SANY SY195C9 Shop Manual
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SANY SY195C9 Shop Manual

Crawler hydraulic excavator
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Table of Contents

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www.sanygroup.com
SANY HEAVY MACHINERY LIMITED
318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District,
Shanghai, P.R. of China 201413
Tel: (86) 21 5700 8518
Service hotline:(86) 4006 098 318
E-mail: crd@sany.com.cn
Documentation No.: ZJSYF0301EN(07-12)-SY55C3/55C9/60C1
https://www.tractormanualpdf.info/
Crawler Hydraulic
Excavator
SY195C9
SY205C9
SY215C9
SY225C9
Shop Manual
Quailty Changes the World

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Summary of Contents for SANY SY195C9

  • Page 1 Quailty Changes the World Crawler Hydraulic Excavator SY195C9 SY205C9 SY215C9 SY225C9 SANY HEAVY MACHINERY LIMITED 318A, Lianggang Avenue, Lingang Industrial Park, Fengxian District, Shanghai, P.R. of China 201413 Tel: (86) 21 5700 8518 Service hotline:(86) 4006 098 318 E-mail: crd@sany.com.cn Documentation No.: ZJSYF0301EN(07-12)-SY55C3/55C9/60C1 Shop Manual https://www.tractormanualpdf.info/...
  • Page 2 ● 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. Ma- terial or technical specifi cation is subject to change without prior notice.
  • Page 3 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. https://www.tractormanualpdf.info/...

  • Page 4: Table Of Contents

    Table of Contents SY195/205/215/225C9 Crawler Hydraulic Excavator Table of Contents 1 Introduction 1.1 How to Read the Shop Manual ................1-3 1.2 Terms for Maintenance Standard ................1-5 1.3 Handling Electrical and Hydraulic Components............1-7 1.3.1 Points to remember when handling electric components ......1-7 1.3.2 Points to remember when handling hydraulic equipment ......
  • Page 5 Table of Contents SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.16 Fire Extinguisher and Emergency Exits ............. 2-14 2.2.17 Personal Protective Equipment..............2-14 2.2.18 Running the Machine ................. 2-15 2.2.19 Accumulator ....................2-16 2.2.20 Adding Fluids to a System ................. 2-16 2.2.21 Track Recoil Springs .................. 2-17 2.2.22 High-Pressure Fluid Lines................
  • Page 6 Table of Contents SY195/205/215/225C9 Crawler Hydraulic Excavator 4.3.2 Idler ......................4-16 4.3.3 Carrier roller ....................4-18 4.3.4 Track roller ....................4-19 4.3.5 Track shoe ....................4-20 4.3.6 Triple grouser shoe ..................4-23 4.4 Hydraulic System, Part 1 ..................4-24 4.4.1 Hydraulic equipment layout................4-24 4.4.2 Hydraulic tank and fi...
  • Page 7 Table of Contents SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.6.1 Operation of components ..............4-95 4.6.7 Valve control system .................. 4-107 4.6.8 Pilot valve....................4-109 4.6.8.1 Work equipment and swing pilot valve ..........4-109 4.6.8.2 Travel PPC valve ................4-113 4.6.9 Solenoid valve.....................4-117 4.6.10 Accumulator ....................4-118 4.6.11 Pilot oil fi...
  • Page 8 Table of Contents SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.4.1 Electrical positive fl ow control ............4-175 4.9.4.2 Constant power control ..............4-178 4.9.5 Valve control function ................. 4-180 4.9.5.1 Bucket fl ow control ................4-181 4.9.5.2 Swing priority control ................. 4-182 4.9.6 Duo travel speed control ................
  • Page 9 Table of Contents SY195/205/215/225C9 Crawler Hydraulic Excavator 6.5.1 Testing ......................6-13 6.5.2 Adjusting ...................... 6-15 6.6 Engine Oil Pressure - Measure................6-17 6.7 Engine Speed Sensor - Adjust ................6-19 6.8 A/C Compressor Belt Tension - Test and Adjust ........... 6-20 6.8.1 Testing ......................
  • Page 10 Table of Contents SY195/205/215/225C9 Crawler Hydraulic Excavator 7.6 Troubleshooting of Electrical System (E - Mode)........... 7-63 7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode) ...... 7-93 8 Disassembly and Assembly 8.1 How to Read This Manual ..................8-5 8.1.1 Removing and Installing an Assembly ............
  • Page 11 Table of Contents SY195/205/215/225C9 Crawler Hydraulic Excavator 8.12.1 Removal ..................... 8-46 8.12.2 Installation ....................8-47 8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble......8-48 8.13.1 Disassembly....................8-48 8.13.2 Assembly....................8-53 8.14 Idler AS - Disassemble and Assemble ..............8-58 8.14.1 Disassembly....................
  • Page 12 Table of Contents SY195/205/215/225C9 Crawler Hydraulic Excavator 8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble ......8-91 8.25.1 Assembly....................8-91 8.26 Pilot Valve AS (Travel) - Disassemble and Assemble .......... 8-93 8.26.1 Assembly....................8-93 8.27 Hydraulic Cylinder AS - Disassemble and Assemble........... 8-94 8.27.1 Disassembly....................
  • Page 13 Table of Contents SY195/205/215/225C9 Crawler Hydraulic Excavator 8.37.2 Removal ....................8-152 8.37.3 Installation ....................8-153 8.37.4 Replacement .................... 8-153 8.38 Start Switch......................8-154 8.38.1 Structure ....................8-154 8.38.2 Removal ....................8-155 8.39 Fuse Box......................8-157 8.39.1 Removal ....................8-157 8.40 Wiper ......................... 8-158 8.40.1 Structure ....................

  • Page 14: Introduction

    Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Introduction 1 Introduction 1.1 How to Read the Shop Manual ................1-3 1.2 Terms for Maintenance Standard ................1-5 1.3 Handling Electrical and Hydraulic Components............1-7 1.3.1 Points to remember when handling electric components ......1-7 1.3.2 Points to remember when handling hydraulic equipment ......
  • Page 15 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 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.

  • Page 16: How To Read The Shop Manual

    Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 1 INTRODUCTION 1.1 How to Read the Shop Manual 1. Composition of shop manual This shop manual contains the necessary technical information for services performed in a work- shop. For ease of understanding, the manual is divided into the following sections. Introduction This section provides an overview of what is covered in the rest of this manual and how to use this manual,.
  • Page 17 This section provides hydraulic circuit diagrams and electrical circuit diagrams. 2. Revision and distribution Any additions, revisions, or other change of notices will be sent to Sany distributors. Get the most up-to-date information before you start any work. 3. Units In this shop manual, the units are indicated with International System of units (SI).

  • Page 18: Terms For Maintenance Standard

    Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 1.2 Terms for Maintenance Standard The maintenance standard values necessary for judgment of products and parts are de- scribed by the following terms. 1. Standard size and tolerance ● To be accurate, the finishing size of parts is a little different from one to another.
  • Page 19 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Example 4. Repair limit and allowable value ● The size of a part changes due to wear Tolerance Standard size and deformation while it is used. The limit Shaft Hole of changed size is called the "repair limit". -0.030 +0.046 φ60...

  • Page 20: Handling Electrical And Hydraulic Components

    Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 1.3 Handling Electrical and Hydraulic Components To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct "oper- ation", "maintenance and inspection", "trouble- shooting", and "repairs" must be carried out. This section deals particularly with correct re- pair procedures for mechatronics and is aimed at improving the quality of repairs.
  • Page 21 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 2. Main failures occurring in wiring har- ness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely Improper insertion to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly...
  • Page 22 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet.
  • Page 23 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 3. Removing, installing, and drying con- nectors and wiring harnesses 1) Disconnecting connectors a. Hold the connectors when disconnect- ing. Press lightly when removing When disconnecting the connectors, hold the connectors. For connectors Lock stopper held by a screw, loosen the screw fully, then hold the male and female connec- tors in each hand and pull apart.
  • Page 24 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator c. Action to take after removing connec- tors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. NOTE: If the machine is left disas- sembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
  • Page 25 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator b. Fix the connector securely. Align the position of the connector cor- rectly, and then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. c. Correct any protrusion of the boot and any misalignment of the wiring harness.
  • Page 26 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 4) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
  • Page 27 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Handling the integrated control monitor 1) The controller contains a microcomputer and an electronic control circuits. They control all of the electronic circuits on the machine, so be extremely careful when handling the integrated control monitor. 2) Do not place objects on the controller.
  • Page 28 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 5. Points to remember when troubleshoot- ing electric circuits 1) Always turn the power OFF before discon- necting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. NOTE: Disconnect and connect the related connectors several times to check.

  • Page 29: Points To Remember When Handling Hydraulic Equipment

    Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 1.3.2 Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
  • Page 30 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Do not let any dirt or dust get in during refi lling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers.

  • Page 31: Hose Connector

    Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 7. Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when run- ning the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fi...

  • Page 32: Type Of Hose Connector

    Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 1.4.1 Type of hose connector ° ° Male Female ZX215-1000029 1.4.2 Hose connector tightening torque table Wrench size mm Wrench size mm Tightening torque Type Connecting nut Hose joint N·m(kgf·m,Ibf·ft) 59(6,44) 98(10,72) 118(12,87) 235(24,173) 24° Male 295(30,218) 490(50,361) 670(68,494)

  • Page 33: Connection Of O-Rings

    Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 1.4.3 Connection of O-rings Place O-ring (6) in contact with the contact surface of the joint (7) to seal the pressurized oil. NOTICE ● Replace o-rings (6) with new ones when re-connecting hoses. Hose connector ●...

  • Page 34: Table Of Standard Tightening Torques

    Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 1.5 Table of Standard Tightening Torques Table of tightening torques for bolts and nuts ● Unless specifi ed otherwise, tighten metric nuts and bolts to the torque below. (When using torque wrench) Hexagonal bolt Hexagonal socket head bolt Bolt Bolt Wrench...

  • Page 35: Type Of Bolts

    Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 1.6 Type of Bolts Tighten nuts and bolts properly to specified torque values. The type and grade of bolts are illustrated on the right. Hex bolt Socket head hex bolt Use correct bolts and tighten them properly when assembling machines or components.

  • Page 36: Maintenance Of Half Flanges

    Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 1.8 Maintenance of Half Flanges 1. Clean the sealing surface of the fl ange and check it carefully. Scratches and coarse- ness cause leaks or abrasion of seals. Uneven surface may squeeze the seal out. If these faults are not corrected properly, parts may have to be replaced.

  • Page 37: Conversion Table

    Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 1.9 Conversion Table The conversion table in this section is provided to enable simple conversion of fi gures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1.
  • Page 38 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Length Millimeters to Inches 1mm=0.03937in 0.000 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260...
  • Page 39 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Inches to Millimeters 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 3.1750 15.8750 9/64 3.5719 41/64 16.2719 5/32...
  • Page 40 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Feet to Meters 0.305 0.610 0.914 1.219 1.524 1.829 2.134 2.438 2.743 3.048 3.353 3.658 3.962 4.267 4.572 4.877 5.182 5.486 5.791 6.096 6.401 6.706 7.010 7.315 7.620 7.925 8.230 8.534 8.839 9.144 9.449 9.754 10.058 10.363 10.668 10.973 11.278 11.582 11.887 12.192 12.497 12.802 13.106 13.411 13.716 14.021 14.326 14.630 14.935 15.240 15.545 15.850 16.154 16.459 16.764 17.069 17.374 17.678 17.983...
  • Page 41 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Miles to Kilometers miles miles 1.609 3.219 4.828 6.437 8.047 9.656 11.265 12.875 14.484 16.093 17.703 19.312 20.921 22.531 24.140 25.749 27.359 28.968 30.577 32.187 33.796 35.405 37.015 38.624 40.234 41.843 43.452 45.062 46.671 48.280 49.890 51.499 53.108 54.718...
  • Page 42 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Area Square inches to square centimeters 6.452 12.903 19.355 25.806 32.258 38.710 45.161 51.613 58.064 64.516 70.968 77.419 83.871 90.322 96.774 103.226 109.677 116.129 122.580 129.032 135.484 141.935 148.387 154.838 161.290 167.742 174.193 180.645 187.096 193.548 200.000 206.451 212.903 219.354 225.806 232.258 238.709 245.161 251.612 258.064 264.516 270.967 277.419 283.870 290.322 296.774 303.225 309.677 316.128 322.580 329.032 335.483 341.935 348.386 354.838 361.290 367.741 374.193 380.644...
  • Page 43 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Volume Cubic inches to cubic centimeters (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...
  • Page 44 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator U.S. Gallons to liters U.S. U.S. 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 37.8543 41.6397 45.4251 49.2106 52.9960 56.7814 60.5668 64.3523 68.1377 71.9231 75.7085 79.4940 83.2794 87.0648 90.8502 94.6357 98.4211 102.2065 105.9920 109.7774 113.5628 117.3482 121.1337 124.9191 128.7045 132.4899 136.2754 140.0608 143.8462 147.6317 151.4171 155.2025 158.9879 162.7734 166.5588 170.3442 174.1296 177.9151 181.7005 185.4859...
  • Page 45 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator U.K. Gallons to Liters 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 45.4590 50.0049 54.5508 59.0967 63.6426 68.1885 72.7344 77.2803 81.8262 86.3721 90.9180 95.4639 100.0098 104.5557 109.1016 113.6475 118.1934 122.7393 127.2852 131.8311 136.3770 140.9229 145.4688 150.0147 154.5606 159.1065 163.6524 168.1983 172.7442 177.2901 181.8360 186.3819 190.9278 195.4737 200.0196 204.5655 209.1114 213.6573 218.2032 222.7491 227.2950 231.8409 236.3868 240.9327 245.4786 250.0245 254.5704 259.1163 263.6622 268.2081...
  • Page 46 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Weight Pound to Kilogram lbs. lbs. 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 4.536 4.989 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154 13.608 14.061 14.515 14.968...
  • Page 47 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Newton to Kilogram 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 30.592 31.611 32.631 33.651 34.670 35.690...
  • Page 48 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Pressure Lb/in² to Kg/cm² lb/in (psi) kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm kg/cm (psi) 0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5625 0.6328 0.7031 0.7734 0.8437 0.9140 0.9843 1.0546 1.1249 1.1952 1.2655 1.3358 1.4061 1.4764...
  • Page 49 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Kg/cm² to Kpa 98.1 196.1 294.2 392.3 490.3 588.4 686.5 784.5 882.6 980.7 1078.7 1176.8 1274.9 1372.9 1471.0 1569.1 1667.1 1765.2 1863.3 1961.3 2059.4 2157.5 2255.5 2353.6 2451.7 2549.7 2647.8 2745.9 2843.9 2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6 3922.7 4020.7 4118.8 4216.9 4314.9 4413.0 4511.1 4609.1 4707.2 4805.3 4903.4 5001.4 5099.5 5197.6 5295.6 5393.7 5491.8 5589.8 5687.9 5786.0 5884.0 5982.1 6080.2 6178.2 6276.3 6374.4 6472.4 6570.5 6668.6 6766.6...
  • Page 50 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Torque Ft·lbs to Kg·m ft·lbs 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 1.383 1.521 1.659 1.797 1.936 2.074 2.212 2.350 2.489 2.627 2.765 2.903 3.042...
  • Page 51 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Kg·m to N·m kg·m 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 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 196.13 205.94 215.75 225.55...
  • Page 52 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 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 fi gures. These fi g- ures refer to the temperature in either Fahrenheit or Centigrade degrees.
  • Page 53 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 1°C = 33.8°F °C °C °F °F °C °C °F °F °C °C °F °F °C °C °F °F -11.7 11 11 51.8 114.8 27.2 177.8 -40.0 -40.0 -11.1 53.6 116.6 27.8 179.6 -37.2 -31.0 -10.6 55.4 118.4...
  • Page 54 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator Shop Manual - June 2013 1-41 https://www.tractormanualpdf.info/...
  • Page 55 Introduction SY195/205/215/225C9 Crawler Hydraulic Excavator 1-42 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 56: Shop Safety

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator Shop Safety 2 Shop Safety 2.1 Hazard Alert Information ..................2-3 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.................
  • Page 57 Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.25 Battery Hazards ..................2-20 2.2.26 Jump-Start Safety ..................2-21 2.2.27 Disconnecting the System Power .............. 2-21 2.2.28 Lockout/tagout ................... 2-22 2.2.29 Sequence of Procedures ................2-22 2.2.30 Chemical hazard ..................2-24 2.2.31 Material Safety Data Sheets (MSDS) ............2-24 2.3 Precautions for sling work and giving signals ............

  • Page 58: Hazard Alert Information

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2 SHOP SAFETY 2.1 Hazard Alert Information Most accidents are usually caused by the fail- ure to follow fundamental repair procedures and safety rules for the system under repair. To avoid accidents it is important to read and understand all information outlined in this manual before performing repairs on the ma- chine system.
  • Page 59 This symbol is used in a graphic to alert the user to not do something. SANY cannot predict every circumstance that might involve a potential hazard in a repair of the machine. Therefore the safety message in this manual and on the machine may not in- clude all possible safety precautions.
  • Page 60 In no event should you or others engage in prohibited uses or actions as described in this manual. ● SANY delivers machines that comply with all applicable regulations and standards of the country to which the machines have been shipped.

  • Page 61: General Shop Safety

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2 General Shop Safety It's important to establish good shop safety rules for everyone who enters or uses the shop area. Implementing shop safety rules will keep employees safe and provide the most productive environment for working or learning.

  • Page 62: Rules And Shop Behavior

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.1 Rules and shop behavior ● Study all shop rules relating to the proce- dure carefully and constantly apply them. When in doubt about any task, get help! DO NOT take chances. ● Know your job. It is foolish, and often di- sastrous, to make repairs to a machine without first receiving proper instructions.

  • Page 63: Shop Liquids Storage

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.3 Shop Liquids Storage ● Liquids, cleaning solvents or machine flu- ids should be properly stored in an area away from work locations. These storage areas should be ventilated to an outdoor location to avoid any vapor accumulation in a confi...

  • Page 64: Jacking Up The Machine

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.5 Jacking Up the Machine ● If you will be working under the machine always use approved jack stands that will support the weight of the machine you are working on. ● Never rely on the hydraulics of the ma- chine or a hydraulic jack to support the machine during repairs.

  • Page 65: Removing Attachments

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.7 Removing Attachments ● If you will be removing large heavy attach- ments from the machine, always be sure to use the correct lifting equipment rated for the capacity of the load you will be lifting. ●...

  • Page 66: Hoisting A Load

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator ● Before starting the work, thoroughly check the tools, machine, forklift, crane, service car, etc. ● Keep your tools clean, and when the job is complete, take inventory of the tools you were using to be sure no tools were left in the machine.

  • Page 67: Appropriate Working Apparel

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.11 Appropriate Working Apparel Improper or loose clothing, casual dress cloth- ing, jewelry, incorrect shoes or long hair can result in possible injury. Make a list of the types of clothing that are not allowed in the shop area.

  • Page 68: Two People When Engine Running

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.13 Two people when engine run- ning In order to prevent injury, do not perform the service while the engine is running. If the ser- vice must be performed while the engine is running, operate only when two people are on the spot and follow the regulations below: ●...

  • Page 69: Aligning Parts Or Components

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.15 Aligning Parts or Components ● Be careful when installing or aligning parts or components. ● Avoid using your fi ngers or hands to posi- tion holes or part mating surfaces, serious injury could result if your hand or fingers should get ought between the surfaces.

  • Page 70: Running The Machine

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.18 Running the Machine Run the machine during repair procedures ONLY if directed to do so in this shop manual. If the machine must be run when making re- pairs, it is important to follow some basic safe- ty rules.

  • Page 71: Accumulator

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.19 Accumulator If the machine is equipped with an accumula- tor charged with high-pressure nitrogen gas, it is important to follow these basic precautions. ● Do not disassemble the accumulator. ● Never expose the accumulator to high heat or open fl...

  • Page 72: Track Recoil Springs

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.21 Track Recoil Springs If you are making repairs to a machine equipped with tracks, always be aware of the dangers involved with track recoil springs. This spring is under extreme pressure at all times. If it is disassembled by mistake, the spring may fl...

  • Page 73: Safe Work Preparations

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.23 Safe Work Preparations Before starting any repairs, be sure the ma- chine is sitting on a level stable surface. Lower all the work equipment to a safe and stable position on the ground. Turn the engine OFF and neutralize the work equipment con- trols by rotating them to the left and right (joy- stick control) or moving them back and forth...

  • Page 74: Mounting And Dismounting

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.24 Mounting and Dismounting It is important to follow these procedures when mounting or dismounting the equipment: ● Use all hand-holds and step plates on your equipment. ● Never jump off or onto the equipment. ●...

  • Page 75: Battery Hazards

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.25 Battery Hazards Working around batteries always poses a haz- ard, especially if the battery has been in ser- vice for a long period of time. Listed below are some basic precautions to be aware of when servicing or working around batteries.

  • Page 76: Jump-Start Safety

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.26 Jump-Start Safety When using jumper cables to start the ma- chine, connect the positive (+) jumper first, then the negative (-) jumper to a remote loca- tion on the chassis away from the battery. CAUTION Never use a welder or a machine with a higher voltage system to jump-start the...

  • Page 77: Lockout/Tagout

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.2.28 Lockout/tagout Due to the size and complexity of this ma- chine, Lockout and Tagout procedures may be required by your company to ensure the safety of yourself and others involved in the repair process of the machine. While work is in progress, all power sources must be disabled, locked and tagged with a warning label.
  • Page 78 Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator Locking out of service 1. Notify all employees who may be poten- tially affected by the repair process on the machine. 2. Secure the machine in a safe position. If DANGER equipped, set the parking brake or hydrau- lic lock lever in the PARK or LOCKED posi- DO NOT OPERATE tion.

  • Page 79: Chemical Hazard

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Remove the Lockout/Tagout equipment and any additional alert equipment and re- energize the machine for return to service. 2.2.30 Chemical hazard Exposure to hazardous chemicals pose a serious danger if released or mishandled. Handling hazardous materials often releases substances that could pose a hazard.

  • Page 80: Precautions For Sling Work And Giving Signals

    Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2.3 Precautions for sling work and giving signals 1. Only one appointed worker is allowed to give signals and co-workers must commu- nicate with each other frequently. The ap- pointed signal person must give specified signals clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily.
  • Page 81 Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator When hoisting a load with 2 or more ropes, the force subjected to each rope will in- crease with the hanging angle. The table below shows the variation of allowable 19.6 load in kN {kg} when hoisting is made with 18.6 2000 16.7...
  • Page 82 Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator ● Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.
  • Page 83 Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator Selecting wire ropes 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 11.5 13.7 12.5...
  • Page 84 Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator Shop Manual - June 2013 2-29 https://www.tractormanualpdf.info/...
  • Page 85 Shop Safety SY195/205/215/225C9 Crawler Hydraulic Excavator 2-30 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 86: Specifi Cations

    Specifi cations SY195/205/215/225C9 Crawler Hydraulic Excavator Specifi cations 3 Specifi cations 3.1 Dimensions ......................3-3 3.2 Working Ranges ...................... 3-4 3.3 Technical Specifi cations ................... 3-5 3.4 Weight Table ......................3-8 3.5 Recommended Oil, Fuel and Coolant..............3-9 3.6 Capacity Table ....................... 3-10 3.7 Engine Performance Curve ..................3-11 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 87 Specifi cations SY195/205/215/225C9 Crawler Hydraulic Excavator 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.

  • Page 88: Dimensions

    Specifi cations SY195/205/215/225C9 Crawler Hydraulic Excavator 3 SPECIFICATIONS 3.1 Dimensions CJ13032601-1 Unit: mm (ft, in) Item SY195C-9 SY205C-9 SY215C-9 SY225C-9 Overall length (shipping) 9560 {31'4''} 9680 {31'9''} 9680 {31'9''} 9680 {31'9''} Overall width 2800 {9'2''} 2800 {9'2''} 2980 {9'9''} 2980 {9'9''} Overall height (Shipping) 3250 {10'8''} 3440 {11'3''}...

  • Page 89: Working Ranges

    Specifi cations SY195/205/215/225C9 Crawler Hydraulic Excavator 3.2 Working Ranges CJ13032602-1 Unit: mm (ft, in) Item SY195C-9 SY205C-9 SY215C-9 SY225C-9 Max. cutting height 9410 {30'10''} 9570 {31'5''} 9570 {31'5''} 9570 {31'5''} Max. dumping height 6490 {21'4''} 6700 {21'12''} 6700 {21'12''} 6700 {21'12''} Max.

  • Page 90: Technical Specifi Cations

    Specifi cations SY195/205/215/225C9 Crawler Hydraulic Excavator 3.3 Technical Specifi cations Machine model SY195C-9 SY205C-9 SY215C-9 SY225C-9 Bucket capacity m³ Operating weight 21000 21200 21800 22600 Max. bucket digging force Max. arm digging force Swing speed Travel speed (Hi/Lo) km/h 5.4/3.3 5.4/3.3 5.4/3.3 5.4/3.3...
  • Page 91 Specifi cations SY195/205/215/225C9 Crawler Hydraulic Excavator Engine Item Specifi cation Engine model 6D34TLE2A Type In-line 6-cylinder; water-cooled, 4-cycle diesel engine Combustion chamber type Direct injection Valve mechanism Max. output power kW{PS}/rpm 114{155}/2050 Max. torque N·m{kgf·m}/rpm 590{60}/1400 Bore×Stroke φ104×115 Total displacement cm³{L} 5860{5.860} Compression ratio...
  • Page 92 Specifi cations SY195/205/215/225C9 Crawler Hydraulic Excavator Travel motor Maker Model MAG-170VP-3400E Variable displacement piston type Type (w/ brake valve and parking brake) Weight Equivalent displacement cm³/rev q x i Large displacement q1 cm³/rev 130.4 Motor displacement q Small displacement q2 cm³/rev 74.9 Speed reduction rate i...

  • Page 93: Weight Table

    Specifi cations SY195/205/215/225C9 Crawler Hydraulic Excavator 3.4 Weight Table Unit: kg Machine Model SY195C-9 SY205C-9 SY215C-9 SY225C-9 Engine Radiator assembly Hydraulic tank assembly (w/o hydraulic oil) Fuel tank assembly (w/o fuel) Revolving frame 1770 1770 1770 1770 Operator cab Operator seat & control console Counterweight 3900 3900...

  • Page 94: Recommended Oil, Fuel And Coolant

    Specifi cations SY195/205/215/225C9 Crawler Hydraulic Excavator 3.5 Recommended Oil, Fuel and Coolant Ambient temperature Fluid Reservoir 122°F type 50°C SAE 30 SAE 10W Engine oil pan SAE 10W-30 SAE 15W-40 Swing machinery Engine oil case Idler SAE 30 Track roller Carrier roller SAE 10W SAE 10W-30...

  • Page 95: Capacity Table

    SY195/205/215/225C9 Crawler Hydraulic Excavator ● 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. 3.6 Capacity Table Unit: L {US Gal}...

  • Page 96: Engine Performance Curve

    Specifi cations SY195/205/215/225C9 Crawler Hydraulic Excavator 3.7 Engine Performance Curve Testing condition: 1) Temperature: 298K, one standard atmospheric pressure. 2) No fan. N·m Torque Power output g/kw·h Fuel consumption 1000 1200 1400 1600 1800 2000 Engine speed min ZX215-1001003 Shop Manual - June 2013 3-11 https://www.tractormanualpdf.info/...
  • Page 97 Specifi cations SY195/205/215/225C9 Crawler Hydraulic Excavator 3-12 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 98: Structure And Function

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Structure and Function 4 Structure and Function 4.1 Engine and Cooling System ..................4-5 4.1.1 Engine-related parts..................4-5 4.1.2 Radiator and intercooler................. 4-6 4.2 Power Train......................4-7 4.2.1 Power transmission system ................4-7 4.2.2 Final drive assembly ..................
  • Page 99 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.2 Operating principle ..................4-48 4.5.2.1 When spool is in neutral position ............4-48 4.5.2.2 Travel ....................4-50 4.5.2.3 Arm ...................... 4-51 4.5.2.4 Boom ....................4-56 4.5.2.5 Bucket ....................4-59 4.5.2.6 Swing ....................4-61 4.5.2.7 Option ....................
  • Page 100 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7.4.1 Refrigeration cycle diagram .............. 4-134 4.7.4.2 Heating cycle diagram ..............4-134 4.7.5 Compressor ....................4-135 4.7.6 Clutch ......................4-137 4.7.8 Condenser ....................4-138 4.7.7 Expansion valve ..................4-138 4.7.9 Evaporator ....................4-139 4.7.10 Receiver tank ...................
  • Page 101 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.11.4 Coolant temperature sensor ............4-195 4.9.11.5 Fuel level sensor ................4-196 4.9.11.6 Oil pressure switch ................4-197 4.10 Monitoring System ..................... 4-198 4.10.1 Machine monitor ..................4-199 4.10.2 Monitor functions..................4-200 4.10.3 Monitor operation ..................4-203 WARNING Read and understand all safety precau- tions and instructions in this manual be-...

  • Page 102: Engine And Cooling System

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4 STRUCTURE AND FUNCTION 4.1 Engine and Cooling System 4.1.1 Engine-related parts ZX215-1002001 Specifi cation Front engine mount Oil capacity: 22 L Fuel fi lter Start motor Rubber damper assembly Rear engine mount Muffl...

  • Page 103: Radiator And Intercooler

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.1.2 Radiator and intercooler WX215-1204009G Radiator outlet hose Specifi cations Radiator inlet hose Radiator assembly: Radiator ZH860×385×1050-S70Y75Z20Q/SY015 Intercooler air intake Aluminum pipe, belt-type radiator Reserve tank Radiator and oil cooler in parallel connection; Intercooler intercooler in series connection with radiator Intercooler air outlet...

  • Page 104: Power Train

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.2 Power Train 4.2.1 Power transmission system ZX215-1002003 Swing motor Accumulator Swing reducer Control valve Swing bearing Final drive AS Idler Hydraulic pump Central swivel joint 10) Engine Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 105: Final Drive Assembly

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.2.2 Final drive assembly Final drive AS (KYB) 73±3.6 N·m 205±10 N·m 59±4.9 N·m 157±8 N·m ZX215-1002004-1 ZX215-1002005 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 106 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Cylinder GP No. 2 sun gear (No. of teeth: 19) Shaft 10) No. 2 planetary gear (No. of teeth: 36) Gear hub (No. of teeth: 85) 11) Seal ring No. 2 planetary carrier 12) Travel motor No.
  • Page 107 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Final drive AS (Daewoo) 14 15 4 10 WX215-1204010G O-ring 13) Planetary gear shaft 25) Seal ring Mandrel 14) Sun gear 26) O-ring Float seal 15) Snap ring 27) Thrust washer Gear carrier 16) Planetary gear 28) Thrust washer 17) Needle bearing...

  • Page 108: Swing Machinery

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.2.3 Swing machinery 59~74 Nm ZX215-1002007 Shop Manual - June 2013 4-11 https://www.tractormanualpdf.info/...
  • Page 109 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Plug 11) No. 2 planetary gear GP Oil seal 12) No. 2 planetary gear (No. of teeth:17) Self-aligning bearing 13) Spring pin Ring gear (No. of teeth:52) 14) Swing reducer screw plug No. 2 planetary carrier 15) Grease fi...

  • Page 110: Swing Bearing

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.2.4 Swing bearing 549±50 Nm 549±50 Nm ZX215-1002008 Swing bearing inner race (Teeth: 91) Specifi cations Ball Reduction ratio: 91/13= 7 Swing bearing outer race Amount of fi lled grease: 13±1 Kg a. Inner race soft zone S position b.

  • Page 111: Undercarriage And Frame

    Track frame the basic structure is the same. Carrier roller Sprocket Model Q'ty (One side) Track roller SY195C9 Track shoe SY205C9 Center guard SY215C9 Front guard SY225C9 4-14 Shop Manual - June 2013...
  • Page 112 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Standard track shoe Model SY195C9 SY205C9 SY215C9 SY225C9 Item Shoe width(mm) Link pitch(mm) Q'ty (One side) Unit: mm Check item Criteria Remedy Standard size Tolerance Repair limit Vertical width of Track frame —...

  • Page 113: Idler

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.3.2 Idler 157~255 Nm W13081901 4-16 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 114 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Unit: mm Check item Criteria Remedy Standard size Repair limit Outside diameter of protru- sion — Outside diameter of tread Build-up Thickness of tread welding or replace Difference of tread Total width — Width of tread 39.5 —...

  • Page 115: Carrier Roller

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.3.3 Carrier roller ZX215-1002011 Unit: mm Check item Criteria Remedy Standard size Repair limit Outside diameter of fl ange — Outside diameter of tread Width of tread — Thickness of tread 41.5 Width of fl ange —...

  • Page 116: Track Roller

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.3.4 Track roller 549±59 Nm W13081902 Unit: mm Check item Criteria Remedy Standard clearance Repair limit Outside diameter of fl ange — Outside diameter of tread Build-up weld- Thickness of tread 46.5 40.5 ing or replace Total width —...

  • Page 117: Track Shoe

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.3.5 Track shoe W13100801 4-20 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 118 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Unit: mm Check item Criteria Remedy Standard size Repair limit Link pitch Reverse or replace Standard size Repair limit Outside diameter of bushing 59.45 53.7 Thickness of bushing metal 10.75 5.75 Standard size Repair limit Repair or replace Link height...
  • Page 119 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Unit: mm Check item Criteria Remedy Tightening torque (Nm {kgm}) Retightening angle (°) a. Regular link Triple grouser 750±22.5 120±10 shoe {62.5±2.3} Shoe bolt Retighten Tightening torque Retightening angle Lower limit torque (Nm {kgm}) (°) (Nm {kgm}) b.

  • Page 120: Triple Grouser Shoe

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.3.6 Triple grouser shoe ZX215 1002014 Unit: mm Check item Criteria Remedy Standard size Repair limit Height Thickness 29.5 Length of base Build-up welding or replace 20.5 Length at tip Standard size Repair limit Thickness Shop Manual - June 2013 4-23...

  • Page 121: Hydraulic System, Part 1

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.4 Hydraulic System, Part 1 4.4.1 Hydraulic equipment layout Bucket cylinder Arm cylinder Boom cylinder Hydraulic tank Hydraulic oil fi lter Control valve Hydraulic pump Radiator Accumulator 10) Left travel motor 11) Right travel motor 12) Swing motor 13) Lockout lever 14) Left pilot valve...
  • Page 122 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator W13081903 Shop Manual - June 2013 4-25 https://www.tractormanualpdf.info/...

  • Page 123: Hydraulic Tank And Fi Lter

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.4.2 Hydraulic tank and fi lter ZX215-1002017 Hydraulic tank Specifi cations Level gauge Tank capacity: 239 L (63 US gal) Oil fi ller cap Available capacity: 172 L (45.5 US gal) Return oil fi lter element Breather valve Bypass valve Filter fi...

  • Page 124: Hydraulic Pump

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.4.3 Hydraulic pump Type: K3V112DTP1N9R {36N·m} {36N·m} {16N·m} {36N·m} Clockwise DR1{170N·m} DR2{170N·m} Psv2 {36N·m} DR3{170N·m} DR4{170N·m} ZX215-1002018 Shop Manual - June 2013 4-27 https://www.tractormanualpdf.info/...
  • Page 125 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 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.
  • Page 126 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ZX215-1002019 Front shaft End cover Min. delivery adjusting screw 10) Rear shaft Front casing 11) Rear casing Swash plate 12) Gear pump Slipper 13) Piston Plunger 14) Max. delivery adjusting screw Cylinder block 15) Gear shaft Valve plate 16) Driving pin...
  • Page 127 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ZX215-1002020 Function ● The torque of the engine is transmitted to the pump shaft (1), and drives cylinder block (7) to rotate. At the same time, nine plungers (6) slide along the thrust plate (8). Plunger (6) moves back and forth inside cylinder block (7) and pressurized oil is sucked and discharged alternatively.
  • Page 128 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Structure ● Cylinder block (7) is supported to shaft (1) by spline (17). ● Shaft (1) is supported by front and rear bearings (18). ● Tip of plunger (6) is shaped as a concave ball and slipper (5) is caulked to it to form one unit.
  • Page 129 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Operation of pump ● Cylinder block (7) rotates together with shaft (1), and slipper (5) slides on fl at sur- face (A). ● When this happens, swash plate (4) moves along cylindrical surface (B), so angle (a) between central line (X) of swash plate (4) and the axial direction of cylinder block (7) changes.
  • Page 130 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Control of delivery ● If swash plate angle (a) becomes larger, the difference between volumes (E) and (F) becomes larger and pump delivery (Q) increases. ● Piston (13) is used for changing swash plate angle (a).

  • Page 131: Pilot Pump

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.4.4 Pilot pump NOTE: For the location of the pilot pump on the machine, see “Hydraulic equipment layout” on page 4-24. ZX215-1002025 307: Valve stem 361: Body 308: Valve base 433: Screw 309: Retainer 434: Screw 310: Spring 435: screw...

  • Page 132: Regulator

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.4.5 Regulator (KR3G-0E11-AV) NOTE: Both the front pump and the rear pump are equipped with a regulator. For the location of the hydraulic pump, see “Hydraulic equipment layout” on page 4-24. SKY5P - 17 - S 651 652 733 (KDRDE5K) Tightening tor ue...
  • Page 133 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Category Part No. Part name Q’ty Remark Hexagon socket head locating screw Hexagon nut JIS B 1181 N-M10 O-ring O-ring O-ring O-ring O-ring O-ring Cover plate Spool valve Sleeve Guide spring Pilot plunger Pf pilot sleeve Adjusting roller Spring seat...

  • Page 134: Control Mechanism Makeup

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Function ● The regulator controls the pump discharge amount according to the command signal pressure, keeping the driving power of the pump lower than the engine output. ● Pumps 1 and 2 are both equipped with a regulator.

  • Page 135: Adjustment Of The Regulator

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.4.5.2 Adjustment of the regulator 548 531 ZX215-1002028 531: Inclination pin SKY5P 532: Servo piston - 17 - S 548: Feedback pin 806: Retaining nut 808: Retaining nut 953: Adjusting screw 954: Adjusting screw ●...
  • Page 136 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Maximum flow adjustment (pump block side) ● Loosen the hexagon nut (808), and tighten (or loosen) hexagon socket head locating screw (954). No control features except the maximum fl ow changes. Command current I ZX215-1002033 Minimum flow adjustment (pump block side)

  • Page 137: Operation

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Flow control feature adjustment ● After hexagon nut (810) is loosened, tight- en (or loosen) the hexagon socket head lo- cating screw (924) to carry out adjustment. When the hexagon socket head locating screw (924) is being tightened, the control diagram (as shown) will move to the right.
  • Page 138 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Action of increasing fl ow rate ● When command current I increases, the solenoid proportional pressure reducing valve secondary pressure P2 will increase, and the spool valve (652) will move the right with the help of the guide piston (643). When a relative balance between the right- ward hydraulic force and the spring force of guide spring (646) is achieved, spool...
  • Page 139 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Action of reducing fl ow rate ● When command current I decreases, the solenoid proportional pressure reducing valve secondary pressure P2 will decrease, and guide piston (643) will move to the left. However, as spool valve (652) moves, out- put pressure P1 is introduced into the large diameter chamber of the servo piston via the port cl.

  • Page 140: Hydraulic System, Part 2

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5 Hydraulic System, Part 2 4.5.1 Control valve NOTE: For the location of the control valve on the machine, see “Hydraulic equipment layout” on page 4-24. (XAo) XBp2 XAa1 XAa2 XAb1 XBtr XBtL (PTa) XBtr PnA2...
  • Page 141 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator XAtr : R. travel (reverse) pilot port XBp2: Bypass cut spool pilot port (P2 side) XBtr : R. travel (forward) pilot port XAb2: Boom confl uence (UP) pilot pressure (XAo): (Option pilot port) Psp: Swing priority pilot port (XBo): (Option pilot port)
  • Page 142 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Hydraulic circuit diagram (with bucket confl uence function) (P3) (P0) CMR2 CMR1 XBtr TRAVEL R TRAVEL (PTa) STRAIGHT XAtr SWING TRAVEL L XBtl 4- 2.1 XAtl SWING PRIORITY XBb1 BOOM1 XAb1 XAb2 BOOM2 (ROD) (HEAD) (XBo)

  • Page 143: Operating Principle

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.2 Operating principle 4.5.2.1 When spool is in neutral position [Main circuit] ● When all the spools are in neutral position, ● Working oil supplied from the hydraulic working oil supplied from the hydraulic pump (Rear) fl...
  • Page 144 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator (PTa) XBtL XAtL XBb1 XAbL XBa2 XAa2 (P3) XAtr XBtr XAb2 (XAo) (XBo) XAa1 XBa1 (XBp1) XBp2 ZX225-1102011 Shop Manual - June 2013 4-47 https://www.tractormanualpdf.info/...

  • Page 145: Travel

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.2.2 Travel ● Likewise, when pressure at port XBtr for [Pilot circuit] the right travel spool (301) rises, neutral ● When the left or right travel spool is bypass (2) at arm 1 side is closed, and switched, the side bypass circuit is closed working oil supplied from the hydraulic and pressure at port Py (travel signal port)

  • Page 146: Arm

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.2.3 Arm (1) Arm OUT ● On the other hand, working oil from port [Pilot circuit] P1 is introduced into neutral bypass (2) via ● When the arm 2 spool (306) is switched, main passage (1).
  • Page 147 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 256-101 XAa2 XAa1 ZX225-1102013 4-50 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 148 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator (2) Arm IN from neutral bypass pushes open the cone [Pilot circuit] valve (511) of the check valve and flows ● When the arm 2 spool (306) is switched, into the arm 2 spool (306) via the U pas- the side path is closed and pressure at sage.
  • Page 149 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● Light load Arm weight XBa2 (302-317) XBa1 ZX225-1102014 4-52 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 150 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● When pressure at arm cylinder head end (H) rises XBa2 (302-317) XBa1 (257-211) ZX225-1102015 Shop Manual - June 2013 4-53 https://www.tractormanualpdf.info/...

  • Page 151: Boom

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.2.4 Boom (1) Boom UP ● At the same time, pilot pressure oil is also [Pilot circuit] supplied to port XAb2 and boom 2 spool ● When the boom 1 spool (303) is switched, (307) moves to the right.
  • Page 152 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator XAb1 XAb2 ZX225-1102016 Shop Manual - June 2013 4-55 https://www.tractormanualpdf.info/...
  • Page 153 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator (2) Boom DOWN passage. Then, it flows into the periphery [Pilot circuit] of boom 1 spool (303) and is supplied into ● When the boom 1 spool (303) is switched, the boom cylinder rod end (R) via port Bb. the side path is closed and pressure at port Px (work equipment signal port) rises.

  • Page 154: Bucket

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.2.5 Bucket (1) Bucket DIG Then, it fl ows into the periphery of bucket [Pilot circuit] spool (304) and is supplied into the bucket ● When the bucket spool (304) is switched, cylinder head end (H) via port Ak. the side path is closed and pressure at port Px (work equipment signal port) rises.
  • Page 155 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator (2) Bucket DUMP tral bypass is cut off by switching bucket [Pilot circuit] spool (304). Therefore, working oil in the ● When the bucket spool (304) is switched, parallel passage pushes open the cone the side path is closed and pressure at port valve (511) of the check valve, and flows Px (work equipment signal port) rises.

  • Page 156: Swing

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.2.6 Swing (1) Swing operation (305). Therefore, working oil in the parallel [Pilot circuit] passage pushes open the logic cone valve ● When the swing spool (305) is switched, (2540-101) of the swing logic valve GP, the side path is closed and pressure at port and fl...
  • Page 157 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator (2) Swing priority function ● Switch swing priority spool (311). The [Pilot circuit] opening area of the swing priority reduces. ● Pilot pressure oil is supplied to port Psp As a result, working oil from arm 1 spool and swing priority spool (311) is switch.
  • Page 158 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.2.7 Option Option spool is used to control optional work equipment attachment. (1) Operation (309). Therefore, working oil in the parallel [Pilot circuit] passage pushes open the cone valve (511) ● When the option spool (309) is switched, of the check valve, and fl...

  • Page 159: Travel Straight

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.2.8 Travel straight When travel spool (301) and other spool are [Main circuit] operated simultaneously. ● W h e n s t r a i g h t t r a v e l s p o o l ( 3 0 8 ) i s The following case shows when travel spool switched, the right/left travel spool (301) (301) and swing spool (305) are operated si-...

  • Page 160: Lock Valve Function

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.2.9 Lock valve function ● 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).
  • Page 161 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator (2) Boom DOWN operation ● When boom DOWN is operated, pilot pres- into spring chamber (RH). In addition, oil sure oil is supplied to port PbL and port in the spring chamber (RH) fl ows into drain XBb1.

  • Page 162: Main Relief Valve Function

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.2.10 Main relief valve function 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- ●...

  • Page 163: Port Relief Valve Function

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.2.11 Port relief valve function The port relief valve is installed between the tank port and low-pressure path. In addition to the function as relief valve, it has also the function of anti-cavitation oil complement check valve.
  • Page 164 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● When pressure in passage (P) exceeds the elastic force of spring (621), cone valve (611) is pushed open. Therefore, working oil fl ows through hole (C) via the periphery of cone valve (611) and enters low-pres- sure path (R).
  • Page 165 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● Opening of cone valve (611) causes pres- sure in chamber (B) to drop and valve rod (511) is open. In this way, working oil in passage (P) flows into low-pressure path (R) directly. ZX225-1102031 ZX225-1102032 4-68...
  • Page 166 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator (2) Anti-cavitation oil complement check valve ● When negative pressure is formed in path (P), working oil is supplied from path (R). When pressure in path (R) gets higher than pressure in path (P), valve seat (541) moves to the right direction.

  • Page 167: Section View

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.5.3 Section view 273×10 (Po) TRAVEL XAtr TRAVEL R STRAIGHT 273×12 XAtl TRAVEL L SWING XAb2 XBbl BOOM1 BOOM2 978×2 BUCKET OPTION XBa1 XBa2 ARM1 ARM2 (BYPASS CUT1) (XBp1) PnA2 BYPASS CUT2 PCV1 XBa2 (XBp1) View O-O...
  • Page 168 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Section A-A, N-N 101 159 (PTa) XAtL XBtL XBb1 XAbL XBa2 XAa2 514 521 561 551 561 521 View A-A 151 168 151 168 2-156 View N-N ZX225-1102036 Shop Manual - June 2013 4-71 https://www.tractormanualpdf.info/...
  • Page 169 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Section B-B (P3) XBtr XAtr XAb2 (XAo) (XBo) XAb1 XBa1 XBp2 (XBp1) View B-B ZX225-1102037 4-72 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 170 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Section C-C (Travel right, travel straight) TRAVEL TRAVEL RIGHT STRAIGHT XAtr CMR1 CMR2 XBtr (PTa) View C-C ZX225-1102038 Shop Manual - June 2013 4-73 https://www.tractormanualpdf.info/...
  • Page 171 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Section D-D (Swing, travel left) SWING TRAVEL LEFT XAtL XBtl View D-D ZX225-1102039 4-74 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 172 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Section E-E, L-L (Boom 1, boom 2) BOOM2 BOOM1 XBb1 XAb2 XAb1 SWING PRIORITY View E-E View L-L ZX225-1102040 Shop Manual - June 2013 4-75 https://www.tractormanualpdf.info/...
  • Page 173 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Section F-F (Option, bucket) BUCKET OPTION (XBo) 971×4 (Ao) (Bo) 971×4 (XAo) View F-F ZX225-1102041 4-76 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 174 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Section G-G (Arm 1, arm 2) XBa1 XBa2 LCAT2 XAa2 XAa1 View G-G ZX225-1102042 Shop Manual - June 2013 4-77 https://www.tractormanualpdf.info/...
  • Page 175 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Section H-H (Bypass cut 1, bypass cut 2) 612 169 162 152 158 154 164 152 162 162 164 154 158 152 162 164 154 169 612 162 152 PCV2 PCV1 XBp2 (XBp1) 163 262 331 337 373 372 331333 203 203 333 331 372 373 337 331 262 View H-H...
  • Page 176 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Mounting Mounting Part name Q’ty Part name Q’ty torque (N·m) torque (N·m) SPOOL ASS’Y, travel BLOCK, valve A straight BLOCK, valve B SPOOL, option 13~17 PLUG SPOOL, bypass cut 34~39 PLUG SPOOL, swing priority 220~250 PLUG SPRING...
  • Page 177 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Mounting Mounting Part name Q’ty Part name Q’ty torque (N·m) torque (N·m) O-RING O-RING O-RING O-RING 25~34 SCREW, hex, S,H,C 69~78 VALVE, main relief 98~120 SCREW, hex, S,H,C 69~78 VALVE, port relief SPOOL, travel 120~140 VALVE, port relief SPOOL ASS’Y, arm 1...

  • Page 178: Hydraulic System, Part 3

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6 Hydraulic System, Part 3 4.6.1 Swing motor NOTE: For the location of the swing motor on the machine, see “Hydraulic equipment layout” on page 4-24. ZX215-1002081 Main oil port 1. Relief valve Main oil port 2.
  • Page 179 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ZX215-1002082 Spacer Check valve spring 11) Plate Casing Check valve 12) Piston Disc Oil distribution plate 13) Drive shaft Brake spring Cylinder Shell 10) Brake piston 4-82 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 180: Swing Holding Brake

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.2 Swing holding brake ● Port PG is connected with the pilot gear pump directly, and a pressure of 3.9MPa is main- tained. Pump Main valve 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.

  • Page 181: Relief Valve Portion

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.3 Relief valve portion NOTE: For the location of the relief valve on the swing motor, see “Swing motor” on page 4-81. Structure ● The relief valve portion consists of relief valves (1) and (2), check valves (3) and (4). Function ●...
  • Page 182 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Operation 1. When swing begins (suppose pressur- ized oil enters Port A) From port M ● When the swing control lever is operated for right swing, pressurized oil from the pump is supplied to port (A) via control valve (5).

  • Page 183: Reverse Prevention Valve

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.4 Reverse prevention valve 4.6.4.1 Operation drawing NOTE: For the location of the reverse prevention valve on the swing motor, see “Swing motor” on page 4-81. Swing motor Swing control valve ZX215-1002087 Valve body Spool (B side) Spool (A side) Spring (B side)

  • Page 184: Explanatory Drawing Of Effects

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.4.2 Explanatory drawing of effects With reversal prevention valve :Without reversal prevention valve Reversal pressure Pressure MA Containment pressure Reversal pressure Pressure MB 1st reversal 2nd reversal Motor speed Reversal Start Brake Time ZX215-1002088 Outline ●...
  • Page 185 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Operation 1. When port (B) brake pressure is gener- ated ● Pressure (MB) is conducted to chamber (d) via the notch. The pressure compresses spring (6) by use of the difference in areas of circles (D1 >...

  • Page 186: Center Swivel Joint

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.5 Center swivel joint NOTE: For the location of the central swivel joint on the machine, see “Hydraulic equipment lay- out” on page 4-24. ZX215-1002092 Swing shaft Plug (ZG3/4) Dust seal Plug (ZG1/4) O-ring 10) Cover Swing body...
  • Page 187 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator From main valve BTL From main valve BTR From main valve ATL From main valve ATR To L. travel motor port (P1) To R. travel motor port (P2) To L. travel motor port (P2) To R.

  • Page 188: Travel Motor

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.6 Travel motor Model: TM40VD-A-99/163-1 NOTE: For the location of the travel motor on the machine, see “Hydraulic equipment layout” on page 4-24. WX215-1204014G Duo speed pilot hose port Drain port Pressure detection port Plug Pressure detection port Main oil port...
  • Page 189 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Explosive view 23 24 WX215-1204013G Flange, rear 16) Plug 31) Baffl e 46) Ball bearing H5 balance valve 17) Spool 32) Spheric bush 47) Spring spool 18) Spring 33) Timing plate 48) Piston Plug 19) Ball 34) Parking piston...
  • Page 190 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Model: MAG-170VP-3400E NOTE: For the location of the travel motor on the machine, see “Hydraulic equipment layout” on page 4-24. ZX215-1002132 Duo speed pilot hose port A. Mounting surface with sprocket Pm1: Pressure detection port B.
  • Page 191 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Connected to sprocket Mounted on the undercarriage Piston motor shaft ZX215-1002093 4-94 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 192: Operation Of Components

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.6.1 Operation of components Counterbalance valve Function ● When external load makes the rotating speed of the piston motor faster than the rated rotating speed of supplied delivery, this valve controls the speed of the motor and prevent over-speed of the motor in re- lation with the supplied delivery.
  • Page 193 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 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 Circuit B Circuit C2...
  • Page 194 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator B. When the motor is activated ● When hydraulic oil from the main pump damper chamber (A1) via orifi ce (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.
  • Page 195 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator C. Counterbalance function ● When the engine runs at an excessively high speed because of external force ap- plied on it, the motor may lose control. At this time, port P1 serves as the inlet side, and the pressure drops.
  • Page 196 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 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...
  • Page 197 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator E. Shuttle valve function for high pressure selection ● 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 fi...
  • Page 198 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Operation of parking brake 1) When travel begins ● As the travel lever is operated, pressurized oil from the pump activates counterbalance valve spool (10), opens the parking brake circuit, and flows to chamber A of brake piston (12).
  • Page 199 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Brake valve operation ● The brake valve consists of suction safety valve (8A) and counterbalance valve (18). Travel control valve Functions and operations of respective components are described below. ZX215-1002101 1) Counterbalance valve and check valve Function ●...
  • Page 200 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● The pressurized oil on the supply side fl ows to chamber (S1) via orifi ce (E1) and Travel control valve orifi ce (E2) of the spool (19). As the pres- sure in chamber (S1) goes above the spool selector pressure, spool (19) is pushed toward the right.
  • Page 201 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 2) Safety valve Function ● When the machine travel is stopped (or it is travelling downhill), the counterbalance valve closes the inlet and outlet circuits of the motor. Since the motor is rotated by inertial force, pressure in the motor outlet port side is abnormally increased, poten- tially resulting in damages on the motor...
  • Page 202 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 2. When starting travel (or when traveling at a constant speed) Travel control valve ● As the travel lever is operated, the pres- surized oil from the pump moves spool (19) toward right. The passage to the suction safety valve functions as a circuit which passes through notch (B2) of spool (19), producing large differential pressure.
  • Page 203 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator B. Damping function ● When the relief valve begins to function, damping piston (2-9-9) moves to the left. 2-9-2 Area S2 2-9-5 As a result, low pressure is maintained in spring chamber D. At this time, the loaded area of cone valve (2-9-2) is S1, and it is much larger than the normal set loaded area S1-S2 of the relief valve.

  • Page 204: Valve Control System

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.7 Valve control system ZX215-1002112 Shop Manual - June 2013 4-107 https://www.tractormanualpdf.info/...
  • Page 205 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Control lever position Travel PPC valve (1) HOLD L. travel control lever (2) Boom UP R. travel control lever (3) Boom DOWN Right PPC valve (4) Bucket DUMP Right joystick (5) Bucket DIG Accumulator (6) HOLD Transition block...

  • Page 206: Pilot Valve

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.8 Pilot valve 4.6.8.1 Work equipment and swing pilot valve 19~22Nm 64~73.5Nm ZX215-1002113 From pilot pump relief valve L.H. Pilot valve: Arm OUT R.H. Pilot valve: Boom DOWN L.H. Pilot valve: Arm IN R.H.
  • Page 207 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ZX215-1002114 Plunger Nut (for lever connection) Metering spring Joint Centering spring Plate Piston Retainer Disc 10) Valve body 4-110 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 208 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Operation 1. When in neutral ● Ports (A) and (B) of the control valve and ports (P1) and (P2) of the pilot valve are connected to drain chamber (D) via orifi ce (f) in plunger (1). 2.
  • Page 209 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 3. During fi ne control (When control lever is returned) ● When disc (5) starts to return, plunger (1) is pushed up by the force of centering spring (3) and the pressure at port (P1). ●...

  • Page 210: Travel Ppc Valve

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.8.2 Travel PPC valve ZX215-1002119 From pilot pump P4: R.H. forward P1: L.H. reverse P5: Travel signal P2: L.H. forward P6: Travel signal P3: R.H. reverse To tank Shop Manual - June 2013 4-113 https://www.tractormanualpdf.info/...
  • Page 211 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 37~30Nm 65~45Nm 8~6Nm 2，4 1，3 13~11Nm 8~6Nm ZX215-1002120 Plate Centering spring Body Metering spring Piston Valve Collar 4-114 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 212 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Operation 1. When in neutral ● Ports (A) and (B) of the control valve and ports (P1) and (P2) of the Pilot valve are connected to drain chamber (D) via orifi ce (f) in plunger (1). 2.
  • Page 213 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 3. Fine control (When control lever is returned) ● When lever (5) starts to return, plunger (1) is pushed up by the force of centering spring (3) and pressure at port (P1). ● Because of this, orifi ce (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.

  • Page 214: Solenoid Valve

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.9 Solenoid valve Pilot valve lock, travel speed, bucket confl uence, swing priority WX13060401 Travel hi/lo speed solenoid valve To oil tank Swing priority solenoid valve From accumulator and pilot pump Bucket confl uence solenoid valve To center swivel joint port Boom to arm priority solenoid valve To main valve port PsP...

  • Page 215: Accumulator

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.10 Accumulator ZX215-1002126 Gas plug Specifi cations Shell Gas capacity: 300 cm³ Poppet Holder Bladder Oil port 4-118 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 216: Pilot Oil Fi Lter

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.11 Pilot oil fi lter 型号 压力 精度 ZX215-1002127 Specifi cations Name plate Max. delivery: 40 L/min Head cover Filter fi neness: 10 μm O-ring Operating pressure: 20 Mpa Seal Max. operating pressure: 40 Mpa Filter Pressure loss: 0.05 Mpa Case...

  • Page 217: Pump Oil Pressure Sensor

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.12 Pump oil pressure sensor ZX215-1002128 Pressure connector Name plate Connector Vent hole Function ● 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.

  • Page 218: Hydraulic Cylinder

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.13 Hydraulic cylinder Boom cylinder 5340±50N·m 544.9±5.1kgm 56.9±10.7N·m 267±35N·m 5.8±1.1kgm 27.2±3.6kgm ZX215-1002129 Arm cylinder 7900±50N·m 806.1±5.1kgm 56.9±10.7N·m 367±35N·m 5.8±1.1kgm 37.4±3.6kgm ZX215-1002130 Bucket cylinder 5480±50N·m 559.2±5.1kgm 56.9±10.7N·m 267±35N·m 5.8±1.1kgm 27.2±3.6kgm ZX215-1002131 Shop Manual - June 2013 4-121 https://www.tractormanualpdf.info/...
  • Page 219 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 100 hours greasing Unit: mm Check item Criteria Remedy Tolerance Standard Standard Clearance Cylinder size clearance limit Shaft Hole -0.036 +0.222 Boom 0.083 – 0.312 0.412 Clearance between pis- Replace -0.090 +0.047 ton rod and bushing bushing -0.036 +0.222...

  • Page 220: Work Equipment

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.6.14 Work equipment ZX215-1002133 ZX215-1002134 Shop Manual - June 2013 4-123 https://www.tractormanualpdf.info/...
  • Page 221 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 100 hour greasing Unit: mm Check item Criteria Remedy Tolerance Standard Standard clear- Clearance Clearance between pin connect- size ance limit Shaft Hole ing boom and revolving frame and –0.036 +0.140 bushing 0.141 ~ 0.211 –0.071 +0.105 Clearance between pin connecting...
  • Page 222 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Arm dimension WX13060402 Shop Manual - June 2013 4-125 https://www.tractormanualpdf.info/...
  • Page 223 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Unit: mm SY195/205/215C-9 SY225C-9 Standard size Tolerance Standard size Tolerance +0.1 +0.1 φ80 φ80 ±0.5 ±0.5 -0.3 -0.3 -0.8 -0.8 -0.036 -0.036 φ90 φ90 -0.071 -0.071 ±1 ±1 ±0.8 ±0.8 ±1 ±1 2,911 ±2 2,911 ±2...
  • Page 224 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Bucket dimension WX13060403 Shop Manual - June 2013 4-127 https://www.tractormanualpdf.info/...
  • Page 225 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Unit: mm SY195/205/215C-9 SY225C-9 Standard size Tolerance Standard size Tolerance 457.5 ±0.5 457.5 ±0.5 ±0.5 ±0.5 91.8° — 91.8° — — — 1,483 — 1,483 — — — 45° — 45° — +0.2 +0.2 φ80 φ80...

  • Page 226: Air Conditioning System

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7 Air Conditioning System ZX215-1002137 Hot water piping A. Fresh air A/C compressor (DENSO.2) B. Recirculated air Refrigeration piping C. Warm air/cool air Condenser (SG447750-A040) Receiver tank (DENSO.4) Hot water return piping A/C unit assembly (SG443180-9320) Air duct Shop Manual - June 2013 4-129...

  • Page 227: A/C Components Layout Drawing

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7.1 A/C components layout drawing ZX215-1002138 Sunlight sensor Compressor Control panel Fresh air sensor Air conditioning unit Recirculated air sensor Condenser 4-130 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 228: Control Panel

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7.2 Control panel CZ205-1203020G OFF switch Auto mode switch Fan speed control switch Air circulation control switch Temperature control switch LCD display Air outlet mode switch A/C switch Shop Manual - June 2013 4-131 https://www.tractormanualpdf.info/...

  • Page 229: Circuit Diagram

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7.3 Circuit diagram 1.25B 1.25B 0.85B 0.50 1.25R 4-132 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 230 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Wire No. Diameter/Color code Wire color Wire No. Diameter/Color code Wire color Black 0.5VW Violet+white Br(R) Brown 0.5YB Yellow+black 0.85W White 0.5WO White+orange Red+blue 0.5PB Pink+black Green 0.5VR Violet+red 0.5BL Black+blue 0.5BG Black+green 0.5R Red+blue 0.5WY...

  • Page 231: Refrigeration Principle

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7.4 Refrigeration principle 4.7.4.1 Refrigeration cycle diagram Expansion valve Cool air Lo temp\Lo press liquid (Mist) Evaporator Cooling fan Blower Air in cab Out side fresh air Hi-temp hi-pres gas Hi-pres. Lo-pres. side side Compressor Hot air...

  • Page 232: Compressor

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7.5 Compressor ZX215-1002143 Stator Slipper Front radial bearing 10) Front cylinder block Thrust bearing 11) Piston Front radial bearing 12) Front cylinder head Rear cylinder head 13) Shaft seal Safety valve 14) Main shaft Rear cylinder block 15) Hub Swash plate...
  • Page 233 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 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.

  • Page 234: Clutch

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7.6 Clutch Rotor Stator coil Snap ring Ball bearing Stator Center piece ● The electromagnetic clutch is used to transmit moment of torsion. When the en- ZX215-1002145 gine is operating, the compressor may not be working.

  • Page 235: Condenser

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7.8 Condenser ZX215-1002146 Condenser core Refrigerant inlet Bracket Refrigerant outlet Bolt with gasket Function ● The condenser converts high-temperature, high-pressure gas refrigerant (16Kg/cm², about 80°C) to high-temperature and high- pressure liquid refrigerant (16Kg/cm², be- low 60°C) through radiating.

  • Page 236: Evaporator

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7.9 Evaporator Expansion valve Evaporator Operating principle ● The evaporator is a kind of heat exchanger that looks like a condenser. Hot air in the cab is conducted into the evaporator via the blower motor and undergoes heat ex- change with the surface of the evaporator.

  • Page 237: Pressure Switch

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7.11 Pressure switch O-ring Pressure Mobile contact point Hood Plug and fi xed contact Spring Chamber Diaphragm Function ● The pressure switch is installed between the receiver tank and the expansion valve (hi-pressure pipe). It is a combina- tion switch (Hi-Lo pressure combination switch).

  • Page 238: Fresh Air Sensor

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7.12 Fresh air sensor The fresh air sensor is installed beside the condenser or around the fresh air inlet. It mea- sures the temperature of outside air and it is composed of thermistors. Technical specifi...
  • Page 239 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 2. Refrigerant cycle ● After evaporation in the evaporator, refrigerant turns from gas into liquid via the compressor and the condenser, which fi nishes a refrigerant cycle. Compressor LO press. side (inlet): LO temp LO press. Gas Pressure/Temperature: 2Kg/cm²，...
  • Page 240 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 3. Feeding of refrigerant ● Filling method and volume: 1) Refrigerant: HFC-134a 2) Feeding volume: 850±50 g (for reference) 3) Feeding method: Feeding of liquid refrig- erant from the low-pressure end is not al- lowed.
  • Page 241 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Evacuation ● No moisture shall exit in the air condition- ing unit. Refrigerant (R134a) is soluble in water. Very small amount of moisture in the unit can cause the orifi ce of the expan- sion valve to ice up, or cause the compres- sor valve to rust.
  • Page 242 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Step 2: Evacuation 1) Open the high-pressure valve (HI) and low- pressure valve (LO) on the manifold pres- sure gauge. 2) Turn on the vacuum pump and evacuate for about 15 minutes. 3) When negative pressure reading on the gauge (degree of vacuum) reaches above 750 mmHg, turn off the vacuum pump and close the Hi-pressure valve and the Lo-...
  • Page 243 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Step 4: Leak check 1) Connect the green hose that is previously Valve connected to the vacuum pump to the fl uorine cylinder. OFF OFF 2) Connect the other end of the green hose to the pressure gauge.
  • Page 244 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 5. Refrigerant charging operation ● When evacuation is fi nished, add refrigerant into the cooling system as per the following in- struction: 75cm-Hg or more More than 15 min. Wait 5 min Pres. gauge normal Pres.
  • Page 245 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator CAUTION ● Do not operate the compressor when refrigerant charging is in progress. Otherwise, refrigerant will counterflow and cause the cylinder and hoses to ex- plode. ● Operating the compressor with no re- frigerant in the system will cause dam- age to the compressor.
  • Page 246 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 6. When refrigerant charging is finished, close the Lo-pressure valve of the mani- fold pressure gauge and the valve of the fl uorine cylinder. 7. Check carefully for air leaks with a leak detector.
  • Page 247 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Replace the fl uorine cylinder When the refrigerant in a cylinder is used up, replace the cylinder as per the following in- Handle struction: 1. Close the Hi- and Lo-pressure valves of the manifold pressure gauge. Air hose connector 2.
  • Page 248 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 6. Fault testing with manifold pressure gauge After the engine has been preheated, read the pressure value on the gauge under the following conditions: 1) Temperature at air inlet: 30 – 35°C 2) Engine speed: 1500 rpm 3) Fan speed: High 4) Temperature control: Minimum.
  • Page 249 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● Moisture in the refrigerating system Symptom: Intermittent refrigeration to non-refrigeration {cmHg kgf/cm {cmHg kgf/cm - 50 - 76 - 76 - 01 - 01 ZX215-1002168 Symptom Cause Analysis Remedy ● When the system is ●...
  • Page 250 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● Insuffi cient refrigeration Symptom: Insuffi cient refrigeration {cmHg kgf/cm {cmHg kgf/cm - 50 - 76 - 76 - 01 - 01 ZX215-1002169 Symptom Cause Analysis Remedy ● Pressure at both Hi- and ●...
  • Page 251 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● Defective refrigerant circulation Symptom: insuffi cient refrigeration {cmHg kgf/cm {cmHg kgf/cm - 50 - 76 - 76 - 01 - 01 ZX215-1002170 Symptom Cause Analysis Remedy ● Pressure at both ● Contaminant in the ●...
  • Page 252 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● Refrigerant not circulating Symptom: Non-refrigeration (intermittent refrigeration) {cmHg kgf/cm {cmHg kgf/cm - 50 - 76 - 76 - 01 - 01 ZX215-1002171 Symptom Cause Analysis Remedy ● Vacuum at Lo-pres- ● Moisture or contami- ●...
  • Page 253 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● Over-charging of refrigerant or insuffi cient refrigeration of condenser Symptom: Insuffi cient refrigeration {cmHg kgf/cm {cmHg kgf/cm - 50 - 76 - 76 - 01 - 01 ZX215-1002172 Symptom Cause Analysis Remedy ●...
  • Page 254 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● Air is observed in the refrigerating system Symptom: Poor refrigeration NOTE: If refrigerant is added with no evacuation operation performed, the following gauge read- ing will appear: {cmHg kgf/cm {cmHg kgf/cm - 50 - 76 - 76 - 01...
  • Page 255 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● Improper installation of expansion valve/thermal pipe defect (wide opening) Symptom: insuffi cient refrigeration {cmHg kgf/cm {cmHg kgf/cm - 50 - 76 - 76 - 01 - 01 ZX215-1002174 Symptom Cause Analysis Remedy ●...
  • Page 256 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● Compressing error Symptom: No refrigeration {cmHg kgf/cm {cmHg kgf/cm - 50 - 76 - 76 - 01 - 01 ZX215-1002175 Symptom Cause Analysis Remedy ● Pressure at Lo-pressure ● Compressor internal ● Compressing fault; ●...

  • Page 257: Compressor Oil

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.7.14 Compressor oil 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.

  • Page 258: Engine Control

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.8 Engine Control ZX215-1002176 Battery relay Outline Battery ● Start and stop the engine only with the en- Engine start switch gine start switch (3). Fuel control dial ● The controller (6) receives the signal from Start motor the fuel control dial (4) and transmits the Engine controller...

  • Page 259: System Operation

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.8.1 System operation Engine startup ● When the start switch is turned to the START position, the starting signal is trans- (Power) mitted to the start motor. Then, the start Start S/W Engine Start motor Starting relay Fuel ctrl dial...

  • Page 260: Components

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.8.2 Components 4.8.2.1 Fuel control dial 140° 9×10° Level 1 Level 10 25° Left limit Right limit Yellow Blue ZX215-1002180 Knob Ball Dial Potentiometer Spring Connector Shop Manual - June 2013 4-163 https://www.tractormanualpdf.info/...
  • Page 261 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Function ● Turning of the fuel control dial changes the resistance of the sliding rheostat inside the （%） dial and the voltage signal collected by the 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.

  • Page 262: Controller

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.8.2.2 Controller Controller TYPE USE FOR ZX215-1002182 Controller port layout ......................ZX215-1002183 Shop Manual - June 2013 4-165 https://www.tractormanualpdf.info/...
  • Page 263 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Input and output signals Input/ Input/ Signal name Signal name output output Power ground Rear pump pressure sensor Input Power ground Sensor power ground Input Power ground Sensor power ground Input Power supply(24V constant) Input Sensor power Output...

  • Page 264: Electrical Control System

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9 Electrical Control System 4.9.1 Control function Engine-Pump composite control function Pump control function Valve control function Dual travel speed control Electronic control system Engine preheating/overheating alarm Engine oil under-pressure alarm Auto-deceleration/acceleration control Engine speed calibration function Self-diagnosis function NOTE: For detailed information about self-diagnosis function, see "Troubleshooting"...

  • Page 265: Machine Control System Diagram

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.2 Machine control system diagram Battery Battery relay Fuel control dial Fuse Power ON signal Start switch Swing priority signal Monitor panel R. travel signal Network signal Working mode signal L. travel signal Signal monitor info Travel spd select signal Boom UP signal...
  • Page 266 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator R. travel pressure sensor L. travel pressure sensor Boom UP pressure sensor Boom DOWN pressure sensor Valve Arm IN pressure sensor Arm OUT pressure sensor Bucket CURL pressure sensor Bucket DUMP pressure sensor Swing pressure sensor PPC Basic pressure Swing...

  • Page 267: Engine And Pump Composite Control Function

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.3 Engine and pump composite control function Operator cab PPC valve Monitor Travel Travel Boom UP/DOWN Arm IN/OUT Bucket DIG/DUMP Swing Fuel control dial MC Controller input Option pressure Pressure H/S/L/B sensor sensor Auto-idle cancel Travel speed swithing Alarm output...
  • Page 268 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Function ● This function allows the operator to select a working mode according to the job to be performed and change engine power output. Four different working modes are available: H, S, L and B. To select a work- ing mode, use the working mode selector switch on the machine monitor.
  • Page 269 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Control method of each working mode H mode ● The matching point of H mode: rated speed 114kW/2050rpm ● If pump load increases and pump pressure rises, engine speed drops. In this case, engine speed will rise to near the match- ing point, allowing the pump controller to reduce pump discharge.
  • Page 270 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator S mode/B mode/L mode Power output rate of at each working mode Mode Power output rate ● At this time, the controller keeps the pump oil-suction torque in line with the stabling motor curve, and controls engine speed through combined control of the engine Engine speed N and pump.

  • Page 271: Pump Control Function

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.4 Pump control function Press.sensor Main Press.sensor Engine pump Throttle Fuel injection motor pump Speed Servo Servo sensor Fuel control dial Monitor Controller (CAN bus) ZX215-1002196 4-174 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 272: Electrical Positive Fl Ow Control

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.4.1 Electrical positive fl ow control Pump 1 delivery amount Boom RAISE PPC pressure Pump 1 delivery amount Arm IN PPC pressure Pump 1 delivery amount Arm OUT PPC pressure Pump 1 Corresponding delivery delivery output amount...
  • Page 273 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Pump 2 delivery amount Boom RAISE PPC pressure Pump 2 delivery amount Arm IN PPC pressure Pump 2 delivery amount Arm OUT PPC pressure Pump 2 Corresponding delivery delivery output amount Bucket CURL PPC pressure Pump 2 delivery amount...
  • Page 274 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Function ● Use the joystick pilot pressure signal di- rectly as the hydraulic pump discharge control signal. Pilot pressure is applied on the valve stem and, on the other hand, is collected by the controller. The controller keeps the discharge amount of the hydrau- lic pump at the specifi...

  • Page 275: Constant Power Control

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.4.2 Constant power control Function ● Calculation of theoretical maximum dis- charge amount of the pump. The system applies constant power control. The two adjustor act together hydraulically, and Pump P-Q curve Flow keep two executing unit of the same speci- fication and acting together in synchroni- zation.
  • Page 276 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ESS control Function ● Changing of the engine speed due to load change controls the pump power, and en- gine output can be used more efficiently. (This function can also prevent the engine from losing control when the machine is operating under harsh conditions (eg.

  • Page 277: Valve Control Function

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.5 Valve control function Swing priortity Bucket Confluence Main valve Press.sensor Engine Press.sensor Main pump Throttle Fuel injection motor pump Speed Servo Servo sensor Fuel control dial Monitor Controller (CAN bus) ZX215-1002200 Valve control function ●...
  • Page 278 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.5.1 Bucket fl ow control Function ● Control the pump swash plate angle ac- Swash plate angle cording to the operation of bucket control lever. Bucket control lever PPC pressure ZX215-1002201 Operation Bucket confluence ●...
  • Page 279 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.5.2 Swing priority control Function ● Pressurized oil from pump 1 bypasses bucket 1 valve spool, and flows first to swing motor valve spool to activate swing fi rst. Operation ● When signals from pump 1 pressure sen- sor, arm pressure sensor and swing pres- sure sensor meet the following conditions, the controller activates the solenoid valve.

  • Page 280: Duo Travel Speed Control

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.6 Duo travel speed control Travel motor Regulator Regulator Travel Speed Main valve solenoid valve Engine Injection Throttle Main pump pump motor Servo Servo Fuel control dial Monitor Controller (CAN bus) ZX215-1002203 Shop Manual - June 2013 4-183 https://www.tractormanualpdf.info/...
  • Page 281 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Function ● Control travel mode. Operating condition ● When Hi speed travel mode on the monitor is enabled. Operation ● When the travel mode is set at LO speed, the swash plate angle of the travel motor is the largest, and travel speed is low.

  • Page 282: Engine Preheating/Overheating Alarm

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.7 Engine preheating/overheating alarm Start switch Heat Main valve Preheat relay Preheat s/w Engine Main pump Throttle motor Coolant tempe sensor Servo Servo Fuel control dial Monitor Controller (CAN bus) ZX215-1002204 Shop Manual - June 2013 4-185 https://www.tractormanualpdf.info/...

  • Page 283: Engine Preheating

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.7.1 Engine preheating Function ● Preheating control Operation ● This function shall be used in combination with the preheating switch located on the right armrest. Turn the engine start key counterclockwise to the HEAT position and hold on, the engine will start preheating.

  • Page 284: Engine Overheating Alarm

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.7.2 Engine overheating alarm Function ● When engine coolant temperature be- comes excessively high (above 110°C) during operation, overheating alarm will be displayed on the monitor screen. Operation ● The controller collects signal from the cool- ant temperature sensor.

  • Page 285: Auto Deceleration/Acceleration Control

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.9 Auto deceleration/acceleration control Right joystick Boom Bucket Engine Left joystick Swing Engine throttle controller Fuel control dial L.Travel R.Travel Travel lever (Throttle signal) Monitor Controller (CAN bus) Control lever signal ZX215-1002205 4-188 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 286 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Function ● If all the control levers are neutralized, en- gine speed will drop to the medium level automatically to reduce fuel consumption and noise. ● If any of the levers is operated, the engine speed rises to the set level instantly.

  • Page 287: Engine Speed Calibration Function

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.10 Engine speed calibration function Bucket confluence Swing pripority Main valve Pressure sensor Pressure sensor Engine Main pump Throttle Injection motor pump Speed Servo Servo sensor Fuel control dial Monitor Controller (CAN bus) Calibtator MEMORYON DOWN...
  • Page 288 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Function ● Set the maximum engine speed under each working mode. This set speed is the standard to control engine speed. Operation ● Calibrating procedure for positive fl ow exca- vators. 1) Selection of fixing point of throttle motor soft shaft 2) H, S, L maximum speed calibration, and A/ I speed calibration.

  • Page 289: Electrical Components

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.11 Electrical Components 4.9.11.1 Pump pressure sensor Connection diagram Signal name PWR +5V Output Terminal C Terminal B Terminal A ZX305-1002066 Operation ● The relationship between the pressure ap- plied on the sensor (P) and output voltage (E) is shown in the right diagram.

  • Page 290: Pilot Pressure Sensor

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.11.2 Pilot pressure sensor Connection diagram Signal name PWR +5V Output Terminal C Terminal B Terminal A ZX305-1002066 Operation ● The relationship between the pressure ap- plied on the sensor (P) and output voltage (E) is shown in the right diagram.

  • Page 291: Engine Speed Sensor

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.11.3 Engine speed sensor ZX215-1002211 Function ● The engine revolution sensor is installed to the ring gear of the engine fl ywheel. It elec- trically calculates the number of the gear teeth which pass in front of it and transmits the result to the engine controller.

  • Page 292: Coolant Temperature Sensor

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.11.4 Coolant temperature sensor ZX215-1002212 Sensor Connector Function ● 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. Specifi...

  • Page 293: Fuel Level Sensor

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.11.5 Fuel level sensor ZX215-1002246 Float Casing Lever Coupler 4-196 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 294: Oil Pressure Switch

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.9.11.6 Oil pressure switch Load Pressure ZX215-1002214 O-ring Sensor Connector Function ● The oil pressure switch is installed on the outlet circuit of the oil filter. It detects oil pressure and transmits warning signals to the controller.

  • Page 295: Monitoring System

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.10 Monitoring System CAN signal Monitor Controller Power Sensor Battery W13053001 ● The state of the machine is monitored 1. Alert information when a machine fault is by the sensors mounted on the machine detected.

  • Page 296: Machine Monitor

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.10.1 Machine monitor Enter WX215-1204002H 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. working mode.

  • Page 297: Monitor Functions

    Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4.10.2 Monitor functions The front side of the machine monitor is made up of three sections: A. Warning and signal indicators B. Display screen C. Key pad Enter XP13031506 Warning and signal indicators ●...
  • Page 298 This display is also the interface where most monitor operations are performed. Items on a normal operation display include: 1. Working mode indicator 2. Coolant temperature gage Sany Hydraulic Excavator 3. Fuel level gage 4. Failure code 5. Total service hours 6. Function icons 7.
  • Page 299 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 1. Function keys Functions of the fi ve keys ( ) are indicated by the function icons above them on the screen. Function keys and icons Function key Icon Function Operation interface Working mode selection Home page Select the next item;...

  • Page 300: Monitor Operation

    Operation Working mode selection (1) Sany Hydraulic Excavator ● Press switch between S, H. L and B mode. NOTE: S mode is the default working mode.
  • Page 301 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator When neither of the joysticks are operated for 5 seconds, the engine enters the idling state automatically in order to save fuel and reduce noise. High and low travel speed (3) ● Press to switch between high and low travel speed.
  • Page 302 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 2. Information Menu password entry A 5-digit password is required to access the “Information Menu”. You can ask your local dealer to obtain this password. Operation 1. Press to change the number where the cursor blinks in an ascending order.
  • Page 303 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 3. Information Menu The information menu is a list of system func- tions. On this page, you can select and access any of the items on the list. Information Menu Operation Running parameter ●...
  • Page 304 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Engine & Throttle Signal Select “Running Parameter” on the Informa- tion Menu page and press , and the Enter display moves to Engine & Throttle Signal Engine & Throttle Signal page. This page is a real-time display of the running parameter of the engine and throttle.
  • Page 305 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 6. Main Pump & Main Valve Signal This page is a real-time display of the main pump and main valve signals of the hydraulic system. Main Pump & Main Valve Signal Operation Pump1 press kg ●...
  • Page 306 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 8. Throttle Installation Select “Throttle Installation” on the Information Menu page and press , and the dis- Enter play moves to Throttle Installation page. This Throttle Installation page displays throttle installation assistance function. Current gear N Operation Eng speed rpm...
  • Page 307 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 10. System Time Setup Select “System Time Setup” on the Informa- tion Menu page and press , and the Enter display moves to this page. You can set sys- System Time Setup tem time on this page. Operation Current time and time zone: 1234·12·12 12:12:12 W...
  • Page 308 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator ● The blue-white bars show signal-to-Noise ratio ranges from 0 to 99. ● When the altitude is nonzero and the longi- tude and latitude is zero, it means that the system is receiving GPS data, yet still in the process of precise positioning.
  • Page 309 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 13. System Setup password entry Press on the Information Menu page to en- ter the Password Entry page before accessing the System Setup page. System Setup Operation Please enter the password 1. For password entry method, see Informa- tion Menu Password Entry page.
  • Page 310 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 15. Machine Confi guration password entry Select Machine Configuration on the System Setup list and press , and the display Enter moves to the Password entry page before ac- System Setup cessing the Machine Confi guration page. Please enter the password Operation 1.
  • Page 311 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 17. Service Hour Setup password entry Select “Service Hour Setup” on the System Setup list and press , and the display Enter moves to the Password entry page before ac- System Setup cessing the Service Hour Setup page. Operation Please enter the password 1.
  • Page 312 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 19. Machine Confi guration Setup password entry Select “Machine Configuration Setup” on the System Setup list and press , and the Enter display moves to this Password entry page. Operation 1. For password entry method, see Informa- tion Menu Password Entry page.
  • Page 313 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 20. Machine Confi guration Setup This page is used to set up machine confi gu- ration after installation of the monitor. Machine Config Setup Operation ● Press to change machine model. Machine model: ●...
  • Page 314 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator Remark: The machine serial number is composed of 4 parts: 1) Production year, 2) Product code, 3) Tonnage code, 4) Alteration code, 5) Serial number, and 6) Tail number “8”. 1) Press to move the cursor to different Enter part (Production year, Product code and Serial number) in the machine number.
  • Page 315 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 21. Hydraulic Oil Temperature Select “Hydraulic Oil Temperature” on the Sys- tem Setup list and press , and the Enter display moves to this page. Hydraulic Oil Temp Operation Hydraulic Oil Temp: ● Press to return to the “System Setup”...
  • Page 316 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 22. Lockout Information (Level 1) This display indicates that the machine has entered lockout state (level 1). Lockout Information Operation ● Press to enter “System Unlock” page. Macine model: Machine No.: Machine state: Lockout (1) NOTE: Contact your local dealer to unlock the Current time:...
  • Page 317 Structure and Function SY195/205/215/225C9 Crawler Hydraulic Excavator 4-220 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 318: Standard Values

    Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator 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 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 319 Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator 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.

  • Page 320: Standard Values Of Engine - Related Parts

    Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator 5 STANDARD VALUES 5.1 Standard Values of Engine - related Parts Std. value for Item Measurement condition Unit Permissible value new machine High Idling 2,060 ± 70 2,060 ± 70 Engine Speed Low Idling 1,050 ±...

  • Page 321: Standard Values Of Chassis-Related Parts

    Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator 5.2 Standard Values of Chassis-related Parts Std. value for Permis- Categ. Item Measurement condition Unit new machine sible value ● Engine coolant temperature: Within operational range ● Hydraulic oil temperature: Within operational range 2 pumps at relief 2,030 ±...
  • Page 322 Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator Std. value for Permis- Categ. Item Measurement condition Unit new machine sible value Boom control Max. 19.6 Max. 24.5 lever {Max. 2.0} {Max. 2.5} Arm control Max. 19.6 Max. 24.5 ● Hydraulic oil temp: Within operational lever {Max.
  • Page 323 Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator Std. value for Permis- Categ. Item Measurement condition Unit new machine sible value ● Hydraulic oil temp: Within operational range ● Engine running at high idle Swing ● Working mode: H Deg. Max. 100 Max.
  • Page 324 Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator Std. value for Permis- Cat. Item Measurement Condition Unit new machine sible value ● Hydraulic oil temp: Within operational range 20 ± 2.5 17.5~22.5 ● Engine running at high idle ● Working mode: H sec.
  • Page 325 Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator Std. value for Permis- Categ. Item Measurement condition Unit new machine sible value ● Hydraulic oil temp: Within operation- al range ● Engine running at high idle ● Working mode: H sec. 3.4 ± 0.4 Max.
  • Page 326 Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator Std. value for Judgement Cat. Item Measurement condition Unit new machine criteria ● Hydraulic oil temp: Within operational range ● Engine running at low idle ● Working mode: H ● Time required from maneuvering the joystick to the moment that the bucket reaches the sec.
  • Page 327 Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator Machine postures for measuring (For all models) Control value: Spool stroke Travel 1: Travel speed (without load) ZX215-1003002 ZX215-1003005 Swing 1: Swing brake angle, time taken to Travel 2: Travel speed (actual run), Travel de- start swing, time taken to swing viation 45°...
  • Page 328 Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator Travel 4: Hydraulic drift of Travel Work equipment 3: Arm speed 12° ZX215-1003008 ZX215-1003011 Work equipment 1: Hydraulic drift of work Work equipment 4: Bucket speed equipment ZX215-1003009 ZX215-1003012 Work equipment 2: Boom speed Work equipment 5: Boom delay ZX215-1003013 ZX215-1003010...
  • Page 329 Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator Work equipment 6: Arm delay Work equipment 7: Bucket delay ZX215-1003014 ZX215-1003015 5-12 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 330 Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator Shop Manual - June 2013 5-13 https://www.tractormanualpdf.info/...
  • Page 331 Standard Values SY195/205/215/225C9 Crawler Hydraulic Excavator 5-14 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 332: Testing And Adjusting

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator Testing and Adjusting 6 Testing and Adjusting 6.1 Engine Speed - Test and Calibrate ................6-3 6.1.1 Testing ......................6-3 6.1.2 Adjusting ......................6-3 6.2 Exhaust Gas Color - Test ..................6-6 6.3 Valve Clearance - Adjust ..................6-8 6.3.1 Testing ......................
  • Page 333 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.13 Solenoid Valve Output Pressure - Measure ............6-32 6.14 Pilot Valve Output Pressure - Measure ..............6-34 6.15 Pilot Valves (Work Equipment and Swing) - Adjust ..........6-36 6.16 Work Equipment Hydraulic Drift - Test ..............6-37 6.17 Residual Pressure in Hydraulic Circuit - Release ..........

  • Page 334: Engine Speed - Test And Calibrate

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6 TESTING AND ADJUSTING 6.1 Engine Speed - Test and Calibrate Engine speed calibrator Part Number Part Name B249900001206 Engine Speed Calibrator 6.1.1 Testing Start the engine and keep the engine running until engine coolant temperature rises within the operational range.
  • Page 335 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 5. Tighten the fixing position of the flexible shaft when engine speed is lower than 1050 rpm; loosen the fixing position of the flexible shaft when engine speed is higher than 1150 rpm. 6.
  • Page 336 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator Engine speed reference (SY215C9) Level Speed (rmp) Level Speed (rmp) 1100 1100 1200 1200 1300 1300 1500 1500 1600 1600 1650 1700 1750 1800 1850 1900 1950 2000 2050 2100 2150 2200 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 337: Exhaust Gas Color - Test

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.2 Exhaust Gas Color - Test Testing tools Model Part Name YDJ-2006 Smoke meter SV-2TY Opacimeter CAUTION ● Do not touch any hot parts when mount- ing or dismounting the testing tools. 1. Measure with a smoke meter 1) Put the fi...
  • Page 338 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 2. Measure with an opacimeter 1) Mount the opacimeter onto the exhaust pipe by clamping it to the pipe outlet. ZX215-1004003 2) Open the opacimeter and preheat it for about 15 minutes. 3) Start the engine and keep the engine running until engine coolant tempera- ture is within the operational range.

  • Page 339: Valve Clearance - Adjust

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.3 Valve Clearance - Adjust Service Standard (Unit: mm) Location Service Item Standard Value Limits Remedy — Valve clearance (engine cold) — Adjust Special Tools Symbol Tool Name and Shape Part Number Application Flat head screwdriver Valve clearance adjustment MH060008...
  • Page 340 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator NOTE: When the rocker arm at the intake side and rocker arm at the exhaust side cannot be turned with hands, it is indicated that the pis- ton has reached the top dead center of com- pression stroke.

  • Page 341: Adjusting

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.3.2 Adjusting 1. To adjust valve clearance, loosen the lock- Adjustment Screw nut before adjusting the adjustment screw. Standard clearance is achieved when re- sistance to the feeler gauge is felt when Locknut pulling it out from the clearance.

  • Page 342: Compression Pressure - Measure

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.4 Compression Pressure - Measure Service Standard Location Service Item Standard Value Limits Remedy Each cylinder (at 200 2550kPa {26kgf/cm²} 1960 kPa {20kgf/cm²} Test Compression rpm) — Differential pressure pressure — Below 390 kPa {4kgf/cm²} Test between cylinders Special Tool...
  • Page 343 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6. Cover the fuel injector mounting opening with cloth. Rags 7. Activate the start motor in order to run the engine. Check if the cloth is stained by for- Injector mounting hole eign substances. 8.

  • Page 344: Fuel Injection Timing - Test And Adjust

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.5 Fuel Injection Timing - Test and Adjust Service Standard Location Service Item Standard Value Limits Remedy — Fuel injection timing (BTDC) 14° — Adjust Tightening Torque (Unit: N·m) Symbol Parts Tightened Tightening Torque Remark —...
  • Page 345 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 3. Install the prepared injection pipe onto No.1 cylinder. Keep the other end of the in- Injection pipe jection pipe downward so that fuel fl owing out can be observed. 4. Turn the crankshaft manually over 180° in the forward direction to locate No.1 cylin- der in a position that is about 30°...

  • Page 346: Adjusting

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator NOTE: When the fuel injection timing deviates from its standard value, the following steps must be followed for adjustment. 6.5.2 Adjusting 1. Loosen the mounting nuts of fuel injection pump. A: 4 nuts (on the fl ange) B: 1 nut ZX215-1004015 2.
  • Page 347 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 4. When the injection timing is slow, move the injection pump toward the crankcase (di- rection C). 5. When the injection timing is fast, move the injection pump away from the crankcase Injection Pump (direction D).

  • Page 348: Engine Oil Pressure - Measure

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.6 Engine Oil Pressure - Measure Service Standard Location Service Item Standard Value Limits — Min. speed, unloaded 145 KPa 49 KPa Engine oil pressure at 70~90°C — Max. speed, unloaded 295 KPa~490 KPa 195 KPa Tightening Torque (Unit: N·m) Symbol...
  • Page 349 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 3. Preheat the engine until engine oil temper- ature reaches 70-90°C. 4. Measure respectively the unloaded engine oil pressure at minimum speed and maxi- mum speed. 5. If the measured value is lower than the specifi...

  • Page 350: Engine Speed Sensor - Adjust

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.7 Engine Speed Sensor - Adjust NOTE: Remove the engine speed sensor (1) before adjusting. Check for presence of metal chips and for damaged sensor top. Restore the sensor. ZXT215-1004001 1. Screw on the sensor (1) until its end con- tacts with ring gear tip (2) of the fl...

  • Page 351: A/C Compressor Belt Tension - Test And Adjust

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.8 A/C Compressor Belt Tension - Test and Adjust 6.8.1 Testing Press the intermediate point of the belt be- Compressor Belt tween the drive pulley and the compressor pul- Pulley ley with a fi nger force of about 58.8 N(6kgf), and measure defl...
  • Page 352 V-belt free from friction with bottom of the V-groove. ● Contact local Sany dealer and replace the belt in case of the following conditions. ● The fan belt has been stretched and little margin is left for adjustment.

  • Page 353: Swing Bearing Clearance - Measure

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.9 Swing Bearing Clearance - Measure Measuring tool Symbol Part Number Part Name 60033930 Dial gauge ● The following steps are to be followed when measuring the clearance of swing bearing. CAUTION ● Park your machine on a level ground. Lower your work equipment to the ground.
  • Page 354 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator step 2. Check the dial gauge (H) to see if it reads zero. The value indicated by the dial gauge (H) is the clearance of the bearing. For more information, see “Swing bearing” on page 4-13.

  • Page 355: Track Tension - Test And Adjust

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.10 Track Tension - Test and Adjust 6.10.1 Testing 1. Move your machine forward for a distance that is equal to the length of track on the ground. Keep running the engine at low idle.

  • Page 356: Adjusting

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.10.2 Adjusting ● If track tension is incorrect, make adjust- ment as per the following instruction. 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.

  • Page 357: Hydraulic Pressure In Hydraulic Circuits - Test And Adjust

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.11 Hydraulic Pressure in Hydraulic Circuits - Test and Adjust Testing and adjusting tools Part Number Part Name 60038932 Hydraulic Tester — B210770000084 Adaptor NOTE: The hydraulic pressure in work equip- ment, swing and travel (hydraulic pump out- put) circuits can be viewed on the monitor.
  • Page 358 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 2. Measurement of unloading pressure 1) Start the engine. 2) Measure the hydraulic pressure when the engine is running at high idle and all control levers are in a neutral posi- tion. NOTE: The hydraulic pressure indicat- ed is the pressure when the unloading valve unloads.

  • Page 359: Adjusting

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 5. Measurement of travel pressure at relief 1) Start the engine and lock the travel mechanism. NOTE: Place the pin (1) between the sprocket and the track frame to lock the travel mechanism. 2) Measure the hydraulic pressure when the engine is running at high idle and the travel circuit is in relief condition.
  • Page 360 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 3) Check the pressure again after adjust- ment. Measure the pressure according to the procedure described above. ● Connect the pilot hose before measur- ing the pressure. ● Adjustment of the high pressure setting side will affect the low pressure setting side.

  • Page 361: Control Circuit Oil Pressure - Test And Adjust

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.12 Control Circuit Oil Pressure - Test and Adjust Testing and adjusting tools Part Number Part Name 21008760 Hydraulic Tester — B210770000084 Adaptor 6.12.1 Testing CAUTION ● Lower the work equipment to the ground and stop the engine.

  • Page 362: Adjusting

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.12.2 Adjusting 1. If the measurement is less than 3.5 kgf/ cm², loosen the retaining nut (2) and screw in adjusting stud (3). Watch the change of readings on the pressure gauge at the same time.

  • Page 363: Solenoid Valve Output Pressure - Measure

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.13 Solenoid Valve Output Pressure - Measure Measuring tools Part Number Part Name 21008760 Hydraulic Tester — B210770000084 Adaptor NOTE: Make sure that the initial pressure of control oil circuit is normal before measuring the output pressure of solenoid valve.
  • Page 364 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Start the engine and keep it running un- til the hydraulic oil temperature rises to a point within the operational range. 5. Run the engine at full speed. Operate the control levers to open or close each sole- noid valve, and measure the pressure.

  • Page 365: Pilot Valve Output Pressure - Measure

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.14 Pilot Valve Output Pressure - Measure Measuring tools Part Number Part Name 21008760 Hydraulic Tester — B210770000084 Adaptor NOTE: Make sure that the initial pressure of control oil circuit is normal before measuring the output pressure of pilot valve.
  • Page 366 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator NOTE: When the measured output pres- sure reads the following values, the pilot valve is normal. Control Lever Hydraulic Pressure Neutral 0{0} Close to the average initial pres- Full stroke sure of oil control circuit (See Table of Standard Values) 5.

  • Page 367: Pilot Valves (Work Equipment And Swing) - Adjust

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.15 Pilot Valves (Work Equipment and Swing) - Adjust ● If the play of work equipment or swing con- trol lever is excessive, make adjustment as per the following procedure. 1. Remove the work equipment and swing pi- lot valve assembly.

  • Page 368: Work Equipment Hydraulic Drift - Test

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.16 Work Equipment Hydraulic Drift - Test NOTE: If hydraulic drift exists in the work equipment cylinder, check it according to the following procedure and determine whether the failure lies in the cylinder seal or in the control valve.
  • Page 369 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 1) Park your machine in an attitude as shown. The distance between the arm cylinder and the digging stroke end is 100 mm. Stop the engine. 2) Operate the control levers in order to place the arm in the digging position.
  • Page 370 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator closed by a check valve), and the oil fl ows to the drain circuit from the head side. As a result, the lowering speed increases. 3. Checking the pilot valve While the pressure in the accumulator is high, set the hydraulic lockout control in the LOCKED/FREE position and measure the hydraulic drift respectively.

  • Page 371: Residual Pressure In Hydraulic Circuit - Release

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.17 Residual Pressure in Hydraulic Circuit - Release 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.

  • Page 372: Oil Leakage - Measure

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.18 Oil Leakage - Measure 1. Measure oil leakage from boom cylinder 1) Start the engine and keep it running un- til the hydraulic oil temperature is within the operational range. Fully extend the boom cylinder.
  • Page 373 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 2. Measure oil leakage from arm cylinder 1) Start the engine and keep it running un- til the hydraulic oil temperature is within the operational range. Fully extend the arm cylinder. NOTE: Release the residual pressure in the circuits.
  • Page 374 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 3. Measure oil leakage from bucket cylin- 1) Start the engine and keep it running un- til the hydraulic oil temperature is within the operational range. Fully extend the bucket cylinder. NOTE: Release the residual pressure in the circuits.
  • Page 375 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Measure oil leakage from swing motor 1) Fully extend the work equipment. Lower the bucket on the ground and raise the machine slightly. Secure machine from rotating clockwise or counter clockwise while testing. Stop the engine. 2) Disconnect the hose (4) and the hose (5).
  • Page 376 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 5. Measure oil leakage from travel motor 1) Remove the cover of the travel motor. 2) Start the engine and lock the travel mechanism. NOTE: Insert pin (1) between the sprocket and the track frame to lock the travel mechanism.

  • Page 377: Air In Each Component - Bleed

    Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6.19 Air in Each Component - Bleed Air bleeding procedures Air bleeding item Bleed air Bleed Bleed air Bleed air Starting Starting Contents of work from hydrau- air from from swing form travel engine operation lic pump...
  • Page 378 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 2. Bleed air from hydraulic cylinder 1) Start the engine and keep the engine running at low idle for 5 minutes. 2) Raise or lower the boom 4 or 5 times with the engine running at low idle. NOTE: Be careful not to apply relief pressure.
  • Page 379 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Bleed air from travel motor 1) Start the engine and run the engine at low idle. 2) Loosen the bleeder (2) and check that oil oozes out through the air bleeder. 3) Tighten the air bleeder (2) if oil is seen. Bleeder: 27.5~35.3 N·m{2.8~3.6 kgf·m} ZXT215-1004016...
  • Page 380 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator Table of monitored items Monitored Item Unit Remark Controller Mode Selection Graph High/Low Travel Speed Selection Graph Auto Idle Selection Graph Engine Speed r / min Pressure - Front pump Pressure - Rear pump Current - Proportional Valve (Solenoid, Front pump) Current - Proportional Valve (Solenoid, Rear pump) Pilot Pressure - Boom Raise...
  • Page 381 Testing and Adjusting SY195/205/215/225C9 Crawler Hydraulic Excavator 6-50 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 382: Troubleshooting

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator Troubleshooting 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)..........
  • Page 383 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 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.

  • Page 384: Points To Remember When Troubleshooting

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7 TROUBLESHOOTING 7.1 Points to Remember When Troubleshooting ● Stop the machine in a level ground, and check that lock pins, blocks, and parking brake are securely fi tted. ● 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.
  • Page 385 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator the failure? When were these repairs car- 5. Troubleshooting ried out? ● Use the results of the investigation and 6) Has the same kind of failure occurred be- inspection in Items 2 – 4 to narrow down fore? the causes of failure, then use the trouble- shooting fl...

  • Page 386: Troubleshooting Procedures

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7.2 Troubleshooting Procedures 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 fi nd the causes and work out the corresponding methods.
  • Page 387 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator Item Criterion Remedy 1. Check fuel level and type of fuel — Add fuel 2. Check for impurities in fuel — Clean, drain 3. Check hydraulic oil level — Add oil 4. Check hydraulic oil strainer —...
  • Page 388 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator ● Failure codes may not indicate machine 4. Operate machine by yourself (trial run) 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.

  • Page 389: Connector Location And Electrical Circuit Diagram

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7.3 Connector Location and Electrical Circuit Diagram Location Connec- No. of Sensor, Type Name of device Engine tor No. Layout solenoid circuit circuit circuit T-101 Terminal Battery relay coil (positive) T-102 Terminal Battery relay coil (negative) Battery relay contact (out- T-103 Terminal...
  • Page 390 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator Location Connec- No. of Sensor, Type Name of device Engine tor No. Layout solenoid circuit circuit circuit CN-241M Intermediate connector CN-1-112 Intermediate connector CN-1-111 Intermediate connector CN-7-705 Monitor panel CN-801F Intermediate connector CN-445M Intermediate connector CN-204F Intermediate connector CN-412F...
  • Page 391 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator Location Connec- No. of Sensor, Type Name of device Engine tor No. Layout solenoid circuit circuit circuit CN-304M Wiper switch CN-104M Horn switch CN-306M Preheating switch CN-207F Air conditioner unit CN-113F F. pump solenoid valve CN-114F R.
  • Page 392 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator Connector code Description SWP type, Yazaki A/AMP AMP, Japan DT type, Japan Hebi Hulane Connectors Ling Xing Electronic Equipment Delphi, U.S. AMP, Japan Terminal Round terminal Shop Manual - June 2013 7-11 https://www.tractormanualpdf.info/...

  • Page 393: Connector Location Layout

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7.3.1 Connector location layout CN-105M CN-104M CN-101M CN-102M ZX215-1005033 7-12 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 394 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator CN-448M CN-113M F-108 CN-113F T-112 CN-801F CN-114F T-106 CN-115M T-115 CN-116M T-111 CN-445M CN-800M T-107 CN-112M CN-124M CN-125M CN-126M F-104 F-103 CN-128M CN-127M CN-123M CN-122M CN-121M CN-120M CN-131F CN-132F CN-133F CN-134F CN-135F CN-136F ZX215-1005034 Shop Manual - June 2013 7-13 https://www.tractormanualpdf.info/...
  • Page 395 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator CN-306M CN-307M CN-132F CN-305M CN-304M CN-303M CN-104M CN-302 CN-131M CN-301M CN-7-705 CN-7-707 ZX215-1005035 7-14 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 396 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator CN-1-111 CN-161M CN-152M CN-661F CN-1-112 T-201 T-202 CN-241M CN-121F CN-142M CN-613F CN-615F CN-616F CN-412F CN-204F PF021 CN-207F CN-107M CN-106F ZX215-1005036 Shop Manual - June 2013 7-15 https://www.tractormanualpdf.info/...
  • Page 397 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7-16 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 398 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator CN-1-002M CN-1-005 CN-1-001M CN-1-103M CN-1-004M CN-1-110 CN-150M ZX215-1005037 Shop Manual - June 2013 7-17 https://www.tractormanualpdf.info/...

  • Page 399: Electrical Element Circuit Diagram (Cab Circuit)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7.3.2 Electrical element circuit diagram (cab circuit) PF021 CN-1-112 (D-3) 20 A CANH 120 resistance CANL CN-7-705 CN-616F (D-12) CANH CANL Ground CN-1-111 (D-8) 24Vpower CN-131M CN-302F CN-142M (D-12) (A-3) (D-12) 20 A CN-412F AIN16 (A-3) CAN+ CAN-...
  • Page 400 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator ★ This circuit diagram has been compiled by extracting the wiper system and each switch control system from the overall electrical circuit diagram. Access lamp Horn relay Lamp relay Top lamp relay 3 4 5 3 4 5 3 4 5 CN-1-110...

  • Page 401: Electrical Control Circuit Diagram (Engine Circuit)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7.3.3 Electrical control circuit diagram (engine circuit) CN-332M TERMINAL T-102 R2 C CN-616F T-119 T-110 HEAT Body ground CN-241F (D-12) Grounding START Controller power supply PF021 CN-153M CN-152M Throttle position feedback X -1 X -2 X -3 X -4 X -5...
  • Page 402 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator ★ 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 Preheat relay Parking relay F13 160A T-108 T-109 Preheater CN-661M (S-16) Preheater indicator CN-442F...

  • Page 403: Electrical Control Circuit Diagram (Sensor And Solenoid Valve Circuit)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7.3.4 Electrical control circuit diagram (sensor and solenoid valve circuit) CN-101M (S-1) CN-616F Fuel level sensor CN-448M (S-2) 108A Grounding 108B Engine speed sensor Controller power supply CN-113M (A-2) Hydraulic oil temp. sensor Oil level sensor CN-152M (A-2) 240欧...

  • Page 404: Swp Type Connector

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7.3.5 SWP type connector Male (Plug) Female (Socket) 7222-7414-40 7123-7414-40 (No.of pin: 1) 7222-1424-40 7123-1424-40 (No.of pin: 2) 7222-7464-40 7123-7464-40 (No.of pin: 6) 7222-7484-40 7123-7484-40 (No.of pin: 8) 7123-7564-40 (No.of pin: 16) 7222-7564-40 Shop Manual - June 2013 7-23 https://www.tractormanualpdf.info/...

  • Page 405: A/Amp Type Connector

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7.3.6 A/AMP type connector Female (Socket) Male (Plug) 282104-1 282080-1 (No.of pin: 2) 282105-1 282087-1 (No.of pin: 3) 174354-2 174352-2 (No.of pin: 2) 1473255-1 (No.of pin: 40) 1473252-1 1473244-1 1473247-1 (No.of pin: 81) 7-24 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 406: Dt Type Connector

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7.3.7 DT type connector Shell (Plug) Shell (Socket) DT06-2S DT04-2P DT06-3S DT04-3P (No.of pin: 3) DT06-6S DT04-6P (No.of pin: 6) DT04-8P (No.of pin: 8) DT06-8S DT06-12S DT04-12P (No.of pin: 12) Shop Manual - June 2013 7-25 https://www.tractormanualpdf.info/...

  • Page 407: Failure Symptoms And Troubleshooting Codes

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7.4 Failure Symptoms and Troubleshooting Codes Troubleshooting Symptom Code E mode H mode (Engine) Action to be taken concerning Service Code, User Code and Failure Code Display User Code in monitor panel According Display Service Code in electrical system after checking to displayed failure history Display Failure Code in mechanical system after checking...
  • Page 408 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator Troubleshooting Symptom Code E mode H mode (Engine) Other work equipment moves, when specifi c work equip- H-12 ment is relieved 28 Boom-up speed or power is low. 29 Arm speed or power is low. 30 Bucket speed or power is low.

  • Page 409: Troubleshooting With An Event Code

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7.5 Troubleshooting with an Event Code Information in troubleshooting table ..................7-29 E111 (controller memory failure (FROM)) .................. 7-30 E212 (throttle motor current & motor connection abnormal) ............. 7-31 E213 (throttle motor operation suspends) ................7-32 E214 (throttle motor working range abnormal) ................

  • Page 410: Information In Troubleshooting Table

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator Information in troubleshooting table User Code Service Code Trouble Title of failure shown in failure history Display on monitor — Failure description Failure is described on the monitor display. When failure is detected, the controller has taken action to protect the affected Response from controller system or equipment.

  • Page 411: E111 (Controller Memory Failure (From))

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E111 (controller memory failure (FROM)) User Code Service Code Trouble Controller memory fails and the system slows down. E111 When the power is on, abnormality is detected by checking through FROM sum- Failure description mation and RAM verifi cation. Response from controller Stop the operation of motor and solenoid coil.

  • Page 412: E212 (Throttle Motor Current & Motor Connection Abnormal)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E212 (throttle motor current & motor connection abnormal) User Code Service Code Throttle motor loading circuit is abnormal and the Trouble engine acceleration fails. E212 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.

  • Page 413: E213 (Throttle Motor Operation Suspends)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E213 (throttle motor operation suspends) User Code Service Code Operation of throttle motor suspends and engine Trouble acceleration fails. E213 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.

  • Page 414: E214 (Throttle Motor Working Range Abnormal)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E214 (throttle motor working range abnormal) User Code Service Code Throttle motor working range is abnormal and the Trouble engine returns to auto idle. E214 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.

  • Page 415: E015 (Power Supply Voltage Abnormal)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E015 (power supply voltage abnormal) User Code Service Code Trouble Power supply voltage is abnormal. E015 Failure description Voltage of power supply is above 36V when the machine is running. Response from controller The system stops the motor and solenoid valve automatically. Symptom of machine Engine acceleration fails and the machine acts slowly.

  • Page 416: E116 (Controller Internal Temperature Abnormal)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E116 (controller internal temperature abnormal) User Code Service Code Internal temperature of controller is abnormal. Engine Trouble acceleration fails and the machine acts slowly. E116 Internal temperature of controller keeps above 80°C or below -30°C for 10 sec- Failure description onds when the power is on.

  • Page 417: E017 (Abnormal Output Of 5V Power Supply In Sensor)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E017 (abnormal output of 5v power supply in sensor) User Code Service Code Trouble Abnormal output of power supply in sensor E017 The controller detects out over current or short circuit of sensor power source Failure description output when the power is on.

  • Page 418: E118 (Abnormal Communication Between Controller And Monitor)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E118 (abnormal communication between controller and monitor) User Code Service Code Abnormal communication between controller and Trouble monitor E118 Communication of monitor is interrupted for 5 consecutive times when the Failure description power is on. Response from controller Only output alarm is enabled.

  • Page 419: E320 (Abnormality In Front Pump Output Pressure)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E320 (abnormality in front pump output pressure) User Code Service Code Front pump output pressure is abnormal. Only output Trouble alarm is enabled. . E320 A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec Failure description when the power is on.

  • Page 420: E321 (Abnormality In Rear Pump Output Pressure)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E321 (abnormality in rear pump output pressure) User Code Service Code Reading of rear pump output pressure is abnormal. Trouble Only output alarm is enabled. . E321 A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec Failure description when the power is on.

  • Page 421: E322 (Abnormality In Arm-In Pilot Pressure)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E322 (abnormality in arm-in pilot pressure) User Code Service Code Arm-in pilot pressure is abnormal. Only output alarm Trouble is enabled. . E322 A pressure feedback voltage other than 0.25~4.75V keeps more than 200msec Failure description when the power is on.

  • Page 422: E323 (Abnormality In Arm-Out Pilot Pressure)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E323 (abnormality in arm-out pilot pressure) User Code Service Code Reading of arm-out pilot pressure is abnormal. Only Trouble output alarm is enabled. E323 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on.

  • Page 423: E324 (Abnormality In Boom-Raise Pilot Pressure)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E324 (abnormality in boom-raise pilot pressure) User Code Service Code Reading of boom-raise pilot pressure is abnormal. Trouble Only output alarm is enabled. . E324 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on.

  • Page 424: E325 (Abnormality In Boom-Lower Pilot Pressure)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E325 (abnormality in boom-lower pilot pressure) User Code Service Code Reading of boom-lower pilot pressure is abnormal. Trouble Only output alarm is enabled. . E325 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on.

  • Page 425: E326 (Abnormality In Bucket-Curl Pilot Pressure)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E326 (abnormality in bucket-curl pilot pressure) User Code Service Code Reading of bucket-curl pilot pressure is abnormal. Trouble Only output alarm is enabled. . E326 A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200msec Failure description when the power is on.

  • Page 426: E327 (Abnormality In Bucket-Dump Pilot Pressure)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E327 (abnormality in bucket-dump pilot pressure) User Code Service Code Reading of Bucket-dump pilot pressure is abnormal. Trouble Only output alarm is enabled. . E327 A pressure feedback voltage other than 0.25 – 4.75V keeps more than 200msec Failure description when the power is on.

  • Page 427: E328

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E328 (abnormality in swing pilot pressure User Code Service Code Reading of swing pilot pressure is abnormal. Only Trouble output alarm is enabled. . E328 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on.

  • Page 428: E329 (Abnormality In Left Travel Pilot Pressure)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E329 (abnormality in left travel pilot pressure) User Code Service Code Reading of left travel pilot pressure is abnormal. Trouble Only output alarm is enabled. . E329 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on.

  • Page 429: E330 (Abnormality In Right Travel Pilot Pressure)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E330 (abnormality in right travel pilot pressure) User Code Service Code Reading of right travel pilot pressure is abnormal. Trouble Only output alarm is enabled. . E330 A pressure feedback voltage other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on.

  • Page 430: E231 (Abnormality In Fuel Control Dial Set Voltage)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E231 (abnormality in fuel control dial set voltage) User Code Service Code Voltage setting of fuel control dial is abnormal. En- Trouble gine returns to auto idle. E231 The voltage of fuel control dial other than 0.25 – 4.75V keeps more than Failure description 200msec when the power is on.

  • Page 431: E237 (Abnormality In Hydraulic Oil Temperature)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E237 (abnormality in hydraulic oil temperature) User Code Service Code Hydraulic oil temperature is abnormal. Only output Trouble alarm is enabled. E237 A voltage other than 0.2 – 4.75V, transformed from hydraulic oil temperature Failure description that is detected by controller, keeps more than 200msec.

  • Page 432: E541 (Abnormality In Engine Speed)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E541 (abnormality in engine speed) User Code Service Code Engine speed is abnormal. Only output alarm is en- Trouble abled. E541 Failure description CPU detects out that engine speed is too low (below 100 rpm). Only output alarm is enabled.

  • Page 433: E450 (Abnormality (A) In Front Pump Proportional Solenoid Coil Current)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E450 (abnormality (a) in front pump proportional solenoid coil current) User Code Service Code Front pump proportional solenoid coil current is ab- Trouble normal. The system operates slowly. E450 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8A lasts for 1 second.

  • Page 434: E450 (Abnormality (B) In Front Pump Proportional Solenoid Coil Current)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E450 (abnormality (b) in front pump proportional solenoid coil current) User Code Service Code Front pump proportional solenoid coil current is ab- Trouble normal. The system operates slowly. E450 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1 A lasts for 1 second.

  • Page 435: E451 (Abnormality (A) In Rear Pump Proportional Solenoid Coil Current)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E451 (abnormality (a) in rear pump proportional solenoid coil current) User Code Service Code Rear pump proportional solenoid coil current is ab- Trouble normal. The system operates slowly. E451 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8 A lasts for 1 second.

  • Page 436: E451 (Abnormality (B) In Rear Pump Proportional Solenoid Coil Current)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E451 (abnormality (B) in rear pump proportional solenoid coil current) User Code Service Code Rear pump proportional solenoid coil current is abnor- Trouble mal. The system operates slowly. E451 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1 A lasts for 1 second.

  • Page 437: E452 (Abnormality (A) In Swing Priority Proportional Solenoid Coil Current)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E452 (abnormality (A) in swing priority proportional solenoid coil current) User Code Service Code Current through the proportional solenoid coil for Trouble swing priority is abnormal. E452 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8A lasts for 1 second.

  • Page 438: E452 (Abnormality (B) In Swing Priority Proportional Solenoid Coil Current)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E452 (abnormality (B) in swing priority proportional solenoid coil current) User Code Service Code Current through the proportional solenoid coil for Trouble swing priority is abnormal. E452 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1A lasts for 1 second.

  • Page 439: E453 (Abnormality (A) In Bucket Confl Uence Proportional Solenoid Coil Current)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E453 (abnormality (A) in bucket confl uence proportional solenoid coil current) User Code Service Code Current through the proportional solenoid coil for bucket Trouble confl uence is abnormal. Motion of bucket is slow. E453 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8 A lasts for 1 second.

  • Page 440: E453 (Abnormality (B) In Bucket Confl Uence Proportional Solenoid Coil Current)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E453 (abnormality (B) in bucket confl uence proportional solenoid coil current) User Code Service Code Current through the proportional solenoid coil for bucket Trouble confl uence is abnormal. Motion of bucket is slow. E453 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1A lasts for 1 second.

  • Page 441: E455 (Abnormality (A) In Boom Priority 2 Proportional Solenoid Coil Current)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E455 (abnormality (A) in boom priority 2 proportional solenoid coil current) User Code Service Code Current through the proportional solenoid coil for Trouble boom priority is abnormal. E455 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 1.8 A lasts for 1 second.

  • Page 442: E455 (Abnormality (B) In Boom Priority 2 Proportional Solenoid Coil Current)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E455 (abnormality (B) in boom priority 2 proportional solenoid coil current) User Code Service Code Current through the proportional solenoid coil for Trouble boom priority is abnormal. E455 Abnormality occurs in loaded circuit of proportional solenoid coil. Current above Failure description 0.1A lasts for 1 second.

  • Page 443: E460 (Abnormality In Dual Speed Travel Solenoid Valve)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E460 (abnormality in dual speed travel solenoid valve) User Code Service Code Connection of the solenoid coil for dual speed travel is Trouble abnormal. High speed travel is not functioning. E460 Failure description Abnormality, open circuit or short circuit occurs in the proportional solenoid coil. Response from controller Only output alarm is enabled.
  • Page 444 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 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 .....................

  • Page 445: Information In Troubleshooting Table

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator Information in troubleshooting table ● 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...

  • Page 446: Engine Does Not Start

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-1 Engine does not start Trouble Engine cannot be started. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform trou- Low battery bleshooting.
  • Page 447 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator START SWITCH TERMINAL BR ACC R1 R2 C HEAT CN-241F BATTERY START (D-12) 22 13 BATTERY RELAY PILOT SWITCH 3 4 5 3 4 5 F16 10A LOCK RELAY 3 4 5 3 4 5 PARK RELAY PARK MOTOR CN-661F...

  • Page 448: Engine Runs Rough Or Is Unstable

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 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 ● Turn engine start switch to OFF position. Keep it at OFF position to per- Open circuit of form troubleshooting.

  • Page 449: Power Supply Of Machine Cannot Be Cut Off

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 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-...
  • Page 450 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator START SWITCH TERMINAL BR ACC R1 R2 C HEAT CN-241F BATTERY START (D-12) 22 13 BATTERY RELAY PILOT SWITCH 3 4 5 3 4 5 F16 10A LOCK RELAY 3 4 5 3 4 5 PARK RELAY PARK MOTOR CN-661F...

  • Page 451: Auto Idle Not Functioning

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 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 ●...

  • Page 452: Preheating Function Fails

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-5 Preheating function fails Trouble Engine does not preheat. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform Failure of pre- troubleshooting.

  • Page 453: Work Equipment Does Not Work

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-6 Work equipment does not work Trouble The machine is motionless while operated after starting. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Start the engine and keep it running to perform troubleshooting.

  • Page 454: Boom-Raise Speed Or Power Is Low

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-7 Boom-raise speed or power is low Trouble Boom-raise speed or power is low. Pilot pressure of the boom in operation can be Related information checked on the monitor. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 455: Arm Speed Or Power Is Low

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-8 Arm speed or power is low Trouble Arm speed or power is low during operation. Related information Pilot pressure of the arm in operation can be checked on the monitor. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 456: Bucket Speed Or Power Is Low

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-9 Bucket speed or power is low Trouble Bucket speed or power is low during operation. Related information Pilot pressure of the bucket can be checked on the monitor. Cause Standard value in normal state/Remarks on troubleshooting ●...
  • Page 457 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator BUCKET-DUMP CN-127M PRESS. SENSOR （DF-3） SIGNAL GND WIRE CONTROLLER CN-124M BUCKET-CURL BUCKET-CURL （DF-3） PRESS. SENSOR PRESS. SENSOR BUCKET-DUMP SIGNAL PRESS. SENSOR GND WIRE SENSOR GND WIRE SENOSR 5V BUCKET CONFLUENCE SIGNAL CN-134F BUCKET CONFLUENCE （AMP-2） PROPORTIONAL VALVE SIGNAL GND WIRE...

  • Page 458: Travel Speed Or Power Is Low

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-10 Travel speed or power is low Trouble Travel speed or power is low during operation. Related information Pilot pressure of travel operation can be checked on the monitor. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 459: Blank Monitor Display

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-11 Blank monitor display Trouble Monitor display is blank after the machine is powered on. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to perform troubleshooting.

  • Page 460: Monitor Displays Nothing

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-12 Monitor displays nothing Display of monitor is illuminated but no information is Trouble shown on the screen after machine is powered on. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to Failure of resis- perform troubleshooting.

  • Page 461: Dual Speed Travel Not Functioning

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-13 Dual speed travel not functioning Trouble Only low speed travel is functioning during operation. Related information Press the Hi/Lo button on the monitor to change travel speed. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 462: Incorrect Engine Coolant Reading

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-14 Incorrect engine coolant reading Engine coolant temperature sensor cannot correctly refl ect cur- Trouble rent coolant temperature. Related information Coolant temperature can be checked on the monitor. Cause Standard value in normal state/Remarks on troubleshooting Standard values for engine coolant temperature sensor 50°C 80 Ω...

  • Page 463: Incorrect Fuel Level Reading

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-15 Incorrect fuel level reading Trouble Engine fuel level sensor cannot correctly refl ect current fuel level. Related information Fuel level can be checked on the monitor. Cause Standard value in normal state/Remarks on troubleshooting ●...
  • Page 464 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-16 Wiper does not work Trouble Wiper does not work Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Keep it at OFF position to perform Internal Fail- troubleshooting.

  • Page 465: Incorrect Arm-In Pilot Pressure Reading

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-17 Incorrect arm-in pilot pressure reading Trouble Reading of arm-in pilot pressure is incorrect. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting.

  • Page 466: Incorrect Arm-Out Pilot Pressure Reading

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-18 Incorrect arm-out pilot pressure reading Trouble Reading of arm-out pilot pressure is incorrect. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting.

  • Page 467: Incorrect Boom-Raise Pilot Pressure Reading

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-19 Incorrect boom-raise pilot pressure reading Trouble Incorrect Boom-Raise Pilot Pressure Reading Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting.

  • Page 468: Incorrect Boom-Lower Pilot Pressure Reading

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-20 Incorrect boom-lower pilot pressure reading Trouble Boom-Lower pilot pressure reading is incorrect. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting.

  • Page 469: Incorrect Bucket-Curl Pilot Pressure Reading

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-21 Incorrect bucket-curl pilot pressure reading Trouble Bucket-curl pilot pressure reading is incorrect. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting.

  • Page 470: Incorrect Bucket-Dump Pilot Pressure Reading

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-22 Incorrect bucket-dump pilot pressure reading Trouble Bucket-dump pilot pressure reading is incorrect. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting.

  • Page 471: Incorrect Swing Pilot Pressure Reading

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-23 Incorrect swing pilot pressure reading Trouble Swing pilot pressure reading is incorrect. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position Failure of 5V to perform troubleshooting.

  • Page 472: Incorrect Left Travel Pilot Pressure Reading

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-24 Incorrect left travel pilot pressure reading Trouble Left Travel Pilot Pressure Reading is incorrect. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting.

  • Page 473: Incorrect Right Travel Pilot Pressure Reading

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator E-25 Incorrect right travel pilot pressure reading Trouble Right travel pilot pressure reading is incorrect. Related information Cause Standard value in normal state/Remarks on troubleshooting ● Turn engine start switch to OFF position. Then, keep it at ON position to Failure of 5V perform troubleshooting.
  • Page 474 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7.7 Troubleshooting of Hydraulic and Mechanical Systems (H - Mode) A Schematic of hydraulic system and mechanical system ............7-94 Information contained in troubleshooting table ................7-96 H-1 Work equipment speed slow, or swing and travel speeds slow ......... 7-97 H-2 Engine speed drops sharply or engine stalls ..............

  • Page 475: A Schematic Of Hydraulic System And Mechanical System

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator A Schematic of hydraulic system and mechanical system PILOT VALVE - L PILOT VALVE - TRAVEL PILOT VALVE - R TRAVEL TRAVEL SWING BOOM BUCKET (LEFT) (RIGHT) LOCK (PILOT VALVE ) BOOM PRIORITY BUCKET CONFLUENCE SWING PRIORITY VARIABLE SPEED (TRAVEL)
  • Page 476 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator ● The system schematic is a simplifi ed hydraulic circuit schematic, which can be used as a ref- erence to the hydraulic system and the mechanical system. SAFETY VALVE SUCTION VALVE SAFETY&SUCTION BUCKET BACKUP VALVE CONFLUENCE CONFLUENCE S&S...

  • Page 477: Information Contained In Troubleshooting Table

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator Information contained in troubleshooting table ● 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...

  • Page 478: Work Equipment Speed Slow, Or Swing And Travel Speeds Slow

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-1 Work equipment speed slow, or swing and travel speeds slow ● Work equipment speed is slow or the travel and swing speeds Trouble are slow. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting.

  • Page 479: Engine Speed Drops Sharply Or Engine Stalls

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-2 Engine speed drops sharply or engine stalls Trouble ● Engine speed drops sharply or engine stalls. Related information ● Information concerned Cause Standard value in normal state/Remarks on troubleshooting Failure of injection pump Injection pump may be defective. Check it directly. Malfunction of regulator Regulator may have malfunction.

  • Page 480: Work Equipment, Swing, And Travel Systems Do Not Work

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-3 Work equipment, swing, and travel systems do not work 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.

  • Page 481: Abnormal Noise In Hydraulic Pump

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-4 Abnormal noise in hydraulic pump Trouble ● Abnormal noise is produced from the hydraulic pump Related information ― Cause Standard value in normal state/Remarks on troubleshooting Low level of Make a visual check. hydraulic oil Inferior hydrau- Hydraulic oil probably contains air.

  • Page 482: Auto Deceleration Not Functioning

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-5 Auto deceleration not functioning Trouble ● Auto-deceleration is not functioning. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 483: Boom Speed Slow

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-6 Boom speed slow Trouble ● The boom moves slowly. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 484: Arm Speed Slow

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-7 Arm speed slow Trouble ● The arm moves slowly. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 485: Bucket Speed Slow

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-8 Bucket speed slow Trouble ● The bucket moves slowly. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 486: Work Equipment Cylinders No Response In Separate Operation

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-9 Work equipment cylinders no response in separate operation ● Boom cylinder gives no response in separate operation. Trouble ● Arm cylinder gives no response in separate operation. ● Bucket cylinder gives no response in separate operation. ●...

  • Page 487: Work Equipment Drifts Excessively

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-10 Work equipment drifts excessively Trouble (1) ● The boom drifts at excessive speed. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting ●...
  • Page 488 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator Trouble (2) ● The arm drifts excessively. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting ● Stop the engine. Perform troubleshooting while the engine is running at high idle.

  • Page 489: Work Equipment Moves Sluggishly

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-11 Work equipment moves sluggishly Trouble ● Work equipment moves sluggishly. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting Malfunction of arm Regeneration valve of arm may have malfunction.

  • Page 490: Travel Speed Drops Considerably While Swinging And Travelling

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-13 Travel speed drops considerably while swinging and travelling Trouble ● Travel speed drops considerably in swinging plus travelling operation. ● If the travel speed is low in only travelling operation, check fi rst ac- Related information cording to H-15.

  • Page 491: Machine Deviates During Travel

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-14 Machine deviates during travel Trouble ● Machine deviates during travel. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 492: Travel Speed Is Low

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-15 Travel speed is low Trouble ● Machine travel speed is low. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 493: Machine Is Not Steered Well Or Steering Power Is Low

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-16 Machine is not steered well or steering power is low Trouble ● Machine is not steered well or steering power is low ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting.

  • Page 494: Travel Speed Cannot Be Changed

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-17 Travel speed cannot be changed Trouble ● Travel speed cannot be changed. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 495: Travel System Fails (Only At One Side)

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-18 Travel system fails (only at one side) Trouble ● One side of the tracks cannot make a turn. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting.

  • Page 496: Swing Operation Fails

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-19 Swing operation fails Trouble (1) ● Upper structure fails to swing in either direction. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting Malfunction of swing Parking brake of swing motor may have malfunction.
  • Page 497 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator Trouble (2) ● Upper structure only fails to swing in one direction. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 498: Swing Acceleration Poor Or Swing Speed Low

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-20 Swing acceleration poor or swing speed low Trouble (1) ● Swing acceleration is poor, or swing speed is low. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting.
  • Page 499 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator ● Swing acceleration is only poor on one side, or swing speed is Trouble (2) low. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting. Cause Standard value in normal state/Remarks on troubleshooting ●...

  • Page 500: Upper Structure Overruns Remarkably When It Stops Swinging

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-21 Upper structure overruns remarkably when it stops swinging ● Upper structure overruns remarkably when it stops swinging in Trouble (1) both directions. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting.

  • Page 501: Large Shock Is Produced When Upper Structure Stops Swinging

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-22 Large shock is produced when upper structure stops swinging Trouble ● Large shock is produced when upper structure stops swinging. ● Set working mode to (S) and fuel control dial at position (10) to Related information carry out troubleshooting.

  • Page 502: Swing Drift Excessive

    Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator H-24 Swing drift excessive ● Hydraulic drift of swing is large (when swing holding brake is ap- Trouble (1) plied). ● When swing lock switch is turned ON or when swing holding Related information brake release switch is in normal position, swing holding brake operates and upper structure is fi...
  • Page 503 Troubleshooting SY195/205/215/225C9 Crawler Hydraulic Excavator 7-122 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 504 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator Disassembly and Assembly 8 Disassembly and Assembly 8.1 How to Read This Manual ..................8-5 8.1.1 Removing and Installing an Assembly ............8-5 8.1.2 Disassembling and assembling an assembly ..........8-5 8.1.3 Special tools....................8-5 8.2.1 The symbols used in this section ..............
  • Page 505 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.9.2 Installation ....................8-34 8.10 Final Drive AS - Remove and Install ..............8-35 8.10.1 Removal ..................... 8-35 8.10.2 Installation ....................8-36 8.11 Final Drive AS - Disassemble and Assemble ............8-37 8.11.1 Disassembly ....................8-37 8.11.2 Assembly ....................
  • Page 506 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.22.1 Removal ..................... 8-80 8.22.2 Installation ....................8-84 8.23 Hydraulic Pump AS - Remove and Install ............8-85 8.23.1 Removal ..................... 8-85 8.23.2 Installation ....................8-89 8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install ....8-90 8.24.1 Removal .....................
  • Page 507 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.35.2 Installation ....................8-147 8.36 Radio ......................... 8-148 8.36.1 Structure ....................8-148 8.36.2 Removal ....................8-149 8.36.3 Installation ....................8-150 8.36.4 Connector model and wiring ..............8-150 8.37 Battery ....................... 8-151 8.37.1 Structure ....................8-151 8.37.2 Removal ....................

  • Page 508: Disassembly And Assembly

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8 DISASSEMBLY AND ASSEMBLY 8.1 How to Read This Manual 8.1.1 Removing and Installing an Assembly Removal ● The "Removal" section contains procedure, precautions and the amount of oil or water to be discharged.

  • Page 509: The Symbols Used In This Section

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.1.4 The symbols used in this section This section uses some symbols and icons that are not used elsewhere in this manual. They in- clude: This symbol indicates the amount of oil or water to be discharged. This symbol indicates that specifi...
  • Page 510 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator ● Precautions to be observed when disassembling the lines The lines disassembled must be blinded with plugs. A: Thread-connected hoses I.D. (mm) Code Description Light Thread Connection B210780001189 Plug B210780001190 Plug B210780000077 Plug B210780000078 Plug B210780000883...
  • Page 511 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 2. Precautions prior to installation operation ● Tighten all the screws and nuts (sleeve nuts) to specifi ed torques. ● Install the hoses without twisting or interference. ● Replace the gaskets, O-rings, cotter pins and lock plates with new parts. ●...
  • Page 512 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 3. Precautions to be observed upon completion of the operations ● 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.

  • Page 513: Start Motor As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.3 Start Motor AS - Remove and Install 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.

  • Page 514: Injection Pump As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.4 Injection Pump AS - Remove and Install 8.4.1 Removal CAUTION ● Disconnect the negative (-) post of the battery. 1. Open the engine hood. ZX215T-1006003 2. Disconnect the air intake hose (1). ZX215T-1006004 3.
  • Page 515 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Disconnect the lubrication tube (6). ZX215T-1006006 5. Disconnect six fuel delivery tubes (7). ZX215T-1006007 6. Disconnect the air hose (8). 7. Remove the bolt (9) fixing the electronic choke. Disconnect the bolt (10) fixing the governor motor.

  • Page 516: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8. Adjust the injection timing of the timing gear. For more information, see “Fuel In- jection Timing - Test and Adjust” on page 6-13. 9. Remove the injection pump mounting nuts in order to disassemble the injection pump assembly.
  • Page 517 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator ● Installation of the fuel injection pump is to be performed as the following: 1) Check the fuel injection timing to see if it has been adjusted properly. ● For more information, see “Fuel Injec- tion Timing - Test and Adjust”...

  • Page 518: Engine Front Seal - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.5 Engine Front Seal - Remove and Install 8.5.1 Removal 1. Remove the radiator assembly. For more information, see “Radiator AS - Remove and Install” on page 8-24. Water pump 2. Remove the engine fan (1), the belt (2) and the pulley (3).

  • Page 519: Engine Rear Seal - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.6 Engine Rear Seal - Remove and Install 8.6.1 Removal 1. Remove the hydraulic pump assembly. For more information, see “Hydraulic Pump AS - Remove and Install” on page 8-85. 2. Remove the bolt (1), the latch piece (2) and the bearing (3).

  • Page 520: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.6.2 Installation ● The installation is to be performed in the reverse order of removal. Bolt: 39 N·m {4.0 kgf·m} + 47° Sealant ● The rear oil seal is to be installed accord- ing to the following procedure: ø2mm 1.

  • Page 521: Cylinder Head As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.7 Cylinder Head AS - Remove and Install 8.7.1 Removal CAUTION ● Disconnect the negative (-) post of the battery. 1. Drain the engine of coolant. Coolant: 18 L 2. Open the engine hood. ZX215T-1006016 3.
  • Page 522 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 5. Remove the fuel filter bracket (4) and the fuel fi lter assembly (5). 6. Remove the six delivery hoses (6). ZX215T-1006019 7. Remove the exhaust muffler connector cover (7). ZX215T-1006020 8. Remove the air cleaner suction hose (8). 9.
  • Page 523 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 11. Remove the turbocharger assembly. ZX215-1006022 12. Remove the exhaust manifold (13). ZX215-1006023 13. Remove the radiator inlet hose (14) and outlet hose (15). ZX215T-1006024 8-20 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 524 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 14. Remove the six nozzle seats (16). ZX215T-1006025 15. Remove the rocker arm housing (17). 16. Remove the rocker arm assembly (18). 17. Remove the pushrod (19). 18. Remove the 25 mounting bolts from the cylinder head assembly.

  • Page 525: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.7.2 Installation ● The installation is to be performed in the reverse order of removal. Installation of cylinder head gasket Choose a cylinder head gasket as per the following. 1. Measure the amount of piston projection of each cylinder.
  • Page 526 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator Bolt (rocker cover installation): 4.9~6.9 N·m {0.5~0.7 kgf·m} Bolt (cylinder head): 147 N·m {15 kgf·m}+90° Bolt threads (cylinder head): Engine oil Tappet circumference: Engine oil Tappet ends: Engine oil ● Adjustment of valve clearance F o r m o r e i n f o r m a t i o n , s e e “...

  • Page 527: Radiator As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.8 Radiator AS - Remove and Install 8.8.1 Removal 1. Open the engine hood. 2. Open the pressure cap (1). Open the drain valve to discharge engine coolant from the coolant tank. Coolant: approx. 18 L Cover plate 3.
  • Page 528 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 9. Disconnect the intercooler air inlet tube (8) and outlet tube (9). ZX215T-1006031 10. Remove the four bolts (10) from the air conditioner radiator. Remove the air condi- tioner radiator and store it properly. ZX215T-1006032 11.
  • Page 529 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 12. Remove the four mounting bolts (12) from the radiator bottom and the two mounting bolts (13) from the left and right brackets. ZX215T-1006034 13. Mount the hoisting bolts (14) to both sides of the radiator in order to hoist the radiator assembly.

  • Page 530: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.8.2 Installation ● Installation is to be performed in the re- verse order of removal. NOTE: ● Adjust the clearance (a) between the fan and the fan guard in order to have a uni- form clearance surrounding the fan.

  • Page 531: Engine And Hydraulic Pump As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.9 Engine and Hydraulic Pump AS - Remove and Install 8.9.1 Removal CAUTION ● Lower the work equipment to the ground. Stop the engine. Disconnect the cable from the battery negative (-) post. ●...
  • Page 532 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 5. Disconnect piping (4), (5) and (6). 6. Remove the sensors (7) and (8). ZX215T-1006037 7. Remove the clamps (9) and (10). Remove the line (11) and the cable (12). ZX215T-1006038 8. Unscrew the connection bolt (13) of the governor motor and the connection bolt (14) of the engine stopper.
  • Page 533 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 11. Disconnect the cables (17) and (18) as well as the tubes (19) and (20) from the compressor. ZX215T-1006040 12. Disconnect the hoses (21), (22), (23) and (24) between the engine and the radiator ZX215T-1006041 13.
  • Page 534 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 14. Disconnect the external cable (26) of the rpm sensor. 15. Disconnect the external cable (27) of en- gine oil pressure sensor. ZX215T-1006043 16. Disconnect the engine oil inlet tube (28) and outlet tube (29). 17.
  • Page 535 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 19. Remove the hose clamp (35). 20. Disconnect the wiring (34) of the water temperature sensor. ZX215T-1006046 21. Disconnect the cables (36) and (37) of the water temperature switch. ZX215T-1006047 22. Disconnect the oil return hose (38). 23.
  • Page 536 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 24. Disconnect the radiator fan guard (40). ZX215T-1006049 25. Remove the fi xing bolt (41) on each of the four mounting plates of the damper. Lift the engine and main pump assembly. Engine and hydraulic pump AS: 640 kg ZX215T-1006050 Shop Manual - June 2013...

  • Page 537: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.9.2 Installation ● Installation is to be performed in the re- verse order of removal. ● Open the radiator tank cover to add cool- ant. Also add coolant to the coolant reser- voir. Engine coolant: approx.

  • Page 538: Final Drive As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.10 Final Drive AS - Remove and Install 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. Remove the sprocket. For more information, see “Sprocket - Remove and Install”...

  • Page 539: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Remove the 30 mounting bolts from the fi nal drive assembly (3), and lift the assem- bly for disassembling. Final Drive Assembly: 250 kg NOTICE ● Be careful not to damage the surface of mounting seal installed on the hose base.

  • Page 540: Final Drive As - Disassemble And Assemble

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.11 Final Drive AS - Disassemble and Assemble 8.11.1 Disassembly 1. Oil draining Open the drain plug to drain the oil from the fi nal drive tank. Final drive tank: approx. 4.7 L 2.
  • Page 541 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. No. 1 planetary carrier assembly 1) Remove the No.1 planetary carrier as- sembly (3). ZX215-1006056 2) Disassembly of No.1 planetary carrier assembly. 3) Remove the screws (4). Remove the coverplate (5) from the planetary carrier assembly (6).
  • Page 542 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 6. Thrust washer Remove the thrust washer (13). 7. No.2 sun gear Remove No.2 sun gear (14). ZX215-1006059 8. Disassembly of No.2 planetary carrier assembly 1) Remove the screws (15). Remove the plate (16) and the planetary gear (17) from the carrier assembly (22).
  • Page 543 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 2) Disassemble the hub assembly as the following. 3) Remove the fl oat seal (25). 4) Remove the bearing (26) and bearing (27) from the hub (28). NOTE: Do not damage the bearing retainer when removing the bearing (26).

  • Page 544: Assembly

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.11.2 Assembly NOTE: Clean all the parts. Check that these parts are free from any contamination or dam- age. Apply some engine oil to the sliding sur- face prior to installation. 1. Hub assembly 1) Install the bearing 26 and bearing (27) by pressing them onto the hub (28).
  • Page 545 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4) Use eyebolts to carefully place the ② hub assembly (24) onto the travel mo- tor. Tap to press fi t the bearing. ZX215-1006061 2. Calculation of shim thickness 1) Measure the thickness (H) of the raised part of No.2 carrier assembly (22).
  • Page 546 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4) Place the shims on the body and insert the dowel pin. Press the carrier assem- bly onto the dowel pin and tighten it with screw (21). Apply locking adhesive Tensiometer to the threads. Screw-locking adhesive: (Tonsan 1277) Screw (21):...
  • Page 547 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Thrust washer Install the thrust washer (13). 5. No.2 sun gear Install No.2 sun gear (14). ZX215-1006059 6. No. 1 sun gear shaft Install No.1 sun gear shaft (12). ZX215-1006058 7. No.1 planetary carrier assembly 1) No.
  • Page 548 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4) Install No.1 planetary carrier assembly (3). ZX215-1006056 8. Spacer Install the spacer (2). ZX215-1006055 9. Cover Use eyebolts to assemble the cover (1). Use a torque spanner to tighten the bolts. Bolts: 73.4±3.63 N·m {7.5±0.4 kgf·m} Torque wrench 10.

  • Page 549: Swing Motor And Swing Drive As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.12 Swing Motor and Swing Drive AS - Remove and Install 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.

  • Page 550: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.12.2 Installation ● Installation is performed in the reverse or- der of removal. Mounting bolts (swing motor and swing drive assembly): 490~608 N·m {50~62 kgf·m} ● Hydraulic oil adding Add hydraulic oil through the fi ller opening to the specified level.

  • Page 551: Swing Motor And Swing Drive As - Disassemble And Assemble

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.13 Swing Motor and Swing Drive AS - Disassemble and Assemble 8.13.1 Disassembly 1. Draining of oil Open the drain plug to drain the oil from the swing drive. Swing drive: approx. 4.4 L 2.
  • Page 552 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. No.1 planetary carrier assembly 1) Remove No.1 carrier assembly (3) and the plate (4). ZX215-1006073 2) Disassemble the carrier assembly. Cut the rivets on the shaft (8) to re- move the shaft (8), and remove in turn the gear (6), bearing (9) and plate (7).
  • Page 553 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 6. No. 2 sun gear Remove No. 2 sun gear (11). ZX215-1006076 7. No.2 planetary carrier assembly 1) Remove No.2 carrier assembly (12). 2) Disassemble No. 2 carrier assembly as per the following procedure. ZX215-1006077 8-50 Shop Manual - June 2013...
  • Page 554 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 3) Insert pin (13) and push the shaft (14) out of the carrier assembly (19). NOTE: Pull out the pin (13) after re- moval of the shaft. 4) Remove the thrust washer (16), gear (17) and a second thrust washer (19).
  • Page 555 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 2) Disassemble the shaft assembly in the Press following procedure. Remove the bearing (23) from the shaft (24). ZX215-1006081 10. Bearing Remove the bearing (25) and the oil seal (26) from the housing (27). ZX215-1006082 8-52 Shop Manual - June 2013...
  • Page 556 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.13.2 Assembly NOTE: Clean all the parts and check for any contamination or damage. Apply engine oil to the sliding surface of the parts. 1. Bearing Press the bearing (23) into the housing (27).

  • Page 557: Assembly

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Bearing Press in the bearing (25). ● When press fitting the bearing, press the bearing inner race and outer race simultaneously. Never press only the inner race. ● After assembling the bearing, check if the housing rotates freely.
  • Page 558 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 6. Assemble in turn the snap ring (20), No.2 carrier assembly and No.2 sun No.2 planetary carrier gear (11). ZX215-1006087 7. Installation of ring gear Apply sealant on the mating surface indicated by (C) and tighten it with screws. Never get the sealant onto the ring gear (10).
  • Page 559 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 5) Install No. 1 carrier assembly (3) and the plate (4). ZX215-1006073 9. No. 1 sun gear assembly Install No. 1 sun gear (2). ZX215-1006072 8-56 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 560 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 10. Installation of swing motor assembly Apply sealant to the contact surfaces of the ring gear and the motor cover, and install the swing motor assembly. Contact surface: Sealant (Loctite 515) Swing motor assembly: 55 kg Mounting bolts (swing motor): 156±5 N·m {16±0.5 kg} NOTE: The 14 bolt holes of the swing...

  • Page 561: Idler As - Disassemble And Assemble

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.14 Idler AS - Disassemble and Assemble 8.14.1 Disassembly 1. Remove the dowel pin (1) and the support (2). 2. Remove the float seals (3) from the sup- 12 10 port (2) and the idler (4). 3.

  • Page 562: Assembly

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.14.2 Assembly 1. Install the bushings (9) and (10) in the idler (4). ZX215-1006093 2. Assemble the O-ring. Install the support (7) to the shaft (5) with the dowel pin (8). 9，10 ZX215-1006092 3.
  • Page 563 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator ● After installation of the float seals, check that the sealing inclination should be less than 1 mm and the seal protru- sion between 5 and 7 mm. ZX215-1006095 4. Install the shaft (5) and support (7) assem- bly to the idler (4).
  • Page 564 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 5. Install the fl oat seal (3) to the idler (4) and support (2). NOTE: Apply oil to the sliding surface of fl oat seal. Care must be taken to keep the sliding surface from any contaminants or dust.

  • Page 565: Sprocket - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.15 Sprocket - Remove and Install 8.15.1 Removal 1. Remove the track assembly. Refer to “Track AS - Remove and Install” on page 8-63. 2. Swing the work equipment 90°and lift the chassis with the work equipment. Place a block between the track frame and the track shoe.

  • Page 566: Track As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.16 Track AS - Remove and Install Special tools Mark Part Name Necessity Qty Manual/electric hydraulic track removing/installing ● machine 8.16.1 Removal 1. Choose a place that has enough space to spread the track. Park the machine when the master pin is between the idler and the carrier roller.
  • Page 567 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Remove the tool (M). Move the machine forward so that the temporary pin is in front of the idler. Place the block . 5. Remove the temporary pin and the dust seal. Move the machine backward to ②...

  • Page 568: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.16.2 Installation ● Installation is to be performed in the re- Track shoe nut Corner verse order of removal. (Square) For more information, see “Track Tension - Test and Adjust” on page 6-24. Corner ●...

  • Page 569: Swing Bearing As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.17 Swing Bearing AS - Remove and Install 8.17.1 Removal 1. Remove the swing platform assembly. For more information, see “Swing Platform AS - Remove and Install” on page 8-68. 2. Dismount the 36 bolts (1) to remove the swing bearing assembly.

  • Page 570: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.17.2 Installation ● Installation is to be performed in the re- verse order of removal. Threads (bolt - swing bearing): Thread adhesive (Tonsun 1277) Mounting bolts (swing bearing): Step 1: Use a pneumatic spanner to tighten the bolts.

  • Page 571: Swing Platform As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.18 Swing Platform AS - Remove and Install 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. 1.
  • Page 572 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 5. Remove the plate (3) and the pin (4). Lift the boom cylinder assembly (2) in order to remove it. ● Remove the boom cylinder assembly on the other side in the same way. Boom cylinder AS: 230 kg ZX215T-1006110 6.
  • Page 573 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 9. Unscrew the 32 swing platform mounting bolts in order to remove the swing platform assembly (15). Lift the swing platform as- sembly off the machine. NOTE: Remove the front and rear mount- ing bolts of the platform.

  • Page 574: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.18.2 Installation ● Installation is to be performed in the re- verse order of removal. Clamping screws (air intake hose): 5.4~6.4 N·m {0.55~0.65 kgf·m} Mating surface (swing bearing): Flat surface sealant (Tonsun 1596) Threads (bolt - swing platform): Thread adhesive: (Tonsun 1277) Mounting bolts (swing platform):...

  • Page 575: Swivel Joint As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.19 Swivel Joint AS - Remove and Install 8.19.1 Removal WARNING ● Release residual pressure in the hy- draulic circuit before disconnecting the hydraulic hoses. Refer to “Residual Pressure in Hydraulic Cir- cuit - Release” on page 6-40. NOTE: Tag each line so as to ensure correc- tion installation.
  • Page 576 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 2. Disconnect the eight hoses from (7) to (14). 7) Central swivel joint (port F) - Left travel motor (port P) 8) Central swivel joint (port F) - Right trav- el motor (port P) 9) Central swivel joint (port G) - Swing motor (port T) 10) Central swivel joint (port F) - Solenoid...

  • Page 577: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.19.2 Installation ● Installation is to be performed in the re- verse order of removal. NOTE: Install the central swivel joint facing the direction indicated in the illustration. Central swivel joint Sprocket ● Oil adding (hydraulic tank) Add through the fi...

  • Page 578: Swivel Joint As - Disassemble And Assemble

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.20 Swivel Joint AS - Disassemble and Assemble 8.20.1 Disassembly 1. Remove the bolt (1) and the spring washer (2). 2. Remove the cover (3). 3. Remove the gasket (4), O-ring (5) and snap ring (6).

  • Page 579: Assembly

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.20.2 Assembly 1. Install the dust seal (12) on the rotor (13). NOTE: Let the lip face the housing while Dust seal installing the dust seal. 2. Install the six seals (10) in the housing (9). 3.

  • Page 580: Hydraulic Tank As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.21 Hydraulic Tank AS - Remove and Install 8.21.1 Removal 1. Drain the hydraulic oil into a suitable container for storage or disposal. Hydraulic oil: approx. 225 L 2. Open the engine hood. 3.
  • Page 581 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8. Disconnect the seven hoses. ● (11): Oil return - pilot T block ● (12): Oil return - main pump ● (13): Oil return D2 - main valve ● (14): Sensor - temperature ●...

  • Page 582: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.21.2 Installation ● Installation is to be performed in the re- verse order of removal. Screw Drain plug (hydraulic tank): 58.8~78.5 N·m {6.0~8.0 kgf·m} NOTE: After tightening the hose clamping screw, check that the screw should be in Down the range indicated in the illustration.

  • Page 583: Control Valve As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.22 Control Valve AS - Remove and Install 8.22.1 Removal WARNING ● 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.
  • Page 584 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 5. Disconnect the pilot hoses (10) to (18) and tag them properly. (10): XBtr Travel RIGHT (11): XAs Swing LEFT (12): PSP Swing priority (13): XAa1 Arm OUT (14): XBp2 Bucket confl uence (15): XBtL Travel LEFT ZXT225-1106012 (16): XAb1 Boom UP...
  • Page 585 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 10. Remove central swivel joint hoses (28), (29), (30) and (31). Remove travel speed switching hose (32) and seal the ports. ZXT225-1106015 11. Remove swing motor hoses (33) and (34). Remove swing motor oil complement hose (35).
  • Page 586 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 13. Remove pipe (37) (main valve to return oil tank). Seal the ports properly. ZXT225-1106018 14. Remove hydraulic pump hoses (38) and (39). ZXT225-1106019 15. Remove hoses (40) to (44) on the solenoid valve and tag them properly.

  • Page 587: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 16. Remove the fi xing bolts (45). Lift the con- trol valve assembly (46) for disassembling. Control valve assembly: 220 kg ZXT225-1106021 8.22.2 Installation ● Installation is to be performed in the re- verse order of removal.

  • Page 588: Hydraulic Pump As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.23 Hydraulic Pump AS - Remove and Install 8.23.1 Removal WARNING ● 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.
  • Page 589 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 3. Remove the pin (2) and the bolts (3). Lift the engine hood in order to remove it. ZX215T-1006146 4. Remove the right upper cover (4). ZX215T-1006147 5. Disconnect the hose (5) supplying oil to the lower proportional valve and the hose (6) delivering oil from the pilot pump.
  • Page 590 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 6. Disconnect the shutdown wire (7). ZX215T-1006149 7. Remove the right door (8). 8. Remove the hydraulic pump cover (9). ZX215T-1006150 9. Disconnect the oil drain hose (10) and seal the openings properly. 10.
  • Page 591 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 14. Disconnect the solenoid valve harnesses (16) and (17). Remove the cable straps (18) and (19). ZX215T-1006152 15. Remove the four bolts (20) of the hydraulic pump. Lift the hydraulic pump assembly (21) to remove it. Hydraulic pump assembly: 112 kg ZX215T-1006153 8-88...

  • Page 592: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.23.2 Installation ● Installation is to be performed in the re- verse order of removal. Screw NOTE: After tightening the hose clamping screw, check that the screw should be in the range indicated in the illustration. Screw (hose clamp): Down 8.8±0.5 N·m {0.9±0.05 kgf·m}...

  • Page 593: Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.24 Middle Oil Seal (Hydraulic Pump Input Shaft)- Remove and Install 8.24.1 Removal 1. Remove the hydraulic pump assembly (1). For more information, see “Hydraulic Pump AS - Remove and Install” on page 8-85. 2.

  • Page 594: Pilot Valve As (Work Equipment) - Disassemble And Assemble

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.25 Pilot Valve AS (Work Equipment) - Disassemble and Assemble NOTE: This section discusses only the precautions when reassembling the work equipment pilot valve assembly. ZX215T-1006156 8.25.1 Assembly ● Reassembly of the work equipment pilot Plug (5) circumference: valve assembly Grease (No.1 Calcium base grease)
  • Page 595 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator ● 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.

  • Page 596: Pilot Valve As (Travel) - Disassemble And Assemble

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.26 Pilot Valve AS (Travel) - Disassemble and Assemble NOTE: This section discusses only the precautions when reassembling the travel pilot valve as- sembly. Plunger ZX215T-1006158 8.26.1 Assembly ● Reassembly of the pedal pilot valve assembly 1.

  • Page 597: Hydraulic Cylinder As - Disassemble And Assemble

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.27 Hydraulic Cylinder AS - Disassemble and Assemble Special tools Application Tool Shape Necessity Quantity Pulling out/pushing ■ in the bushing Press fi tting the ■ dust ring O-ring seal correc- ■ tion Inserting tool Correcting tool Inserting the cylin-...

  • Page 598: Disassembly

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.27.1 Disassembly 1. Drain the oil and remove the tubing. 2. Fix the cylinder. ● Fix the cylinder in a vertical or level manner. A vertically fixed cylinder can be disassembled and assembled eas- ily.
  • Page 599 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Pulling out the piston rod ● Be sure to have removed the tubing cover. ● Prepare a suitable container to collect oil coming out of the oil port. ● After pulling out the piston rod to its limit, slowly loosen the cylinder head and pull it out.
  • Page 600 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 6. Remove of the piston nut (5) Drill bit 1) Remove the fixing screw (3) from the piston nut (5). NOTE: Around the fixing screw there are two points that have been punched against loosening.
  • Page 601 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8. Removal of the buffer sleeve (8) on the bottom end Thread 1) Remove fi rst the piston nut (5). Piston rod 2) Use a tool like rubber hammer to tap the piston nut (5) slightly for removal while keeping the piston rod and the buffer sleeve (8) intact.
  • Page 602 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 11. Removal of the U-ring (17) and the dust ring (18) Press 1) Remove the U-ring (17) with a tool such as screwdriver. Cushion 2) Pierce a tool (such as a screwdriver) into the dust ring (18) and hammer the screwdriver to remove the dust ring (18).

  • Page 603: Assembly

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.27.2 Assembly 1. Installation of bushing (21) 1) Use a mounting tool to press the bush- Press ing (21) into the bushing (lubricated with hydraulic oil) on the side of piston Mounting tool rod and cylinder barrel.
  • Page 604 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4) Installation of buffer ring (16) NOTE: Make sure that the seal is in- stalled in correct direction. Inverse in- stallation can cause high pressure be- tween the buffer ring (16) and the U-ring (17), which may lead to deformation or breakage of oil cylinder.
  • Page 605 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Assembling the piston rod assembly 1) Fix the piston rod (1). Assembly tool 2) Install the cylinder (2) on the piston rod. NOTE: Make sure that the dust ring lip or the U-ring lip is not stopped by the shoulder of any part.
  • Page 606 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 10) The buffer sleeve (6) must be installed according to the illustration on the right. 11) Tighten the piston nut (5). Piston nut (arm): 9600 N·m {979.6 kgf·m} Piston nut (boom and bucket): 6200 N·m {632.6 kgf·m} Gap facing piston side NOTE:...
  • Page 607 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 5. Install the piston into the cylinder barrel Tool Nylon sleeve 1) Fix the barrel in a vertical or level man- (2 pcs type) ner. 2) Install the piston rod into the cylinder (Spread the gaps by 180°) barrel.

  • Page 608: Work Equipment As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.28 Work Equipment AS - Remove and Install 8.28.1 Removal WARNING ● Fully extend the arm and the bucket. Lower the work equipment to the ground. Move the hydraulic lockout control to the LOCK position. ●...
  • Page 609 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 7. Lift the work equipment and remove the plate (9). Remove the pin (10) from the bottom. NOTE: There are shims installed. Count the shims and mark their locations. ZX215T-1006188 8. Lift and disassemble the work equipment assembly.

  • Page 610: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.28.2 Installation CAUTION ● Do not put your finger in the pin bore while aligning the pin bore. ● Installation is to be performed in the re- verse order of removal. NOTE: A clearance (a: 0.5~1.5 mm) shall be left between the plate and the nut when tightening the locknut.

  • Page 611: Air Conditioner As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.29 Air Conditioner AS - Remove and Install Special tools Part Name Model Necessity Qty Refrigerant Robinair ● charger 34711-2K Refrigerant Inoue Qing- ● charger 8.29.1 Removal CAUTION ● Disconnect the cable from the negative (-) post of the battery.
  • Page 612 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Open the left rear cover of the cab with the ignition key. Remove the outer filter ele- ment (2). Cover W13092904 5. Remove the fuse box (3) and storage box (4). 6. Remove outer covering (5). 7.
  • Page 613 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 12. Remove the cover (11). 13. Remove the cab's center connector (12). 14. Remove the radio antenna(13). ZXT225-1006206 15. Remove the connector (14), connector (15) and air conditioner wiring connection (16). Remove the two air conditioner relays (17), three mounting bolts (18).
  • Page 614 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 17. Remove the air conditioner unit (23). NOTE: Also disconnect the two hoses con- necting to the bottom of the air conditioner when removing the air conditioner unit. ZX215T-1006201 Shop Manual - June 2013 8-111 https://www.tractormanualpdf.info/...

  • Page 615: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.29.2 Installation ● Installation is to be performed in the re- verse order of removal. NOTICE ● Keep the hoses free from contamination by dirt, dust or water while installing the return hose of the air conditioner. ●...

  • Page 616: Counterweight As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.30 Counterweight AS - Remove and Install 8.30.1 Removal 1. Remove the cover (1) from the counter- weight. Install eyebolts to the counter- weight. Hold the counterweight. ZX225-1106004 2. Remove the four bolts (2). Wire rope ZX225-1106005 3.

  • Page 617: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.30.2 Installation ● Installation is to be performed in the re- verse order of removal. Threads (mounting bolt - counter- weight): Thread adhesive (Tonsun 1277) Mounting bolt (counterweight): 1,180~1,470 N·m {120~150 kgf·m} Counterweight adjustment 1.

  • Page 618: Cab As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.31 Cab AS - Remove and Install 8.31.1 Removal CAUTION ● Disconnect fi rst the cable connecting to the negative (-) post of the battery. 1. Remove the fl oor mat (1). ZX215T-1006193 2.
  • Page 619 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 7. Remove external air fi lter (10). ZXT225-1006217 8. Disconnect the external air duct (11). ZX215T-1006210 9. Remove the storage box on the armrest (12). ZX215T-1006211 8-116 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 620 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 10. Remove the radio connector (13). 11. Remove the radio wire harness (14). ZX215T-1006212 12. Remove the window washer reservoir (15). ZX215T-1006213 13. Remove the window washer pipe (16). ZX215T-1006214 Shop Manual - June 2013 8-117 https://www.tractormanualpdf.info/...
  • Page 621 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 14. Remove the decor cover (17). ZX215T-1006215 15. Remove the four mounting nuts (18) and the fi ve mounting bolts (19). ZXT225-1006224 16. Lift the cab assembly (20) for removal. Cab assembly: 450 kg ZX215T-1006217 8-118 Shop Manual - June 2013...

  • Page 622: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.31.2 Installation ● Installation is to be performed in the re- verse order of removal. Bolt: 200 N·m {20.4 kgf·m} Nut: 210 N·m {21.4 kgf·m} Shop Manual - June 2013 8-119 https://www.tractormanualpdf.info/...

  • Page 623: Cab Window Glass - Disassemble And Assemble

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.32 Cab Window Glass – Disassemble and Assemble 10 11 ZX215-1006218 Right window glass Left side rear window glass Front window glass Rear window glass Lower front glass Roof window glass Cab door window glass (upper) 10) Rubber sealing strip Cab door window glass (lower) 11) Center adjusting seal...

  • Page 624: Removal

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.32.1 Removal CAUTION ● Removing shattered or cracked window glass may cause fi nger cuts. ● Wear proper PPEs when removing shat- tered cab window glasses. NOTE: To avoid fi nger cut during when remov- ing a shattered or cracked glass, cover it with a piece of adhesive fi...
  • Page 625 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 3) Remove glass (4) and (6) from the frame with a screw driver. Frame Seal ZX215-1006221 3. Removal of glass (8) 1) Remove the retainer from the groove on the rubber with an ordinary screw driver.
  • Page 626 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Removal of glass (1), (2), (5), (7) and (9). ZX215-1006223 1) Remove the resin board, decor strip and retainer along the edge of the glass. Glass Drill 2) Punch a hole through the adhesive with a drill (or a cutter) as illustrated.
  • Page 627 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4) Fix both ends of the piano string onto two screw drivers. Pull the wire back (Outside) and forth in order to cut the adhesive and detach the glass from the cab. This Glass job may require 2-3 people.

  • Page 628: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.32.2 Installation ● Reverse the disassembling sequence when installing glasses (3), (4), (6) and (8). Follow the procedures below to install glasses (1), (2), (5), (7) and (9). 1. Clean the remaining adhesive and rubber on cab frame (contact surface) with a knife or scraper [5].
  • Page 629 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 3. Priming coat (10) ● Priming paint expires 4 months after production. Do not use expired paint. ● Use the paint within 2 hours after it is unsealed. ● Use the paint within 24 hours even if it is sealed again immediately after un- Old adhesive edge sealing.
  • Page 630 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 3) Apply priming paint (for painted sur- face) evenly onto the surface where sealing rubber is to be adhered and where adhesive agent is to be applied (on the cab (8)). Priming paint (for painted sur- face): Sunrise MSI Primer 24 ●...
  • Page 631 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator ● Dry the primer for at least 5 minutes (within 8 hours). ● Do not use wrong priming paint. If, for example, glass primer is mistak- enly used, wash it with unleaded gaso- line.
  • Page 632 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Adhere rubber seal (6) (with adhesive tape on both sides) along the inner edge of the contact surface of the glass. ● Do not detach the waxed paper on the rubber seal before the window glass is installed.
  • Page 633 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 2) Adhere rubber seal (6) on the left cab window as illustrated. ZXT225-1006248 3) Adhere rubber seal (6) onto the lower cab door window as illustrated. ZXT225-1006249 ● Adhere additional rubber seal (6b) onto the lower cab door window frame as il- lustrated.
  • Page 634 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4) Adhere rubber seal (6) onto the front window glass as illustrated. ZX215-1006243 ● Different from the rubber seal (6) on other window, rubber seal (6c) on the bottom of the front window shall be adhered onto the external edge of the lower part of the front window frame.
  • Page 635 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator ● When positioning front window glass (4), cover it across the width of the win- dow frame in the horizontal direction. Set the clearance (p) between the top edge of the glass and the upper frame at 3 mm when positioning it in the verti- cal direction.
  • Page 636 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 6. Adhesive ● Store adhesion agent in dark places where temperature is blow 25°C. ● Do not heat the adhesive to above 30°C. ● Before using adhesive that has been unsealed, remove the hardened part at the nozzle.
  • Page 637 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4) Remove the waxed paper of the rubber seal on the surface where adhesive is to be applied. 5) Apply adhesive (15) along the external edge of the rubber seal (6). ZX215-1006250 ● Adhesive (15) for rubber seal (6) on cab (8) shall be applied as illustrated: Dimension of (s): 10 mm Dimension of (t): 15 mm...
  • Page 638 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator ● Apply adhesive (15) onto the additional rubber seal of the right window (6a) and additional rubber seal of the cab door lower window (6b). ZX215-1006252 ZX215-1006253 7. Install window glass 1) Install window glass (9) and align it with the mark on the cab.
  • Page 639 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator ● After the front window glass has been installed, fi ll the clearance between the glass on area (s) and the center adjust- ing seal (16) to the dimension of (t) and (u). Coat primer onto glass (4) on sec- tion A-A and apply the adhesive as fi...
  • Page 640 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 2) Use foam polystyrene blocks [9] and rubber band [10] to fix the glass and [10] the rubber seal as illustrated. 9. After the glass has been fi xed, remove all the remaining primer and adhesive on the cab and on the glass.

  • Page 641: Front Window As - Disassemble And Assemble

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.33 Front Window AS - Disassemble and Assemble NOTICE ● Before removing the front window as- sembly, lower the work equipment onto the ground and shut down the engine. The front window assembly must be removed from the cab in order to replace the front win- dow glass.
  • Page 642 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 6. Remove pin (7) at the lower left side. ● Plate (8) at the end of the pull rod (9) will come out by removing of pin (7). ● Hang plate (8) onto the mounting bolt of left corner plate (using the washer) and fi...
  • Page 643 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8. Lower the front window assembly (10) completely. ● Be careful not to allow the front window assembly to damage the machine mon- itor. ZX215-1006263 9. Move the front window assembly (10) to the right and the left and remove the two upper rollers (11) and (12) from the guide rail.

  • Page 644: Assemble

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.33.2 Assemble ● Reverse the disassembling sequence. ● Adjust the opening and closing of the front window assembly as per the following in- struction. 1. Open and close the front window assembly and check if it interferes with the guide rail. Check if the roller is jammed.
  • Page 645 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 5. Install left corner plate (1) ● After the "locked" position is adjusted in Step 6, tighten the corner plate. ● Install left corner plate. Clearance (b) between the guide rail and the left cor- ner plate (1) is 0 –...
  • Page 646 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 7. After adjustment is fi nished, fl ush the front window glass and check if any water leaks into the cab. ZX215-1006272 8. Adjust the "locked" position of the lock of front window assembly 1) After the "locked"...
  • Page 647 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 3) Close the front window assembly (10). 4) Loosen the retaining nut (20) at the left and right side of rubber stopper (18), and pull the two rubber stoppers (18) inward so that they can not contact the "unlocked"...
  • Page 648 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 9. Adjust the front window assembly retainer (24). ● Adjust and lock both sides of the retain- er (24) so that surface (d) of stopper (D) of front window assembly contacts surface (c) of retainer (24) when front window assembly is raised.

  • Page 649: Monitor - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.34 Monitor - Remove and Install 8.34.1 Removal CAUTION ● Disconnect fi rst the cable connecting to the negative (-) post of the battery. 1. Unscrew the three bolts (4). Remove the mounting plate and the monitor assembly from the bracket (3).

  • Page 650: Controller As - Remove And Install

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.35 Controller AS - Remove and Install 8.35.1 Removal CAUTION ● Disconnect fi rst the cable connecting to the negative (-) post of the battery. 1. Remove the fuse box (1) and storage box (2).

  • Page 651: Radio

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.36 Radio 8.36.1 Structure 1. Main structure ZX215-1006284 2. Wiring BACK PANEL POWER, GROUND AND AUDIO OUTPUT ZX215-1006285 8-148 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 652: Removal

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.36.2 Removal NOTICE ● Disconnect the power supply prior to removal. 1. Remove the console cover. Arm rest cover Radio ZX215-1006286 2. Remove the radio connector CN-003F. Connector CN-003F Cab harness ZX215-1006287 3. Remove the four screws and the washers in order to remove the radio and the radio mounting brackets from the console cover.

  • Page 653: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.36.3 Installation ● Installation is to be performed in the re- verse order of removal. 8.36.4 Connector model and wiring Harness socket terminals Raido wiring terminals Type: Yasaki 7119-3070 ZX215-1006289 8-150 Shop Manual - June 2013 https://www.tractormanualpdf.info/...

  • Page 654: Battery

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.37 Battery 8.37.1 Structure ZX215-1006290 Spinning post Paste (active material) Charge densiometer "Bag-type" screen Heat-sealing cover Polar group PP casing 10) Liquid-gas separator Central polar ear 11) Central busbar Forged grid Shop Manual - June 2013 8-151 https://www.tractormanualpdf.info/...

  • Page 655: Removal

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.37.2 Removal NOTICE ● Turn the start switch to the OFF posi- tion before removal. ● Do not remove the charge densimeter. Tighten the densimeter clockwise, if it Bolt Terminal Grounding cable is loosened, with a suitable tool. 1.

  • Page 656: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.37.3 Installation ● Installation is to be performed in the re- verse order of removal. 8.37.4 Replacement There are two 12V batteries with ground- ing negative (-) posts in the machine. If one battery fails in the 24V system, it must be re- placed with one of the same type.

  • Page 657: Start Switch

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.38 Start Switch 8.38.1 Structure 12,11 10,9,8,7 25,24 4,3,2 ZX215-1006294 Housing Shield 15) Cover 22) Contact SPR-A 16) Spring 23) Contact B Ring 10) Spring 17) Ball 24) Terminal Knob 11) Disc 18) Spring 25) Bolt 12) Spring 19) Contact SPR-B...

  • Page 658: Removal

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.38.2 Removal NOTICE ● Disconnect the power supply of the start switch before removal. 1. Remove the setscrew to remove the con- sole cover. Start swich Console cover Set screw ZX215-1006295 2. Remove both setscrews in order to remove Set screw Console cover the mounting plate and the start switch from the console cover.
  • Page 659 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator Working principle and wiring of start switch 1. Working principle ON/OFF Key Position Preheat Plug Battery (B) Battery Relay (BR) Accessory Start Relay (C) (R1) (R2) HEAT START 2. Wiring HARNESS PLUG TERMINALS JACKET MODEL YAZAKI 7123-7464-30 KEY SWITCH WIRING TERMINALS JACKET MODEL YAZAKI 7222-7464-30...

  • Page 660: Fuse Box

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.39 Fuse Box 8.39.1 Removal 1. Remove the cover. Cover ZX215-1006300 2. Remove the bolts and take off the back cover along with the fuse box. Back cover Fuse box cover Bolt ZX215-1006301 3.
  • Page 661 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.40 Wiper 8.40.1 Structure Blade Rotating mechanism Wiper motor Connector Mounting bracket ZX215-1006303 8.40.2 Working principle GREEN (LOW SPEED) YELLOW (RESET) BLUE (HIGH SPEED) RED (POWER+) BLACK (POWER-) ZX215-1006304 8-158 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 662 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.40.3 Removal 1. Remove the decorative button in order to remove the interior decoration. Decoration button Inner decor ZX215-1006305 2. Remove the moving mechanism and the motor. Bolt ● Unscrew the bolts to remove the wiper motor and moving mechanism from the Moving cab.

  • Page 663: Installation

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.40.5 Installation ● Installation is to be performed in the re- verse order of removal. 8.40.4 Angle adjustment of wiper arm ● The arm should stops moving when the Stopper blade reaches the stopper. ●...

  • Page 664: Relay

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.41 Relay 8.41.1 Engine relays 1. Starter relay - check ● Check the conduction and action. Replace the relay in case of any failure. SW(-) L(-) ZX215-1006309 2. Mains relay - check 1(+) ●...

  • Page 665: Other Relays

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Safety relay Measure the resistance between terminal 2 and terminal 3. Standard Value Approx. 200Ω ● Check the conduction and action. Replace (P)6 the relay in case of any failure. 3(R) 2(L) (E)4 1(S) 8.41.2 Other relays...
  • Page 666 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 2. Removal 1) Remove relay from its seat. Relay harness Mounting plate 2) Remove the screw in order to remove the relay seat and harness from the mounting plate. 3. Installation ● Installation is to be performed in the re- verse order of removal.
  • Page 667 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 4. Relay connector and wiring Relay wiring terminals Relay model: HELLA 4RD 007 903-027 Horn relay Work lamp relay Pilot control relay Starter control relay Parking relay Head lamp relay Shutdown delay relay Harness socket terminals Socket model: Jacket 8JA003526-00 ZX215-1006315...

  • Page 668: Sensor

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.42 Sensor 1. Water temperature sensor - check ● Put the sensor into a vessel containing en- gine oil. ● Heat the oil to the specified temperature. Stir the oil at the same time. Sensor body ●...
  • Page 669 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 3. Pressure sensor - check ● Input volt: 4.75~5.25VDC ● Output volt: 0.5~4.5V ● Pressure range: 0~50BAR 4. Fuel level sensor - check ● Swing the float up and down in order to measure the effective angle of radial swing, i.e.

  • Page 670: Connector Terminals - Insert And Remove

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.43 Connector Terminals - Insert and Remove 8.43.1 Insertion 1. Hold tightly a wire terminal at a distance of about 25 mm from its end. ZX215-1006320 2. Hold the connector. Let the rear seal face you.

  • Page 671: Removal

    Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8.43.2 Removal 1. Hold the connector, with its back end fac- ing you. Select a suitable tool and clip on the wire. ZX215-1006323 2. Push the tool along the wire into the con- nector so that the tool can expand the ter- minal lock shoulder and reach its flanged part.
  • Page 672 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator Shop Manual - June 2013 8-169 https://www.tractormanualpdf.info/...
  • Page 673 Disassembly and Assembly SY195/205/215/225C9 Crawler Hydraulic Excavator 8-170 Shop Manual - June 2013 https://www.tractormanualpdf.info/...
  • Page 674 System Schematics SY195/205/215/225C9 Crawler Hydraulic Excavator System Schematics 9 System Schematics 9.1 Hydraulic System Diagram ..................9-3 9.2 Air-Conditioning Electrical Circuit Diagram .............. 9-4 9.3 Fuse Box Relay ....................... 9-5 9.4 Control Switches and Monitor Electrical Diagram ........... 9-6 9.5 Operator Cab Electrical Circuit Diagram..............9-7 9.6 Chassis Electrical Circuit Diagram................
  • Page 675 System Schematics SY195/205/215/225C9 Crawler Hydraulic Excavator 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.
  • Page 676 SY195/205/215/225C9 Crawler Hydraulic Excavator System Schematics 9.1 Hydraulic System Diagram PPC LOCK VALVE TO PnA2 BOOM TO ARM PRIORITY TO MAIN VALVE Xbp2 BKT CONFLUENCE TO MAIN VALVE PsP SWING MECHANISM SWING PRIORITY TRANSITION BLOCK (P5) (P4) TO MAIN VALVE BOOM DOWN XBb1 TO SWIVEL JOINT SIGNAL PORT...
  • Page 677 SY195/205/215/225C9 Crawler Hydraulic Excavator System Schematics 9.2 Air-Conditioning Electrical Circuit Diagram CONTROL PANEL A C M CN-M30 CN-M29 CN-M33 CN-M28 CN-M27 SERVO MOTOR - DIFFUSER CONVERSION SENSOR - INTERNAL TEMP. T H I CN-M34 CN-P15 0.5WY FACE 0.5WR FOOT SERVO MOTOR - 0.5BrW DIFFUSER CONVERSION 0.5BW...
  • Page 678 SY195/205/215/225C9 Crawler Hydraulic Excavator System Schematics 9.3 Fuse Box Relay PARKING RELAY TOP LIGHT RELAY HORN RELAY PILOT VALVE RELAY START RELAY HEADLIGHT RELAY 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 105 11 9 10 11 12 13 14 15 16 1 2 3...
  • Page 679 SY195/205/215/225C9 Crawler Hydraulic Excavator System Schematics 9.4 Control Switches and Monitor Electrical Diagram WORK LAMP SWITCH WIPER SWITCH WASHER SWITCH START SWITCH TERMINAL R2 C CN-303M CN-304M CN-305M HEAT 35 H 35 L 35 L START CN-331F TO CAB HARNESS CN-131M 35 H CN-302F CN-306M...
  • Page 680 SY195/205/215/225C9 Crawler Hydraulic Excavator System Schematics 9.5 Operator Cab Electrical Circuit Diagram TO FUSE BOX RELAY HARNESS CN-221M TO CHASSIS HARNESS CN-442F TO FUSE BOX RELAY HARNESS CN-661M CN-121F CN-142M CN-161F TO WIPER MOTOR CN-112M TO ACCESS LAMP 9 10 11 12 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 0 28...
  • Page 681 SY195/205/215/225C9 Crawler Hydraulic Excavator System Schematics 9.6 Chassis Electrical Circuit Diagram CN-441M CN-501M CN-1-111M CN-442F CN-616F CN-152M CN-153M TO FUSE BOX RELAY HARNESS CN-241F TO CONTROL SW MONITOR HARNESS CN-7-111F TO CAB HARNESS CN-142M GROUND TO GPS CN-204F CN-412F CN-7-112F CN-113M F-106 CN-101M...

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