic load 3 ton
-A
NOTICE
● Do not rivet the bearing on the old rivet
Claw Claw
seam.
Front bearing
FD215-1007381
FD215-1007383
Install: Pinion
Overdrive clutch
● Do not energize the starter when installing
Pinion
the pinion.
IO
Pinion stopper
FD215-1007384
● Pull the pinion and fix the stopper onto the Stopper
groove of the pinion check ring. Check ring Pinion
Groove
FD215-1007385
1. Performance test
Terminal
● Connect the starter as illustrated. Terminal Pinion
CAUTION
● Do not apply a voltage more than 24 V.
CAUTION
PD
position and energize the starter, and
the pinion will pop out and rotate.
DC power
FD215-1007387
2. Pinion clearance
Terminal S
Pinion
CAUTION FD215-1007390
9.7.8 Alternator
View A
Terminal E 2
4
Terminal P
Terminal B A
5
Terminal L
4 Terminal R
PD 1
3
FD215-1007392
Disassembling sequence
CAUTION
● When the starter is energized, the pin-
ion will pop out and start rotating. Be
careful not to touch it.
Assembling sequence
Inspection standard
Inspect: Alternator
PD
● The inspection includes: simple inspec-
tion when the alternator is loaded; and
thorough inspection when the alternator is
removed and set on the testing table.
a. Simple inspection A
Terminal Terminal B
FD215-1007393
CAUTION
● To avoid personal injury, disconnect
the negative terminal of the battery
and insulate it before wiring operation.
When the negative terminal (-) is con-
nected, the battery voltage is always
applied on terminal B.
Rated output
E: Terminal E
Load resistance
L: Terminal L (Variable resistance)
B
R: Terminal R
L
Drive motor
● Increase the load resistance to maxi-
mum (nearly no load current)PD R Alternator
FD215-1007394
● Turn switch A and B to the ON position.
Rated current
IO
Current
About 45A
2. Regulating voltage
a. Simple inspection
Ammeter DC power Voltmeter
3
4
5
6
7
2
1
Ta
PD 8
11
10
12
9
FD215-1007397
Disassembling sequence
IO
1) Belt roller and fan 7) Front bracket
2) Spacer ring 8) Field coil
3) Rear bearing 9) Stator
4) Rotor 10) Regulator
5) Cover 11) Commutator
6) Front bearing 12) Rear bracket
Assembling sequence
Inspection standard
T Tightening torque
Unit: N·m{kgf·m}
Rear bracket
Disassemble: Rotor and front bracket PD Front bracket
Stator
● Remove the mounting bolt of the front and
rear brackets. Flat head screw driver
NOTICE
● Be careful not to insert the screw driver
too deep to avoid damage to the stator
coil and a possible short circuit. Coil FD215-1007398
● Fix the rotor onto the vice, remove the nut Belt roller Claw
and dismantle the belt roller.
NOTICE Vice
Rotor
● When the rotor is hold in the vice, hold
the supporting part of the claw. Dam-
age may result if the claw is hold. Support Support
FD215-1007399
NOTICE PD
● If screw B is removed first, the weight
of the field coil may be applied onto the
connecting part with the regulator. The
regulator is fixed with screw A, so the Screw A
connecting part may get damaged. To
avoid this, remove screw A first.
Field coil
IO
● Remove screw B (3).
FD215-1007400
NOTICE
● When screw B is removed, the field coil
may fall under its own weight. Hold the
coil with your hand.
NOTICE
● Do not remove the field coil with force.
Otherwise, the connecting part with the
regulator may get hooked by the stator
coil.
Remove: Stator
Cable
NOTICE
● Melt the weld within 5 seconds; other-
Diode
wise, the diode may get damaged. Commutator Stator
FD215-1007401
Inspect: Stator
IO
● Conduct the following inspection. Replace
the stator in case of any abnormality.
FD215-1007404
Inspect: Commutator
PD A
● If the resistance is infinite under two condi- B
tions, the diode is open. C F
D
● If the resistance is near 0W under two con-
ditions, the diode is short-circuited.
G
E, G: Radiating area
IO
F: Connecting area of the regulator
Install: Stator
FD215-1007406
● Replace the heating plug in case of any
abnormality.
Terminal P
Terminal R
Terminal E Terminal L
Terminal S
FD215-1007407
Inspection standard
Replace alternator or
When engine stops Below 1V –
wiring
Output voltage
When engine is running
at terminal P
(Idling speed above 12 – 16V – Inspect or replace wiring
600rpm)
Output voltage
When engine is running Approx. 24V – Inspect or replace wiring
at terminal R
Output voltage
at terminal L
PD
When engine is running
Below 5V
(but not 0V)
–
parts at 0 V
Replace
Inspect or replace al-
ternator or wiring when
the voltage reaches the
battery voltage
IO
Alternator
E B P
L R
To heating plug relay
To starter relay
terminal L Start switch
Voltmeter OFF
S E L R P (+) R1
AC
(-) START
Safety relay B R1ACBR C
Ground
+
-
Battery
+
-
FD215-1007408
3. Inspection of terminal P output voltage ● Start the engine and measure the voltage
when it is running at idle speed (above 600
● Measure the voltage between terminal P of rpm). If the measurement is 0 V, because
safety relay and earth. If measured value the wiring to terminal P is short-circuited,
exceeds the standard value, inspect the the wiring and the connecting part of the
IO
alternator or the wiring. Replace defective connector shall be checked. Replace de-
parts in case of abnormality. fective parts in case of abnormality.
Alternator
E B P
L R
To heating plug relay
To starter relay
terminal L Start switch
Voltmeter OFF
S E L R P (+) R1
AC
(-) START
Safety relay B R1ACBR C
Ground
+
-
Battery
+
-
FD215-1007409
4. Inspection of terminal R output voltage sured value deviates from the standard
value, inspect the wiring. Replace defec-
● Measure the voltage when the start switch tive parts in case of abnormality.
is moved to the ON position. When mea-
IO
Alternator
E B P
L R
To heating plug relay
To starter relay
terminal L Start switch
Voltmeter OFF
S E L R P (+) R1
AC
(-) START
Safety relay B R1ACBR C
Ground
+
-
Battery
+ PD
-
FD215-1007410
5. Inspection of terminal S output voltage ● Start the engine, and run it at low idle
(above 600 rpm)
● Turn the start switch to the START position
IO
and measure the voltage between terminal ● Measure the voltage at terminal P. Replace
S and the earth when the engine is run- the alternator if measured value exceeds
ning. the standard value.
● Inspect all parts if measured value ex- ● Check that the indicator does not light up
ceeds the standard value. Replace defec- when the engine is idling. Replace the
tive parts in case of abnormality. safety relay when the voltage at terminal P
is normal but the indicator is on.
Alternator
E B P
L R
To heating plug relay
To starter relay
terminal L Engine start switch
OFF
Voltmeter
(+) S E L R P (+) R1
Voltmeter AC
(-) (-) START
Safety relay B R1ACBR C
Earth Earth
Indicator
+
-
+ PD
-
FD215-1007411
6. Inspection of terminal L output voltage ● If the measured value is close to the bat-
tery voltage, inspect the alternator or the
● Measure the voltage when the start switch wiring. Replace the defective parts in case
is moved to the ON position. Replace the of abnormality.
IO
safety relay when measured value exceeds
the standard value.
E
G
PPDA
A IONK
BL
E
PPDAG
IOK
AN
BL
System Schematics
10 System Schematics
10.1 Hydraulic System Diagram .................................................................................. 10-3
10.2 Air-Conditioning Electrical Circuit Diagram .......................................................... 10-4
PD
10.3 Fuse Box Relay ................................................................................................... 10-5
10.4 Control Switches and Monitor Electrical Diagram ............................................... 10-6
10.5 Operator Cab Electrical Circuit Diagram.............................................................. 10-7
10.6 Chassis Electrical Circuit Diagram....................................................................... 10-8
IO
PD
IO
WARNING
Read and understand all safety precau-
tions and instructions in this manual be-
fore reading any other manuals provided
with this machine and before operating or
servicing the machine. Also read the safety
information on machine decals before per-
forming any operations. Failure to do so
can cause machine damage, personal in-
jury or death.
A8
A1
XBp2
P1 T SH R2
BKT DUMP TO MAIN VALVE XBk
PaL
BYPASS CUT
(XBp1)
HVa
CCO
PG (ROD) Aa
接(ROD) Aa
TO MAIN VALVE XAb1 CCk
ARM2 XAa2
XBa2
XBa1
XAa1 ARM1
BUCKET
LCa
XAb2
XBk
PCK
(XAo) OPTION
(XBo)
BOOM L TRAVEL LCK
LCo
PbL
P1 HVb
(HEAD)
Ab CCb
PD
AbR BbR
T P P2
(ROD)
Bb
A B XAb1
TO MAIN VALVE XAs BOOM1 PsP PRIORITY
L SWING XBb1 A4
ARM
Dr1 C2
LCb
Pns
SWING
接As
P1 TO MAIN VALVE XAa1 接Bs Atl
Bs
As
ARM OUT TO MAIN VALVE XAa2
P3 Btl
XAs
SWING
TO MAIN VALVE PaL XBs
LEFT
4-φ2.0
XAtl
LCs
SWING TRAVEL XBtl
Py
Dr6
Dr2
P4 CP1
BTR
TO MAIN VALVE XBs Px CPG
R SWING ATR
STRAIGHT
XATR
TRAVEL (PTa)
XBTR
RIGHT
T P
P3 Pz CMR2 TRAVEL
TO MAIN VALVE R TRAVEL XATR MR CMR1
φ0.7 φ0.7
φ0.7 d2 d1
d3
R TRAVEL
L TRAVEL
P2
TO MAIN VALVE R TRAVEL XBTR
TO MAIN VALVE L TRAVEL XATL
Psv1
PH1
P2
A1
a1 a2
A2
PH2 Psv2
D1 D2 D2 D1
a3 a4
P2 P3 P3 P2
PT PT
BREAKER SET PRESS16.7±6.9kpa
A
P1 P2
0.25Mpa Engine
FRONT REAR
P1 P4 P4 P1 0.45Mpa
As
A B B A
DR B1 B3 A3
ZX225-1108005
Shop Manual - December 2012 10-3
SY195-205-215C9 Crawler Hydraulic Excavator System Schematics
10
6
7
11
17
18
19
21
22
23
26
27
28
29
30
31
32
35
36
1
2
3
4
5
8
9
12
13
14
15
16
20
24
25
33
34
CN-M30 CN-M29
11
10
10
12
13
14
15
16
6
7
1
2
3
4
5
6
7
11
17
18
19
1
2
3
4
5
8
9
8
9
12
13
14
15
16
0.5BrW
0.5BrY
0.5LgR
0.5WY
0.5GO
0.5WO
0.5OW
0.5GW
0.5RY
0.5VR
0.5RW
0.5WR
0.5LO
0.5BG
0.5BW
0.5VW
0.5BR
0.5BL
0.5BY
0.5PB
0.5YB
0.5PG
0.5Sb
0.5R
0.5B
8
0.5LgR
0.5BrW
0.5BrY
0.5BW
0.5WO
0.5OW
0.5GW
0.5WR
0.5VW
0.5WY
0.5RY
0.5GO
0.5BY
0.5RW
0.5LO
0.5BG
0.5YB
0.5PG
0.5VR
0.5BR
0.5PB
0.5BL
0.5Sb
0.5R
0.5B
SWP SWP SWP
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
6
7
1
2
3
4
5
8
CN-M28 CN-M27 CN-M33
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
6
7
1
2
3
4
5
8
1
2
3
4
5
6
7
8
9
10
11
12
7
0.5LgR
0.5BrW
0.5RW
0.5BW
0.5WO
0.5OW
0.5GW
0.5WR
0.5BrY
0.5WY
0.5BG
0.5VW
0.5GO
0.5RY
0.5BY
0.5LO
0.5YB
0.5PG
0.5BR
0.5VR
0.5PB
0.5BL
0.5Sb
0.5R
0.5B
MOTOR - SERVO CONVERSION
MV 2
SENSOR - INTERNAL TEMP.
FACE(DEF)
THI
FOOT
GND
Vz
Pt
6
PD
7
6
5
4
3
2
1
CN-M34
1
2
7
6
5
4
3
2
1
1
2
0.5GW
0.5OW
0.5BW
0.5GO
0.5BR
0.5BR
0.5Sb
050
CN-P15
2 2
1 1
S S 0.5WY FACE
7 7
0.5WR FOOT
6 6
0.5BrW Pt
5 5 5
4 4 SERVO MOTOR - CONVERSION
0.5BW Vz
3 3
2 2
0.5BR GND
1 1 MV I
CN-A30
2 2 0.5YB FRE
7 7
ECC
EC
CN-E06
T HA
1
M
1
S
IO 0.5VW
0.5WO
0.5BW
0.5BR
0.5PB
6
5
4
3
2
1
6
5
4
3
2
1
REC
Pt
Vz
GND
Mcool
SERVO MOTOR -
AIR RECIRCU/FRESH AIR
1
7 7
CN-M26 0.5VR Mhot
6 6
1
12 12 0.5BG Pt
5 5
11 11 4 4 SERVO MOTOR - A/M
TO CN-M26-A TO CN-E06-1 0.85W 0.5BW Vz
10 10 3 3
3 9 9 2B 2 2
0.5BR GND
8 8 1 1 MA M
TO CN-M26-7 TO CN-P15-1 0.5BW
7 7
TO CN-M26-7 TO CN-A30-2 0.5RW
6 6
2Br
5 5 1.25R
20A 4 4
TO CN-M26-2 TO CN-P15-2 3 3 0.5RY 5A
2 2
TO CN-M26-1 TO CN-A30-1 0.5BR
1 1
24V 0.5BR
1 1 SENSOR - LOW TEMP
0.5PG
2 2
THF
1.25G
1.25RL
2G
2RL
0.5BL
2G
2B
0.5BrY
0.85W
0.5LO
0.5R
0.5R
2RL
0.5lgR
2RL
2Br
2Br
0.5BR
0.5BY
2G
0.5B
4
3
4
3
3
4
2
1
3
4
2
1
2
1
2
1
2
1
3
4
2
1
2
1
3
4
2
1
PROTECTION
FOR TEMP.
2
1
2
1
DRIVING TRANSACTION OF
CIRCUIT INPUT SIGNEL
RL RL VOLTAGE
CORRECTION
A B C D E F G H I J K L M N
HORN RELAY HEADLIGHT RELAY PILOT VALVE RELAY START RELAY PARKING RELAY TOP LIGHT RELAY
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
8 1 2 3 4 5
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
1 2 3 4 5 1 2 3 4 5
PD
6
606 34 32 65 12 0 63 64
70 27 24 23 71 72 33 31 105 13 11
0
13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
5 2 1 2 1 2 1
CN-661F
CN-661M
TO CHASSIS HARNESS CN-461M
TO CAB HARNESS N-161F
CONNECTOR 282080-1(3)
3
Fuse
F1
F2
F3
F4
F5
Fuse Box Harness
Rated Value
20A
10A
5A
15A
5A
System
Start Circuit
Charging Indication
Horn Circuit
Work Lamp
Wiper & Washer
IO 20
F1
22
21
10 23 24 25 20 b 26 38 28 29 42 43 49 27 70
22
10
29
42
49
43
1
2
3
4
5
6
7
8
F6 10A Speaker 9
20 10
F7 10A Cab Light
11
F8 20A Air Conditioner 12
21
F9 5A Access Lamp
20 b CN-241F
2
F10 5A Monitor
TO CHASSIS HARNESS CN-441M
F11 20A Controller 23 24 25 26
F14 10A Aux. Controller 27 28 38 70 10
F15 15A Cigar Lighter 1 2 3 4 5 6 7 8 9 10 11 12
A B C D E F G H I J K L M N
HEAT 50
1
506
OFF 1 3 5 7 1 3 5 7 1 3 5 7 2
00
33 24 3
8
ON 35 H 25 35 L 36 37 25
35 L
4
START 72 5
70
6
22 13 16 11
18
7
17 8
9
10
7
11
12
CN-331F
TO CAB HARNESS CN-131M
PD
6
25
1
33
2
35 H 3
36
50 506 00 18 16 4
72 70 37 5
0 6
10 14 17 0 10
5 1 2 3 1 3 5 7 1 3 5 7 7
11
8
13
9
CN-302F CN-306M CN-307M 14
10
F-310 F-311 F-312 F-313 22
TO CONTROL DIAL SWITCH PREHEAT SWITCH TOP LIGHT SWITCH 11
24 12
3
CN-7-705M
CAN+
CAN-
1
2
3
CAN+
IO CIGAR LIGHTER
0
1
CN-7-707M
100
SUNLIGHT SENSOR
61
CN-7-706M
60
2
0
22
29
CN-332M
TO CAB HARNESS CN-132F
CN-7-111F
TO CHASSIS HARNESS CN-1-111M
1
2
3
CAN- 4
4 0
5
100
5 6
60 7
6
61 8
24V 7
2 29
24V 8
22
GND 9
CAN+
0 A
10 CAN-
GND B
11
0 C
12 A B
1 CN-7-709 CN-7-112F
A B
120Ω
A B C D E F G H I J K L M N
TO FUSE BOX RELAY HARNESS CN-221M TO CHASSIS HARNESS CN-442F TO FUSE BOX RELAY HARNESS CN-661M
9
CN-121F CN-142M CN-161F
TO WIPER MOTOR
CN-112M
TO ACCESS LAMP
1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
0 37 0 28 27 28 38 70 22 70 27 24 23 71 72 33 31 0 105
1020 b23 24 25 26 50 506 0060 a 57 18 17 61a 14 13 0 10 18 13 11
CN-131M CN-113M
TO CONTROL SW
8
MONITOR HARNESS CN-331F 23
2 1
2 CN-104M
50 31
1 1 TO HORN S/W
2 506
00
3
35 L
4 105
72 1 CN-106F
7
5 TO PILOT S/W
70 27 2
6
7 18
8 17
9
10 1
PD
6
11 25 2
36
12 3 CN-110M
TO WIPER HARNESS
35 H 4
CN-132F
TO CONTROL SW MONITOR HARNESS CN-332M 35 L 5
25 6
5 1
2 33
3 35 H
57
4 36
1
5 37 61a
4
4
3
6
7
8
9
10
11
12
00
10
11
13
14
22
24
IO 60 a
0
38
38 8
26
5
6
7
CN-207F
TO A/C PANEL
8
CN-107M 0 7
TO RADIO PANEL
20 b 71 6
1
R+ 0 5 CN-150M
2 L- TO SPEAKER,
2
L+ 4
3 L+
CAB LAMP HARNESS
4 0 3
R-
5 20 b 2
R- R+
6 1
L-
7
1
TO CONSOLE GND
A B C D E F G H I J K L M N
PD
M OIL PRESS INPUT
6 PRESS INPUT - TRAVEL(L) 48
508 00 5
200 MT+
BUCKET DUMP PRESS INPUT 49
204 6
BOOM LOWER PRESS INPUT 50
207 17
ARM OUT PRESS INPUT 51 TO PREHEAT FUSE
202 16
REAR PUMP PRESS INPUT 52
53
502 17
s GND
00
s GND 54
00 18 TO PREHEAT RELAY
s PWR 55
50 0 12
56
CAN- 57
CAN- 21
58 ALTERNATOR TERM B
CAN+ 59 10
60
CAN+ 14 ALTERNATOR TERM L/R
61 B01 47
62
ALTERNATOR TERM P
5 63
64 12a 1
65 14 2
PRESS INPUT - TRAVEL (R) 66 10 CN-613F
67
201 3
SWING PRESS INPUT
BUCKET CURL PRESS INPUT 68
208 47 4 TO SAFETY RELAY
BOOM RAISE PERSS INPUT 69
205 5
206 0 6
ARM IN PRESS INPUT 70
FRONT PUMP PRESS INPUT 71
203
501 22 1
s GND 72
00 B01 1
s PWR 73
50 B02 2 64 2
74
63 3 CN-801F
3
s PWR
CAN+
CAN-
CN-615F
SPEED CONTROL OUTPUT
82
83
84
85
86
87
88
89
90
91
92
93
94
50
CAN+
CAN-
B02
B03
B01
607
702
703
B03 3
B04 4
B05 5
B06 6
B07 7
B08 8
42
0 2
1
CN-158M
CALIBRATOR CONNECTOR
CN-159M
IO F PUMP PRESS SENSOR R PUMP PRESS SENSOR
50
CN-115M
A B C
00 501
CN-116M
50
A B C
00 502
CONNECTOR 282080-1
0 606
1 2
0 607
1 2
702
703
0
0 4
65 5
6
2
TO PARK MOTOR
CN-113F
F PUMP SOL
PROP VALVE
CN-114F
R PUMP SOL
PROP VALVE
95 606
96
1
SWING PRTY PRPTL VALVE OUTPUT 97
CN-136F
608
BUCKET CONFL PRPTL VALVE OUTPUT 98
604 0 PILOT SOL VALVE
99 2
100
101
102 604 1
103
CN-134F
FUEL CTRL MOTOR SIGNAL OUTPUT 104
MT+ BKT CONFLUENCE
105 0 SOL VALVE
2 106
2
107
108
608
109 1
110
CN-133F
111 SWING PRIORITY
FUEL CTRL MOTOR SIGNAL OUTPUT 112 0 2 SOL VALVE
GROUND 113
GROUND 114
0 606 34 32 65 12 0 63 64 50 00 50 00 201 50 00 202 50 00 208 50 00 205 50 00 207 50 00 206 50 00 204 50 00 203
115
0
607
116
117 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 A B C A B C A B C A B C A B C A B C A B C A B C A B C 1 CN-131F
24V POWER 118
42
HI/LO TRAVEL
24V POWER 119
42 0 2 SPD SOL VALVE
120
CN-120M CN-121M CN-122M CN-123M CN-124M CN-125M CN-126M CN-127M CN-128M
1 121
CN-461M CN-112M 12 12 a 0 21
122
0 0 34
1 2 2 1
L TRAVEL R TRAVEL ARM-OUT SWING BKT DIG BOOM DOWN BOOM UP BKT DUMP ARM IN
1 2 1 2 TO FUSE BOX RELAY HARNESS CN-661F 282104-1
CN-111F PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR PRESS SENSOR
TO WORK LAMP F-104 F-103 TO START MOTOR
CN-102M CN-106M TO HORN
A B C D E F G H I J K L M N