SANY Crawler Hydraulic Excavator (SY195C9, SY205C9, SY215C9, SY225C9). Shop Manual (2013) - page 22
Troubleshooting
E541 (abnormality in engine speed)
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
—
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ Code 41 will be displayed on the monitor when engine start switch is
Normal condi-
1
turned from the OFF position to the ON position. This is normal as the en-
tion
gine is not started.
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
Open circuit of
2
Between CN-448M ① and pin 38 of controller
1 ȍ
wire harness
Resistance
Between CN-448M ② and pin 19 of controller
1 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
3
wire harness
form troubleshooting.
Between CN-448M ① and ground
Resistance
1M ȍ
(grounded)
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of sen-
form troubleshooting.
4
sor
Unplug the connector CN-448M, and measure the
Resistance
2.3±0.2k ȍ
resistance between the speed sensors's ① and ② .
5
CONTROLLER
ENGINE SPEED
CN-448M
SENSOR
108A
ENGINE SPEED
SIGNAL
38
1
PROBING
108B
GND WIRE
19
2
GND WIRE
CAB
CHASSIS HARNESS
ZX215-1005087
7-51
Troubleshooting
E450 (abnormality (a) in front pump proportional solenoid coil current)
User Code
Service Code
Front pump proportional solenoid coil current is ab-
Trouble
50
E450
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.
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
Open circuit of
1
Between CN-113F ① and pin 88 of controller
1 ȍ
wire harness
Resistance
Between CN-113F ② and ground
1 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
2
wire harness
form troubleshooting.
Between CN-113F ① and wire 0#
Resistance
1M ȍ
(grounded)
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of pro-
form troubleshooting.
3
portional valve
Unplug the connector CN-113F, and measure the
coil
Resistance
17.5 ȍ
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
CONTROLLER
SOLENOID VALVE
CN-113F
(FRONT PUMP)
FRONT PUMP
702#
SIGNAL
SOLENOID VALVE
88
1
SIGNAL OUTPUT PORT
0#
GND WIRE
55
2
GND WIRE
CAB
CHASSIS HARNESS
ZX215-1005088
7-52
Troubleshooting
E450 (abnormality (b) in front pump proportional solenoid coil current)
User Code
Service Code
Front pump proportional solenoid coil current is ab-
Trouble
50
E450
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.
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ 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 ȍ
wire harness
Resistance
Between CN-113F ② and ground
1 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
2
wire harness
form troubleshooting.
(grounded)
Between CN-113F ① and wire 0#
Resistance
1M ȍ
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of pro-
form troubleshooting.
3
portional valve
Unplug the connector CN-113F, and measure the
Resistance
17.5 ȍ
coil
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
CONTROLLER
SOLENOID VALVE
CN-113F
(FRONT PUMP)
FRONT PUMP
702#
SIGNAL
SOLENOID VALVE
88
1
SIGNAL OUTPUT PORT
0#
GND WIRE
55
2
GND WIRE
CAB
CHASSIS HARNESS
ZX215-1005088
7-53
Troubleshooting
E451 (abnormality (a) in rear pump proportional solenoid coil current)
User Code
Service Code
Rear pump proportional solenoid coil current is ab-
Trouble
51
E451
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.
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
Open circuit of
1
Between CN-114F ① and pin 89 of controller
1 ȍ
wire harness
Resistance
Between CN-114F ② and ground
1 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
2
wire harness
form troubleshooting.
Between CN-114F ① and wire 0#
Resistance
1M ȍ
(grounded)
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of pro-
form troubleshooting.
3
portional valve
Unplug the connector CN-114F, and measure the
coil
Resistance
17.5 ȍ
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
CONTROLLER
SOLENOID VALVE
CN-114F
(REAR PUMP)
702#
REAR PUMP
89
1
SIGNAL
SOLENOID VALVE
SIGNAL OUTPUT PORT
0#
GND WIRE
55
2
GND WIRE
CAB
CHASSIS HARNESS
ZX215-1005089
7-54
Troubleshooting
E451 (abnormality (B) in rear pump proportional solenoid coil current)
User Code
Service Code
Rear pump proportional solenoid coil current is abnor-
Trouble
51
E451
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.
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
Open circuit of
1
Between CN-114F ① and pin 89 of controller
1 ȍ
wire harness
Resistance
Between CN-114F ② and ground
1 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
2
wire harness
form troubleshooting.
Between CN-114F ① and wire 0#
Resistance
1M ȍ
(grounded)
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of pro-
form troubleshooting.
3
portional valve
Unplug the connector CN-114F, and measure the
coil
Resistance
17.5 ȍ
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
CONTROLLER
SOLENOID VALVE
CN-114F
(REAR PUMP)
702#
REAR PUMP
89
1
SIGNAL
SOLENOID VALVE
SIGNAL OUTPUT PORT
0#
GND WIRE
55
2
GND WIRE
CAB
CHASSIS HARNESS
ZX215-1005089
7-55
Troubleshooting
E452 (abnormality (A) in swing priority proportional solenoid coil current)
User Code
Service Code
Current through the proportional solenoid coil for
Trouble
52
E452
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
—
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
Open circuit of
1
Between CN-133F ① and pin 98 of controller
1 ȍ
wire harness
Resistance
Between CN-133F ② and ground
1 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
2
wire harness
form troubleshooting.
(grounded)
Between CN-133F ① and wire 0#
Resistance
1M ȍ
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of pro-
form troubleshooting.
3
portional valve
Unplug the connector CN-133F, and measure the
Resistance
17.5 ȍ
coil
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
CONTROLLER
SOLENOID VALVE
CN-133F
(SWING PRIORITY)
SWING PRIORITY
608#
SIGNAL
SOLENOID VALVE
98
1
SIGNAL OUTPUT PORT
0#
GND WIRE
55
2
GND WIRE
CAB
CHASSIS HARNESS
ZX215-1005090
7-56
Troubleshooting
E452 (abnormality (B) in swing priority proportional solenoid coil current)
User Code
Service Code
Current through the proportional solenoid coil for
Trouble
52
E452
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
—
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
Open circuit of
1
Between CN-133F ① and pin 98 of controller
1 ȍ
wire harness
Resistance
Between CN-133F ② and ground
1 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
2
wire harness
form troubleshooting.
(grounded)
Between CN-133F ① and wire 0#
Resistance
1M ȍ
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of pro-
form troubleshooting.
3
portional valve
Unplug the connector CN-133F, and measure the
Resistance
17.5 ȍ
coil
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
CONTROLLER
SOLENOID VALVE
CN-133F
(SWING PRIORITY)
SWING PRIORITY
608#
1
SIGNAL
SOLENOID VALVE
98
SIGNAL OUTPUT PORT
0#
GND WIRE
55
2
GND WIRE
CAB
CHASSIS HARNESS
ZX215-1005090
7-57
Troubleshooting
E453 (abnormality (A) in bucket confluence proportional solenoid coil current)
User Code
Service Code
Current through the proportional solenoid coil for bucket
Trouble
53
E453
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.
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
Open circuit of
1
Between CN-134F ① and 99 pin of controller
1 ȍ
wire harness
Resistance
Between CN-134F ② and ground
1 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
2
wire harness
form troubleshooting.
(grounded)
Between CN-134F ① and wire 0#
Resistance
1M ȍ
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of pro-
form troubleshooting.
3
portional valve
Unplug the connector CN-134F, and measure the
Resistance
17.5 ȍ
coil
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
CONTROLLER
SOLENOID VALVE
CN-134F
(BUCKET CONFLU)
BUCKET CONFLUENCE
604#
SOLENOID VALVE
99
1
SIGNAL
SIGNAL OUTPUT PORT
0#
GND WIRE
55
2
GND WIRE
CAB
CHASSIS HARNESS
ZX215-1005091
7-58
Troubleshooting
E453 (abnormality (B) in bucket confluence proportional solenoid coil current)
User Code
Service Code
Current through the proportional solenoid coil for bucket
Trouble
53
E453
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.
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
Open circuit of
1
Between CN-134F ① and pin 99 of controller
1 ȍ
wire harness
Resistance
Between CN-134F ② and ground
1 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
2
wire harness
form troubleshooting.
(grounded)
Between CN-134F ① and wire 0#
Resistance
1M ȍ
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of pro-
form troubleshooting.
3
portional valve
Unplug the connector CN-134F, and measure the
Resistance
17.5 ȍ
coil
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
CONTROLLER
SOLENOID VALVE
CN-134F
(BUCKET CONFLU)
BUCKET CONFLUENCE
604#
SIGNAL
SOLENOID VALVE
99
1
SIGNAL OUTPUT PORT
0#
GND WIRE
55
2
GND WIRE
CAB
CHASSIS HARNESS
ZX215-1005091
7-59
Troubleshooting
E455 (abnormality (A) in boom priority 2 proportional solenoid coil current)
User Code
Service Code
Current through the proportional solenoid coil for
Trouble
55
E455
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
—
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
Open circuit of
1
Between CN-135F ① and pin 101 of controller
1 ȍ
wire harness
Resistance
Between CN-135F ② and ground
1 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
2
wire harness
form troubleshooting.
(grounded)
Between CN-135F ① and wire 0#
Resistance
1M ȍ
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of pro-
form troubleshooting.
3
portional valve
Unplug the connector CN-135F, and measure the
Resistance
17.5 ȍ
coil
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
CONTROLLER
SOLENOID VALVE
CN-135F
(BOOM PRIORITY 2 )
BOOM PRIORITY 2
603#
SIGNAL
SOLENOID VALVE
101
1
SIGNAL OUTPUT PORT
0#
GND WIRE
55
2
GND WIRE
CAB
CHASSIS HARNESS
ZX215-1005093
7-60
Troubleshooting
E455 (abnormality (B) in boom priority 2 proportional solenoid coil current)
User Code
Service Code
Current through the proportional solenoid coil for
Trouble
55
E455
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
—
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
form troubleshooting.
Open circuit of
1
Between CN-135F ① and pin 101 of controller
1 ȍ
wire harness
Resistance
Between CN-135F ② and ground
1 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
2
wire harness
form troubleshooting.
(grounded)
Between CN-135F ① and wire 0#
Resistance
1M ȍ
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of pro-
form troubleshooting.
3
portional valve
Unplug the connector CN-135F, and measure the
Resistance
17.5 ȍ
coil
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
CONTROLLER
SOLENOID VALVE
CN-135F
(BOOM PRIORITY 2 )
BOOM PRIORITY 2
603#
SIGNAL
SOLENOID VALVE
101
1
SIGNAL OUTPUT PORT
0#
GND WIRE
55
2
GND WIRE
CAB
CHASSIS HARNESS
ZX215-1005093
7-61
Troubleshooting
E460 (abnormality in dual speed travel solenoid valve)
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.
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ 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 ȍ
wire harness
Resistance
Between CN-132F ② and ground
1 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
2
wire harness
form troubleshooting.
Between CN-132F ① and wire 0#
Resistance
1M ȍ
(grounded)
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Failure of pro-
form troubleshooting.
3
portional valve
Unplug the connector CN-132F, and measure the
coil
Resistance
17.5 ȍ
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
CONTROLLER
SOLENOID VALVE
CN-132F
(DUAL-SPEED TRAVEL)
DUAL SPEED TRAVEL
607#
SIGNAL
SOLENOID VALVE
100
1
SIGNAL OUTPUT PORT
0#
GND WIRE
GND WIRE
55
2
CAB
CHASSIS HARNESS
ZX215-1005094
7-62
Troubleshooting
7.6 Troubleshooting of Electrical System (E - Mode)
Information in troubleshooting table
7-64
E-1 Engine does not start
7-65
E-2 Engine runs rough or is unstable
7-67
E-3 Power supply of machine cannot be cut off
7-68
E-4 Auto idle not functioning
7-70
E-5 Preheating function fails
7-71
E-6 Work equipment does not work
7-72
E-7 Boom-raise speed or power is low
7-73
E-8 Arm speed or power is low
7-74
E-9 Bucket speed or power is low
7-75
E-10 Travel speed or power is low
7-77
E-11 Blank monitor display
7-78
E-12 Monitor displays nothing
7-79
E-13 Dual speed travel not functioning
7-80
E-14 Incorrect engine coolant reading
7-81
E-15 Incorrect fuel level reading
7-82
E-16 Wiper does not work
7-83
E-17 Incorrect arm-in pilot pressure reading
7-84
E-18 Incorrect arm-out pilot pressure reading
7-85
E-19 Incorrect boom-raise pilot pressure reading
7-86
E-20 Incorrect boom-lower pilot pressure reading
7-87
E-21 Incorrect bucket-curl pilot pressure reading
7-88
E-22 Incorrect bucket-dump pilot pressure reading
7-89
E-23 Incorrect swing pilot pressure reading
7-90
E-24 Incorrect left travel pilot pressure reading
7-91
E-25 Incorrect right travel pilot pressure reading
7-92
7-63
Troubleshooting
Information in troubleshooting table
Ɣ The following information is contained in the troubleshooting table and related electric circuit
diagrams. Fully understand these information before carrying out troubleshooting.
Trouble
Trouble which occurs on the machine
Related information
Information related to detected trouble or troubleshooting
Cause
Standard value in normal state and remarks on troubleshooting
1
2
3
4
Possible causes of
trouble (Given num-
< Description >
bers are reference
Ɣ 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)
Ɣ A reference value is used to determine OK or N/G.
5
Related circuit diagram
This is part of the circuit diagram which shows the portion where the failure occurred.
Ɣ Connector No.: A connector number Indicates a connector.
Ɣ Arrow: An arrow roughly indicates the installing location.
7-64
Troubleshooting
E-1 Engine does not start
Trouble
Engine cannot be started.
Related information
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
Low battery
1
bleshooting.
capacity
Battery voltage
Voltage
24V
Internal fail-
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
2
ure of start
bleshooting.
OFF position: between wire 22# and wire 11#
Resistance
1M ȍ
switch
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
bleshooting.
Failure of
3
Lockout lever FREE position: between 105 # and 27# wire
1 ȍ
pilot switch
Resistance
Lockout lever LOCKED position: between wire 105# and 27#
1 M ȍ
Ɣ Turn engine start switch to OFF position. Keep the engine running during trouble-
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
Ɣ Turn engine start switch to OFF position. Then, keep it at OFF position to perform
troubleshooting.
Open circuit
Wire 21# and start motor terminal B
1 ȍ
5
of wire har-
Wire 12# and start relay terminal SW
Resistance
1 ȍ
ness
Start relay terminal L and safety relay terminal S
1 ȍ
Failure of
6
Battery terminal "+" (wire 20#) and control dial wire 22#
Resistance
1 ȍ
fuse F1
Short cir-
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to perform trou-
cuit of wire
bleshooting.
7
Start relay terminal SW and ground
1 M ȍ
harness
Resistance
(grounded)
Engine input terminal S and ground
1 M ȍ
Internal
Ɣ 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
Ɣ 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
Ɣ Turn engine start switch to OFF position. Then, keep it at ON position to perform
Failure of
troubleshooting.
10
Between CN-801F 2 and 3
1 ȍ
parking unit
Resistance
Unplug connector CN-801F; measure resistance of motor coil.
App 63 ȍ
7-65
Troubleshooting
START SWITCH
TERMINAL
B
BR
ACC
R1
R2
C
F1
20A
HEAT
20
22
OFF
F2
5A
ON
CN-241F
21
10
START
BATTERY
(D-12)
20
22
22
13
11
1
1
10
2
2
9
9
12
12
BATTERY RELAY
21
PILOT SWITCH
1
2
3 45
1
2
3 45
F16
10A
105
0
LOCK RELAY
1
2
3 45
1
2
3 45
0
22
PARK RELAY
CN-661F
PARK MOTOR
(S-16)
CN-801F
64
64
10
10
22
A
9
9
63
(H-6)
B
65
P1
6
6
65
63
1
1
P2
E
CN-161F
1
2
3 45
(S-16)
0
2
2
10
10
1
2
3 45
0
15
15
13
3
3
6
6
12a
12
14
HLR CHARGE
47
CN-613F
INDICATOR
(L-6)
10
START RELAY
SAFETY RELAY
ALTERNATOR
START MOTOR
ZX215-1005095
7-66
Troubleshooting
E-2 Engine runs rough or is unstable
Trouble
Engine Runs Rough or Is Unstable
Related information
Engine speed can be read on the monitor.
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ 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 ȍ
the resistance between pin 19 and pin 38.
Ɣ 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 ȍ
Short circuit of
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
3
wire harness
form troubleshooting.
Between CN-448M B and ground
Resistance
1M ȍ
(grounded)
Internal failure
No troubleshooting can be done due to internal failure. (Failure lies in the con-
4
of controller
troller if the reasons above are ruled out)
5
CONTROLLER
CN-448M
čS-2Ď
SPEED SENSOR
SPEED SENSOR
38
A
SIGNAL
INPUT SIGNAL
GND
19
B
GND
CAB
CHASSIS HARNESS
ZX215-1005096
7-67
Troubleshooting
E-3 Power supply of machine cannot be cut off
Trouble
Engine cannot be stopped.
Engine stalls when start switch it turned to OFF position. There is no time
Related information
delay for power cutout.
Cause
Standard value in normal state/Remarks on troubleshooting
When engine start switch is operated, if the operation of battery
Failure of bat-
1
relay contact is heard, the battery is normal. Turn the start switch
tery relay
OFFĺONĺOFF.
Ɣ Turn engine start switch to OFF position. Keep it at OFF position to per-
Breakdown of
2
form troubleshooting.
surge diode
Between battery relay wire 20# and wire 21#
Resistance
1M ȍ
3
4
5
7-68
Troubleshooting
START SWITCH
TERMINAL
B
BR
ACC
R1
R2
C
F1
20A
HEAT
20
22
OFF
F2
5A
10
ON
CN-241F
21
START
BATTERY
(D-12)
20
22
22
13
11
1
1
10
2
2
9
9
12
12
BATTERY RELAY
21
PILOT SWITCH
1
2
3 45
1
2
3 45
F16
10A
105
0
LOCK RELAY
1
2
3 45
1
2
3 45
0
22
PARK RELAY
CN-661F
PARK MOTOR
(S-16)
CN-801F
64
64
10
10
22
A
9
9
63
(H-6)
B
65
P1
6
6
65
63
1
1
P2
CN-161F
1
2
3 45
E
0
(S-16)
2
2
10
10
1
2
3 45
0
15
15
13
3
3
6
6
12a
12
14
HLR CHARGE
47
CN-613F
INDICATOR
(L-6)
10
START RELAY
SAFETY RELAY
ALTERNATOR
START MOTOR
ZX215-1005095
7-69
Troubleshooting
E-4 Auto idle not functioning
Trouble
Auto idle speed do not work
Engine speed do not decrease wen the mode is auto idle speed and grip keeps
Related information
still in "NEUTRAL" position
Cause
Standard value in normal state/Remarks on troubleshooting
Ɣ Turn engine start switch to OFF position. Start the engine and keep it
Error of boom-
running to perform troubleshooting.
1
Levers in NEUTRAL, pressure signal transmitted
0 KG
raise signal
Pressure
Lever in operation, pressure signal transmitted
0~39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it
Error of boom-
running to perform troubleshooting.
2
Levers in NEUTRAL, pressure signal transmitted
0 KG
lower signal
Pressure
Lever in operation, pressure signal transmitted
0~39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it
Error of arm-in
running to perform troubleshooting.
3
Levers in NEUTRAL, pressure signal transmitted
0 KG
signal
Pressure
Lever in operation, pressure signal transmitted
0~39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.
Error of arm-out
4
Levers in NEUTRAL, pressure signal transmitted
0 KG
signal
Pressure
Lever in operation, pressure signal transmitted
0~39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.
Error of bucket-
5
Levers in NEUTRAL, pressure signal transmitted
0 KG
curl signal
Pressure
Lever in operation, pressure signal transmitted
0~39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.
Error of Bucket-
6
Levers in NEUTRAL, pressure signal transmitted
0 KG
dump signal
Pressure
Lever in operation, pressure signal transmitted
0~39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it
Error of swing
running to perform troubleshooting.
7
Levers in NEUTRAL, pressure signal transmitted
0 KG
signal
Pressure
Lever in operation, pressure signal transmitted
0~39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it
running to perform troubleshooting.
8
Error of travel
Levers in NEUTRAL, pressure signal transmitted
0 KG
signal
Pressure
Lever in operation, pressure signal transmitted
0~39 KG
Ɣ Turn engine start switch to OFF position. Start the engine and keep it
Error of attach-
running to perform troubleshooting.
9
Levers in NEUTRAL, pressure signal transmitted
0 KG
ment signal
Pressure
Lever in operation, pressure signal transmitted
0~39 KG
Failure of con-
No troubleshooting can be done for it is internal failure. (If it is not caused by
10
troller
one of the factors listed above, it should be the failure of controller.)
7-70