SANY SY195C9 Shop Manual Download

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SANY LATIN AMERICA

7-67

SY195/205/215/225C9 Crawler Hydraulic Excavator

Troubleshooting

Shop Manual - June 2013

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.

Possible causes and standard value in normal state

Cause

Standard value in normal state/Remarks on troubleshooting

Open circuit of
wire harness

●

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

Unplug the connector controller, and measure

the resistance between pin 19 and pin 38.

Resistance

2.3±0.2 K

Internal failure
in sensor

●

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

Between CN-448M A and B

Resistance

2.3±0.2 K

Short circuit of
wire harness
(grounded)

●

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

Between CN-448M B and ground

Resistance

≥

Internal failure
of controller

No troubleshooting can be done due to internal failure. (Failure lies in the con-
troller if the reasons above are ruled out)

（

S-2

）

CN-448M

ZX215-1005096

INPUT SIGNAL

GND

SPEED SENSOR

GND

CONTROLLER

SIGNAL

CAB

CHASSIS HARNESS

https://www.tractormanualpdf.info/

Summary of Contents for SY195C9

Page 1: ...ghai 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 www sanygroup com Quailty Changes the World Crawler Hydraulic Excavator SY195C9 SY205C9 SY215C9 SY225C9 Shop Manual https www tractormanualpdf info ...

Page 2: ...de technical information required for maintenance and repair of the machine Work equipment or optional components not available locally may be included in this shop manual Consult authorized Sany dealers for information on these parts and components Ma terial or technical specification is subject to change without prior notice https www tractormanualpdf info ...

Page 3: ... A M E R I C A 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: ...ening Torques 1 21 1 6 Type of Bolts 1 22 1 7 Tightening Sequence 1 22 1 8 Maintenance of Half Flanges 1 23 1 8 1 Table of tightening torques for half flange bolts 1 23 1 9 Conversion Table 1 24 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 ...

Page 5: ...ockout 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 2 25 3 Specifications 3 1 Dimensions 3 3 3 2 Working Ranges 3 4 3 3 Technical Specifications 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 4 Stru...

Page 6: ...ydraulic System Part 2 4 43 4 5 1 Control valve 4 43 4 5 2 Operating principle 4 46 4 5 2 1 When spool is in neutral position 4 46 4 5 2 2 Travel 4 48 4 5 2 3 Arm 4 49 4 5 2 4 Boom 4 54 4 5 2 5 Bucket 4 57 4 5 2 6 Swing 4 59 4 5 2 7 Option 4 61 4 5 2 8 Travel straight 4 62 4 5 2 9 Lock valve function 4 63 4 5 2 10 Main relief valve function 4 65 4 5 2 11 Port relief valve function 4 66 4 5 3 Secti...

Page 7: ...panel 4 131 4 7 3 Circuit diagram 4 132 4 7 4 Refrigeration principle 4 134 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 4 139 4 7 11 Pressure switch 4 140 4 7 12 Fresh air sensor 4 141 4 7 13 Refrigerant 4 141 4 7 14 Compressor oi...

Page 8: ...0 4 9 11 Electrical Components 4 192 4 9 11 1 Pump pressure sensor 4 192 4 9 11 2 Pilot pressure sensor 4 193 4 9 11 3 Engine speed sensor 4 194 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 5 Standard Values 5 1 Sta...

Page 9: ...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 6 40 6 18 Oil Leakage Measure 6 41 6 19 Air in Each Component Bleed 6 46 7 Troubleshooting 7 1 Points to Remember When Troubleshooting 7 3 7 2 Troubleshooting Procedures 7 5 7 3 Connector ...

Page 10: ... Pump AS Remove and Install 8 11 8 4 1 Removal 8 11 8 4 2 Installation 8 13 8 5 Engine Front Seal Remove and Install 8 15 8 5 1 Removal 8 15 8 5 2 Installation 8 15 8 6 Engine Rear Seal Remove and Install 8 16 8 6 1 Removal 8 16 8 6 2 Installation 8 17 8 7 Cylinder Head AS Remove and Install 8 18 8 7 1 Removal 8 18 8 7 2 Installation 8 22 8 8 Radiator AS Remove and Install 8 24 8 8 1 Removal 8 24 ...

Page 11: ...e and Install 8 66 8 17 1 Removal 8 66 8 17 2 Installation 8 67 8 18 Swing Platform AS Remove and Install 8 68 8 18 1 Removal 8 68 8 18 2 Installation 8 71 8 19 Swivel Joint AS Remove and Install 8 72 8 19 1 Removal 8 72 8 19 2 Installation 8 74 8 20 Swivel Joint AS Disassemble and Assemble 8 75 8 20 1 Disassembly 8 75 8 20 2 Assembly 8 76 8 21 Hydraulic Tank AS Remove and Install 8 77 8 21 1 Remo...

Page 12: ...allation 8 112 8 30 Counterweight AS Remove and Install 8 113 8 30 1 Removal 8 113 8 30 2 Installation 8 114 8 31 Cab AS Remove and Install 8 115 8 31 1 Removal 8 115 8 31 2 Installation 8 119 8 32 Cab Window Glass Disassemble and Assemble 8 120 8 32 1 Removal 8 121 8 32 2 Installation 8 125 8 33 Front Window AS Disassemble and Assemble 8 138 8 33 1 Disassemble 8 138 8 33 2 Assemble 8 141 8 34 Mon...

Page 13: ... 40 3 Removal 8 159 8 40 5 Installation 8 160 8 40 4 Angle adjustment of wiper arm 8 160 8 41 Relay 8 161 8 41 1 Engine relays 8 161 8 41 2 Other relays 8 162 8 42 Sensor 8 165 8 43 Connector Terminals Insert and Remove 8 167 8 43 1 Insertion 8 167 8 43 2 Removal 8 168 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 ...

Page 14: ...er when handling electric components 1 7 1 3 2 Points to remember when handling hydraulic equipment 1 16 1 4 Hose Connector 1 18 1 4 1 Type of hose connector 1 19 1 4 2 Hose connector tightening torque table 1 19 1 4 3 Connection of O rings 1 20 1 5 Table of Standard Tightening Torques 1 21 1 6 Type of Bolts 1 22 1 7 Tightening Sequence 1 22 1 8 Maintenance of Half Flanges 1 23 1 8 1 Table of tigh...

Page 15: ... all safety precau tions and instructions in this manual be fore reading any other manuals provided with this machine and before operating or servicing the machine Also read the safety information on machine decals before per forming any operations Failure to do so can cause machine damage personal in jury or death https www tractormanualpdf info ...

Page 16: ...standing of the machine structure and also serves as a reference for troubleshoot ing Standard Values This section explains the standard values for a new machine and judgement criteria for testing adjusting and troubleshooting This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting Testing and adjusting This section details the ...

Page 17: ...hoisting wire or when working posture is important etc Tightening torque Places that require special attention for tightening torque during assembly Coat Places to be coated with adhesives etc during assembly Oil Coolant Places where oil etc must be added and capacity Drain Places where oil etc must be drained and quantity to be drained 3 Units In this shop manual the units are indicated with Inte...

Page 18: ...rd size NOTE The tolerance may be indicated in the text and a table as standard size upper limit of tolerance lower limit of tolerance Example 120 0 022 0 126 Usually the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft The tightness of fit is decided by the tolerance Indication of size of rota...

Page 19: ...size of their hole and shaft and check that the interference is in the standard range 4 Repair limit and allowable value The size of a part changes due to wear and deformation while it is used The limit of changed size is called the repair limit If a part is worn to the repair limit must be replaced or repaired The performance and function of a product lowers while it is used A value below which t...

Page 20: ...ent particularly gear oil and hydraulic oil 1 3 1 Points to remember when handling electric components ZX215 1000004 1 Handling wiring harnesses and connec tors Wiring harnesses consist of wiring con necting one component to another compo nent connectors used for connecting and disconnecting one wire from another wire and protectors or tubes used for protecting the wiring Compared with other elect...

Page 21: ...ing in wiring har ness 1 Defective contact of connectors defective contact between male and female Problems with defective contact are likely 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 aligned or because there is corrosion or oxidation of the contact surfaces 2 Defectiv...

Page 22: ...ter so if any water gets in immediately dry the connector or take other appropriate action before passing electricity through it ZX215 1000008 5 Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins the oil will not let the electricity pass so there will be defective contact If there is oil or gre...

Page 23: ...male and female connec tors in each hand and pull apart For connectors which have a lock stop per press down the stopper with your thumb and pull the connectors apart NOTE Never pull with one hand b When removing from clips Both of the connector and clip have stoppers which are engaged with each other when the connector is installed ZX215 1000010 Press lightly when removing Lock stopper ZX215 1000...

Page 24: ...ks into position 2 Connecting connectors a Check the connector visually Check that there is no oil dirt or water stuck to the connector pins mating por tion Check that there is no deformation de fective contact corrosion or damage to the connector pins Check that there is no damage or breakage to the outside of the connec tor NOTE If there is any oil water or dirt stuck to the connector wipe it of...

Page 25: ...he 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 For connectors fitted with boots correct any protrusion of the boot In addition if the wiring harness is misaligned or the clamp is out of position adjust it to its correct p...

Page 26: ...the air may cause defective contact so remove all oil and water from the compressed air before blowing with air b Dry the connector with a dryer If water gets inside the connector use a dryer to dry the connector NOTE Hot air from the dryer can be used but regulate the time that the hot air is used in order not to make the connector or related parts too hot as this will cause deformation or damage...

Page 27: ...ted control monitor 2 Do not place objects on the controller 3 Cover the control connectors with tape or a vinyl bag Never touch the connector con tacts with your hand 4 Do not leave it where it may be exposed to rain 5 Do not place the controller on oil water or soil or in any hot place even for a short time 6 Precautions for arc welding When welding on the controller disconnect all wiring harnes...

Page 28: ...ct the related connectors several times to check 3 Always connect any disconnected connec tors before going on to the next step NOTE If the power is turned ON with the connectors still disconnected unnecessary abnormality displays will be generated 4 When carrying out troubleshooting of cir cuits measuring the voltage resistance continuity or current move the related wiring and connectors several ...

Page 29: ... in a specially pre pared dust proof workshop and the perfor mance should be checked with special test equipment 3 Sealing openings After any piping or equipment is removed the openings should be sealed with caps tapes or vinyl bags to prevent any dirt or dust from entering If the opening is left open or is blocked with a rag there is danger of dirt entering or of the surround ing area being made ...

Page 30: ...ge can also be drained out easily from the circuit together with the oil so it is best to change the oil when it is still warm When changing the oil as much as possible of the old hydraulic oil must be drained out Drain the oil from the hydraulic tank also drain the oil from the filter and from the drain plug in the circuit If any old oil is left the contaminants and sludge in it will mix with the...

Page 31: ...effective device ZX215 1000027 1 4 Hose Connector Hose connector is used to connect hoses with a small diameter The metal sealing surface 4 of the joint 1 must be in close contact with the metal sealing surface 5 of the hose 2 to seal pressurized oil ZX215 1000028 1 2 3 4 5 Connector NOTICE Do not over tighten the nut 3 Exces sive force applied on the metal sealing surface 4 and 5 may cause the jo...

Page 32: ...4 22 22 98 10 72 27 27 118 12 87 36 36 235 24 173 41 41 295 30 218 50 50 490 50 361 60 60 670 68 494 70 70 980 100 723 24 Female 19 17 44 4 5 32 22 19 59 6 44 27 22 118 12 87 36 30 32 235 24 173 41 36 295 30 218 50 46 490 50 361 1 4 2 Hose connector tightening torque table NOTICE The torque values listed in the table are intended for general application Do not use torque values listed in this tabl...

Page 33: ...30 218 50 46 490 50 361 ZX215 1000030 Hose connector 6 7 8 9 10 NOTICE Replace o rings 6 with new ones when re connecting hoses Before tightening nut 9 make sure the o ring 6 has been placed into the o ring seat 8 Displacement of the o ring may have it damaged and cause leaks Be careful not to damage the o ring seat 8 or the sealing surface 10 Damaged o ring 6 may cause oil leakage If oil leakage ...

Page 34: ...12 9 24 14 339 34 6 250 18 339 34 6 250 18 M20 12 9 30 17 664 67 75 490 664 67 75 490 Table of tightening torques for bolts and nuts Unless specified otherwise tighten metric nuts and bolts to the torque below When using torque wrench NOTICE The following items apply to fine thread and coarse thread Apply grease zinc white B dissolved in spindle oil onto the nuts and bolts to reduce the friction c...

Page 35: ...are being tightened follow the tightening sequence shown on the right to ensure even tightening ZX215 1000031 Hex bolt Socket head hex bolt 10 9 12 9 8 8 ZX215 1000032 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 Cross tightening Diagonal tightening Central and diagonal tightening ZX215 1000033 CAUTION Always use suitable tools for specific work Use of improper tools and meth ods may cause...

Page 36: ... O rings are not damaged Do not file the surface of the O ring Apply grease onto the O ring to locate it 3 Tighten the half flanges carefully Locate the opening at the center so that it is per pendicular to the oil opening Tighten the bolt manually to maintain the location of the components 1 8 1 Table of tightening torques for half flange bolts Thread diameter of bolt Width across flats Tightenin...

Page 37: ...ntal line from A 2 Locate the number 5 in the row across the top take this as B then draw a perpendicular line down from B 3 Take the point where the two lines cross as C This point C gives the value when con verting from millimeters to inches Therefore 55 mm 2 165 inches 2 Convert 550 mm into inches 1 The number 550 does not appear in the table so divide it by 10 move the decimal point one place ...

Page 38: ...38 3 031 3 425 3 819 0 315 0 709 1 102 1 496 1 890 2 283 2 677 3 071 3 465 3 858 0 354 0 748 1 142 1 535 1 929 2 323 2 717 3 110 3 504 3 898 B C A Millimeters to Inches 1mm 0 03937in 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 80 90 0 0 394 0 787 1 181 1 575 1 969 2 362 2 756 3 150 3 543 0 039 0 433 0 827 1 220 1 614 2 008 2 402 2 795 3 189 3 583 0 079 0 472 0 866 1 260 1 654 2 047 2 441 2 835 3 22...

Page 39: ...1 64 4 3656 43 64 17 0656 3 16 4 7625 11 16 17 4625 13 64 5 1594 45 64 17 8594 7 32 5 5563 23 32 18 2563 15 64 5 9531 47 64 18 6531 1 4 6 3500 3 4 19 0500 17 64 6 7469 49 64 19 4469 9 32 7 1438 25 32 19 8438 19 64 7 5406 51 64 20 2406 5 16 7 9375 13 16 20 6375 21 64 8 3344 53 64 21 0344 11 32 8 7313 27 32 21 4313 23 64 9 1281 55 64 21 8281 3 8 9 5250 7 8 22 2250 25 64 9 9219 57 64 22 6219 13 32 10...

Page 40: ...32 918 33 223 100 Feet to Meters Meters to Feet m 0 1 2 3 4 5 6 7 8 9 m ft ft ft ft ft ft ft ft ft ft 3 2808 6 5617 9 8425 13 1234 16 4042 19 6850 22 9659 26 2467 29 5276 10 32 8084 36 0892 39 3701 42 6509 45 9318 49 2126 52 4934 55 7743 59 0551 62 3360 10 20 65 6168 68 8976 72 1785 75 4593 78 7402 82 0210 85 3018 88 5827 91 8635 95 1444 20 30 98 4252 101 7060 104 9869 108 2677 111 5486 114 8294 1...

Page 41: ...46 450 148 059 149 669 151 278 152 887 154 497 156 106 157 715 159 325 90 100 160 934 162 543 164 153 165 762 167 371 168 981 170 590 172 199 173 809 175 418 100 km 0 1 2 3 4 5 6 7 8 9 km miles miles miles miles miles miles miles miles miles miles 0 621 1 243 1 864 2 485 3 107 3 728 4 350 4 971 5 592 10 6 214 6 835 7 456 8 078 8 699 9 321 9 942 10 563 11 185 11 806 10 20 12 427 13 049 13 670 14 29...

Page 42: ...574 192 80 90 580 644 587 096 593 547 599 999 606 450 612 902 619 354 625 805 632 257 638 708 90 100 645 160 651 612 658 063 664 515 670 966 677 418 683 870 690 321 696 773 703 224 100 Area Square inches to square centimeters Square centimeters to square inches cm2 0 1 2 3 4 5 6 7 8 9 cm2 in2 in2 in2 in2 in2 in2 in2 in2 in2 in2 0 155 0 310 0 465 0 620 0 775 0 930 1 085 1 240 1 395 10 1 550 1 705 1...

Page 43: ... 90 1474 835 1491 222 1507 610 1523 997 1540 384 1556 771 1573 158 1589 545 1605 932 1622 319 90 100 1638 706 1655 093 1671 480 1687 867 1704 254 1720 641 1737 028 1753 415 1769 802 1786 190 100 Volume Cubic inches to cubic centimeters Cubic centimeters to cubic inches cm3 cc 0 1 2 3 4 5 6 7 8 9 cm3 cc in3 in3 in3 in3 in3 in3 in3 in3 in3 in3 0 0610 0 1220 0 1831 0 2441 0 3051 0 3661 0 4272 0 4882 ...

Page 44: ...3321 333 1176 336 9030 80 90 340 6884 344 4739 348 2593 352 0447 355 8301 359 6156 363 4010 367 1864 370 9718 374 7573 90 100 378 5427 382 3281 386 1136 389 8990 393 6844 397 4698 401 2553 405 0407 408 8261 412 6115 100 liters 0 1 2 3 4 5 6 7 8 9 liters gal gal gal gal gal gal gal gal gal gal 0 2642 0 5283 0 7925 1 0567 1 3209 1 5850 1 8492 2 1134 2 3775 10 2 6417 2 9059 3 1701 3 4342 3 6984 3 962...

Page 45: ...74 395 4933 400 0392 404 5851 80 90 409 1310 413 6769 418 2228 422 7687 427 3146 431 8605 436 4064 440 9523 445 4982 450 0441 90 100 454 5900 459 1359 463 6818 468 2277 472 7736 477 3195 481 8654 486 4113 490 9572 495 5031 100 liters 0 1 2 3 4 5 6 7 8 9 liters gal gal gal gal gal gal gal gal gal gal 0 2200 0 4400 0 6599 0 8799 1 0999 1 3199 1 5399 1 7598 1 9798 10 2 1998 2 4198 2 6398 2 8597 3 079...

Page 46: ... 100 45 359 45 813 46 266 46 720 47 173 47 627 48 081 48 534 48 988 49 441 100 Weight Pound to Kilogram Kilogram to Pound kg 0 1 2 3 4 5 6 7 8 9 kg lbs lbs lbs lbs lbs lbs lbs lbs lbs lbs 2 205 4 409 6 614 8 818 11 023 13 228 15 432 17 637 19 842 10 22 046 24 251 26 455 28 660 30 865 33 069 35 274 37 479 39 683 41 888 10 20 44 092 46 297 48 502 50 706 52 911 55 116 57 320 59 525 61 729 63 934 20 3...

Page 47: ... 91 775 92 795 93 814 94 834 95 854 96 873 97 893 98 913 99 933 100 952 900 1000 101 972 102 992 104 011 105 031 106 051 107 071 108 090 109 110 110 130 111 149 1000 kg 0 1 2 3 4 5 6 7 8 9 kg N N N N N N N N N N 9 81 19 61 29 42 39 23 49 03 58 84 68 65 78 45 88 26 10 98 07 107 87 117 68 127 49 137 29 147 10 156 91 166 71 176 52 186 33 10 20 196 13 205 94 215 75 225 55 235 36 245 17 254 97 264 78 2...

Page 48: ... 8901 6 9604 90 100 7 0307 7 1010 7 1713 7 2416 7 3119 7 3822 7 4525 7 5228 7 5932 7 6635 100 Pressure Lb in to Kg cm Kg cm to Lb in kg cm2 0 1 2 3 4 5 6 7 8 9 kg cm2 lb in2 psi lb in2 psi lb in2 psi lb in2 psi lb in2 psi lb in2 psi lb in2 psi lb in2 psi lb in2 psi lb in2 psi 14 22 28 45 42 67 56 89 71 12 85 34 99 56 113 78 128 01 10 142 23 156 45 170 68 184 90 199 12 213 35 227 57 241 79 256 01 2...

Page 49: ...610 6 9708 6 90 100 9806 7 9904 8 10002 8 10100 9 10199 0 10297 0 10395 1 10493 2 10591 2 10689 3 100 Kpa 0 100 200 300 400 500 600 700 800 900 Kpa kg cm2 kg cm2 kg cm2 kg cm2 kg cm2 kg cm2 kg cm2 kg cm2 kg cm2 kg cm2 1 020 2 039 3 059 4 079 5 099 6 118 7 138 8 158 9 177 1000 10 197 11 217 12 237 13 256 14 276 15 296 16 316 17 335 18 355 19 375 1000 2000 20 394 21 414 22 434 23 454 24 473 25 493 2...

Page 50: ...9 13 688 90 100 13 826 13 964 14 103 14 241 14 379 14 517 14 656 14 794 14 932 15 070 100 Torque Ft lbs to Kg m Kg m to Ft lbs kg m 0 1 2 3 4 5 6 7 8 9 kg m ft lbs ft lbs ft lbs ft lbs ft lbs ft lbs ft lbs ft lbs ft lbs ft lbs 7 23 14 47 21 70 28 93 36 17 43 40 50 63 57 86 65 10 10 72 33 79 56 86 80 94 03 101 26 108 50 115 73 122 96 130 19 137 43 10 20 144 66 151 89 159 13 166 36 173 59 180 83 188...

Page 51: ...22 912 02 921 83 931 64 941 44 951 25 961 06 970 86 90 100 980 67 990 48 1000 28 1010 09 1019 90 1029 70 1039 51 1049 32 1059 12 1068 93 100 N m 0 10 20 30 40 50 60 70 80 90 N m kg m kg m kg m kg m kg m kg m kg m kg m kg m kg m 1 020 2 039 3 059 4 079 5 099 6 118 7 138 8 158 9 177 100 10 197 11 217 12 237 13 256 14 276 15 296 16 316 17 335 18 355 19 375 10 200 20 394 21 414 22 434 23 454 24 473 25...

Page 52: ...ter boldface column of figures These fig ures refer to the temperature in either Fahrenheit or Centigrade degrees To convert from Fahrenheit to Centigrade degrees consider the center column as Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left To convert from Centigrade to Fahrenheit degrees consider the center column as Centigrade val ues and read ...

Page 53: ...1 1 66 66 67 67 68 68 69 69 70 70 150 8 152 6 154 4 156 2 158 0 21 7 22 2 22 8 23 3 23 9 71 71 72 72 73 73 74 74 75 75 159 8 161 6 163 4 165 2 167 0 24 4 25 0 25 6 26 1 26 7 76 76 77 77 78 78 79 79 80 80 168 8 170 6 172 4 174 2 176 0 C C F F 11 7 11 1 10 6 10 0 9 4 11 11 12 12 13 13 14 14 15 15 51 8 53 6 55 4 57 2 59 0 8 9 8 3 7 8 7 2 6 7 16 16 17 17 18 18 19 19 20 20 60 8 62 6 64 4 66 2 68 0 6 1 ...

Page 54: ...S A N Y L A T I N A M E R I C A 1 41 SY195 205 215 225C9 Crawler Hydraulic Excavator Introduction Shop Manual June 2013 B L A N K P A G E https www tractormanualpdf info ...

Page 55: ...S A N Y L A T I N A M E R I C A 1 42 SY195 205 215 225C9 Crawler Hydraulic Excavator Introduction Shop Manual June 2013 B L A N K P A G E https www tractormanualpdf info ...

Page 56: ...aning the Machine 2 10 2 2 9 Using the Correct Tools 2 10 2 2 10 Hoisting a Load 2 11 2 2 11 Appropriate Working Apparel 2 12 2 2 12 Safety Partners 2 12 2 2 13 Two people when engine running 2 13 2 2 14 Driving Pins 2 13 2 2 15 Aligning Parts or Components 2 14 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 Accumu...

Page 57: ...icing the machine Also read the safety information on machine decals before per forming any operations Failure to do so can cause machine damage personal in jury or death 2 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 MSD...

Page 58: ...m you that there is a potentially hazardous situation that may lead to damage personal injury or even death In this manual on the machine part or component decals and different signal words are used to express the potential level of a hazard DANGER Indicates an imminent hazard which WILL result in serious injury or death if message is ignored WARNING Indicates a potentially hazardous situation whi...

Page 59: ...e all possible safety precautions If any procedures or actions not specified rec ommended or allowed in this manual are used you must be sure that you and others can perform such procedures and actions safely and without damaging the machine If you are unsure about the safety of some procedures contact your SANY representative This is to alert the user of a hazard It is usually used in a graphic T...

Page 60: ...r proce dures of the machine or system If you perform any repairs not specifically pro hibited you must be sure that it is safe for you and others In no event should you or others engage in prohibited uses or actions as described in this manual SANY delivers machines that comply with all applicable regulations and standards of the country to which the machines have been shipped If this machine has...

Page 61: ...any questions or confusion with them Always keep in mind shop safety is NOT something to be studied at the start of a proj ect and then forgotten most accidents are caused by carelessness being in a hurry or by simply disreguarding safety rules Remember this if you are DILIGENT and follow instruc tions outlined in this shop manual with care repair operations can be safe and enjoyable Safe work pra...

Page 62: ...ing or socializing on the job also increases your chances of injury If you must smoke smoke only in the area provided for smoking Never smoke while on the shop floor or work area 2 2 2 Housekeeping Oils grease fuel antifreeze or any fluid spills should be mopped up immediately These items pose a serious slip hazard Regardless of who was responsible for the spill it is your job as a shop employee t...

Page 63: ...e Always read the container label for infor mation on storage and handling of the liq uids Never store liquids in containers that are not properly labeled for that liquid Confu sion could result in equipment damage fire or an unexpected explosion Never smoke or bring open flames around liquids doing so could result in an unex pected fire or explosion Never handle liquids without using person al pr...

Page 64: ...ma chine before going under the machine 2 2 6 Electrical Dangers When testing electrical circuits always be aware of what you will be checking in these systems High voltage or high amp circuits could damage your equipment or cause a spark explosion or possible fire Before performing any repairs or testing on an electrical system be sure of the system voltage dangers Always check the circuit to be ...

Page 65: ...ning the Machine Always use high pressure hot water and mild nonflammable grease cutting soaps or cleaning agents to clean the machine parts Never use flammable or caustic cleaning agents Never use high pressure steam cleaners to clean the machine Steam cleaners will damage the paint hoses or electrical sys tem Never pressure wash or flood the inside of an operator cab This will damage sensi tive ...

Page 66: ...n good condition and rated for the load to be lifted with them If you must lift the load by hand keep your back straight and parallel with the load and lift the load using your leg muscles to avoid back injuries Always ask for a lifting assistant 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 invent...

Page 67: ...artners No one should be allowed to perform work operations in any shop alone It should be a general shop safety rule for a minimum of two people in the shop area at all times when work procedures are performed A person alone in the shop might not be able to get emergency help in the event of a shop accident When working together always maintain clear contact with each other at all times to avoid ...

Page 68: ...any control lever If some control lever must be operated send signal to other people and warn them to transfer to safe place quickly Do not drop or insert the tools and other objects into the fan or fan belt or the parts will be broken or thrown out 2 2 14 Driving Pins When using a hammer to drive pins metal particles may fly off This may lead to serious eye injuries Always do the following Always...

Page 69: ...e of this equipment 2 2 17 Personal Protective Equipment If your shop specifies the use of safety equip ment OSHA requires this equipment to be used when on the shop floor or in the area where this equipment is required Never allow personnel in the shop area with out the proper personnel protective equipment even for a moment Always keep personnel protective equipment in good condition and replace...

Page 70: ...repair operations while the engine is running one worker must remain in the operator seat of the machine with clear contact between the person performing the repairs on the machine at all times If equipped all lock levers must be in the LOCK position or the parking brake must be in the PARK position The person in the cab must never touch any controls If a control lever must be op erated always mai...

Page 71: ...r Never drill or cut on the accumulator Never strike the accumulator Use only nitrogen gas to charge the ac cumulator Unapproved gases could be explosive 2 2 20 Adding Fluids to a System If it should be necessary to add fluids to a system during running operations always be aware that these systems may be hot and un der high pressure Before adding fluids shut the machine down and allow the systems...

Page 72: ...re Fluid Lines Always keep in mind that these systems are under high pressure When inspecting or re placing piping or hoses always check to be sure the pressure in the system has been relieved before proceeding Working on a sys tem still under pressure could lead to serious injury always do as follows If you will be removing a line or component with fluid in the system always cap and seal the open...

Page 73: ...n trols by rotating them to the left and right joy stick control or moving them back and forth lever control This function will relieve system pressure Block the tracks if equipped or wheels if equipped with chocks to prevent the machine from moving If equipped set the hydraulic lock lever in the LOCKED position If equipped set the parking brake in the PARK position Be sure all personnel and equip...

Page 74: ...f moving equipment These actions may lead to serious injury Always bring the equipment to a full stop and turn the engine OFF When getting on or off the equipment always face the equipment and maintain a three point contact both feet and one hand or one foot and both hands with the handrails steps and platforms to ensure that you support yourself correctly Never climb on areas of the machine that ...

Page 75: ...ys wear personal protective equip ment when working around batteries Battery gasses are extremely explosive When opening a battery compartment al ways allow ample time for the gasses to escape before servicing the battery When working with batteries always work in a wellventilated area If the battery is corroded flush the area with a baking soda and warm water mix If battery acid should get on you...

Page 76: ...the location of the machine main electri cal disconnect switch refer to the machines Safety Operation Maintenance Manual for location and procedures If the battery must be disconnected remove the negative terminal clamp first then re move the positive clamp last When reconnecting the battery be sure every electrical system switch is in the OFF position connect the positive clamp first then the neg...

Page 77: ...from potentially hazardous en ergy and to ensure that the machine is locked out and tagged out before anyone performs repairs on the machine 2 2 29 Sequence of Procedures Only authorized employees performing repairs on the machine shall perform Lockout Tagout in accordance with this procedure listed below If the employee performing repairs to the ma chine is issued a lock and key the employee shal...

Page 78: ...ce before performing any repairs Once an employee has completed there repair procedure they must remove there lock and not access the machine in any manor Returning to service 1 The authorized person who performed the Lock out Tagout procedure shall check the area around the machine to ensure that no one is exposed to any hazard before start up 2 The authorized person who performed the Lock out Ta...

Page 79: ...to the materials the workers could be exposed to MSDS data sheets provide both workers and emergency personnel with the proper procedures for handling or working with a particular substance Information includes physical data health effects first aid re activity storage disposal and protective equipment required Be sure all personnel involved are familiar with all MSDS related information as it re ...

Page 80: ...e operator safely Do not stand under the load Do not step on the load 2 Check the slings before starting sling work 3 Always wear gloves during sling work Wear leather gloves if available 4 Measure the weight of the load by the eye and check its center of gravity 5 Use proper sling according to the weight of the load and method of slinging If too thick wire ropes are used to sling a light load the...

Page 81: ...a lifting angle of 150 each of them is sub jected to a force as large as 39 2 kN 4 000 kg 8 When installing wire ropes to an angular load apply softeners to protect the wire ropes If the load is slippery apply proper material to prevent the wire rope from slip ping 9 Use the specified eyebolts and fix wire ropes chains etc to them with shackles etc 10 Apply wire ropes to the middle portion of the ...

Page 82: ...he crane and check the condition of the slung load wire ropes and soft ener If the load is unstable or the wire rope or chains are twisted lower the load and lift it up again Do not lift up the load slantingly 13 When lowering a load observe the follow ing When lowering a load stop it temporar ily at 30 cm above the floor and then lower it slowly Check that the load is stable and then remove the s...

Page 83: ... to the table below Wire ropes Standard Z twist ropes without galvanizing Nominal Diameter of Rope Allowable Load mm kN Ton 10 9 8 1 0 11 5 13 7 1 4 12 5 15 7 1 6 14 21 6 2 2 16 27 5 2 8 18 35 5 3 6 20 43 1 4 4 22 4 54 9 5 6 30 98 1 10 0 40 176 5 18 0 50 274 6 28 0 60 392 2 40 0 CAUTION The allowable load is one sixth of the breaking strength of the rope used Safety coefficient 6 https www tractor...

Page 84: ...S A N Y L A T I N A M E R I C A 2 29 SY195 205 215 225C9 Crawler Hydraulic Excavator Shop Safety Shop Manual June 2013 B L A N K P A G E https www tractormanualpdf info ...

Page 85: ...S A N Y L A T I N A M E R I C A 2 30 SY195 205 215 225C9 Crawler Hydraulic Excavator Shop Safety Shop Manual June 2013 B L A N K P A G E https www tractormanualpdf info ...

Page 86: ...vator Specifications Shop Manual June 2013 3 1 3 Specifications 3 1 Dimensions 3 3 3 2 Working Ranges 3 4 3 3 Technical Specifications 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 https www tractormanualpdf info ...

Page 87: ...d all safety precau tions and instructions in this manual be fore reading any other manuals provided with this machine and before operating or servicing the machine Also read the safety information on machine decals before per forming any operations Failure to do so can cause machine damage personal in jury or death https www tractormanualpdf info ...

Page 88: ...440 11 3 3440 11 3 3440 11 3 D Width top 2710 8 11 2710 8 11 2710 8 11 2710 8 11 E Overall height to cab roof 2990 9 10 2990 9 10 2990 9 10 2990 9 10 F Std track shoe width 600 1 12 600 1 12 600 1 12 600 1 12 G Track gauge 2200 7 3 2200 7 3 2380 7 10 2380 7 10 H Min ground clearance 440 1 5 440 1 5 440 1 5 440 1 5 I Tail swing radius 2890 9 6 2890 9 6 2890 9 6 2890 9 6 J Length of track on ground ...

Page 89: ...31 5 b Max dumping height 6490 21 4 6700 21 12 6700 21 12 6700 21 12 c Max digging depth 6410 21 0 6600 21 8 6600 21 8 6600 21 8 d Max vertical digging depth 5790 18 12 5800 19 0 5800 19 0 5800 19 0 e Max digging reach 9740 31 11 9950 32 8 9950 32 8 9950 32 8 f Min swing radius 3755 12 4 3595 12 12 3595 12 12 3595 12 12 g Max height at min swing radius 7700 25 3 7665 25 2 7665 25 2 7665 25 2 f a g...

Page 90: ...sumption KW rpm N m rpm rpm rpm g KWh 114 2050 590 1400 2200 50 1000 10 210 Starting motor Alternator 24V 5 0 KW 24V 50A Undercarriage Carrier roller each side 2 2 2 2 Track roller each side 7 7 8 9 Track shoe each side 45 46 47 49 Hydraulic system Hydrau lic pump Type Max delivery Safety valve pressure L min Mpa KAWASAKI Variable displacement piston type 2 210 34 3 Control valve Type x No Control...

Page 91: ...ion ratio 18 2 Producer KAWASAKI Model M5 180CHB 12A 51A 260 Type angle type piston type swing brake controller Theoretical displacement cm rev 129 2 Safety valve set pressure MPa Kg cm 25 5 260 Rated engine speed rpm 2050 Brake release pressure MPa Kg cm 3 4 34 Swing motor Item Specification Model KMX15RB Standard flow rate equivalent to one pump 300 L min Maximum pressure When main relief valve ...

Page 92: ... reduction rate i 60 2 speed switching Pilot pressure Lo Hi Mpa 6 86 Hi Lo Mpa 1 96 Braking torque N m 398 Operating displacement L min 228 Operating pressure Mpa 33 34 Peak pressure Mpa within 44 1 Acting times above 34 3Mpa and below 44 1Mpa times 1 200 000 Swing speed Motor shaft Large flow rpm 1679 Small flow rpm 2861 Reducer Large flow rpm 28 Small flow rpm 47 7 Output torque KN m within 37 I...

Page 93: ...0 Hydraulic pump 120 120 120 120 Control valve 185 185 185 185 Swing reducer assembly 200 200 200 200 Final drive assembly 300 2 300 2 300 2 300 2 Center swivel joint 56 56 56 56 Track frame Swing bearing Idler Tensioning device Carrier roller Track roller 2280 286 116 2 135 2 25 5 4 40 14 2432 286 116 2 135 2 25 5 4 40 14 2746 286 116 2 135 2 25 5 4 40 16 2746 286 116 2 135 2 25 5 4 40 18 Boom as...

Page 94: ... Engine oil SAE 30 SAE 10W SAE 10W 30 SAE 15W 40 Swing machinery case Idler SAE 30 Track roller Carrier roller Hydraulic system SAE 10W SAE 10W 30 SAE 15W 40 Hydraulic oil L HV32 Low temp wear resistant hydraulic oil L HM46 Wear resistant hydraulic oil L HM68 Wear resistant hydra oil Fuel tank Diesel fuel ASTM D 975 No 2 GB252 Super 20 Diesel fuel GB252 Super 35 Diesel fuel Grease fitting Grease N...

Page 95: ...l 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 Engine oil pan Swing mecha nism casing Final drive casing Hydraulic system Cooling system Fuel tank 22 5 81 4 0 1 06 5 5 1 45 239 63 14 22 5 5 94 340 89 82 Unit L US Gal https www tractormanualpdf info ...

Page 96: ... Performance Curve Testing condition 1 Temperature 298K one standard atmospheric pressure 2 No fan ZX215 1001003 240 230 220 210 2000 1800 1600 1400 1200 1000 20 40 60 80 100 120 kW Engine speed min Fuel consumption Fuel consumption Power output Power output 600 500 400 300 Torque N m Torque g kw h 1 https www tractormanualpdf info ...

Page 97: ...S A N Y L A T I N A M E R I C A 3 12 SY195 205 215 225C9 Crawler Hydraulic Excavator Specifications Shop Manual June 2013 B L A N K P A G E https www tractormanualpdf info ...

Page 98: ...12 4 2 4 Swing bearing 4 14 4 3 Undercarriage and Frame 4 15 4 3 1 Track frame and recoil spring 4 15 4 3 2 Idler 4 17 4 3 3 Carrier roller 4 19 4 3 4 Track roller 4 20 4 3 5 Track shoe 4 21 4 3 6 Triple grouser shoe 4 25 4 4 Hydraulic System Part 1 4 26 4 4 1 Hydraulic equipment layout 4 26 4 4 2 Hydraulic tank and filter 4 28 4 4 3 Hydraulic pump 4 29 4 4 4 Pilot pump 4 36 4 4 5 Regulator 4 37 4...

Page 99: ...g brake 4 85 4 6 3 Relief valve portion 4 86 4 6 4 Reverse prevention valve 4 88 4 6 4 1 Operation drawing 4 88 4 6 4 2 Explanatory drawing of effects 4 89 4 6 5 Center swivel joint 4 91 4 6 6 Travel motor 4 93 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 Solenoi...

Page 100: ... 167 4 9 1 Control function 4 167 4 9 2 Machine control system diagram 4 168 4 9 3 Engine and pump composite control function 4 170 4 9 4 Pump control function 4 174 4 9 4 1 Electrical positive flow 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 flow control 4 181 4 9 5 2 Swing priority control 4 182 4 9 6 Duo travel speed control 4 183 4 9 7 E...

Page 101: ...machine and before operating or servicing the machine Also read the safety information on machine decals before per forming any operations Failure to do so can cause machine damage personal in jury or death 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 ...

Page 102: ...n Shop Manual June 2013 4 1 Engine and Cooling System 4 STRUCTURE AND FUNCTION 4 1 1 Engine related parts Specification Oil capacity 22 L ZX215 1002001 6 7 1 3 5 4 2 1 Fan 2 Front engine mount 3 Fuel filter 4 Start motor 5 Rubber damper assembly 6 Rear engine mount 7 Muffler https www tractormanualpdf info ...

Page 103: ...ntake 5 Reserve tank 6 Intercooler 7 Intercooler air outlet 8 Fan guard 9 Radiator cap Specifications Radiator assembly ZH860 385 1050 S70Y75Z20Q SY015 Aluminum pipe belt type radiator Radiator and oil cooler in parallel connection intercooler in series connection with radiator and oil cooler Reservoir capacity 8 9 L 2 35 US gal Engine coolant capacity 9 5L 2 51 US gal 6 4 7 9 1 2 8 5 3 WX215 1204...

Page 104: ...d Function Shop Manual June 2013 4 2 Power Train 4 2 1 Power transmission system ZX215 1002003 2 1 3 4 5 6 7 8 9 10 1 Swing motor 2 Swing reducer 3 Swing bearing 4 Idler 5 Central swivel joint 6 Accumulator 7 Control valve 8 Final drive AS 9 Hydraulic pump 10 Engine https www tractormanualpdf info ...

Page 105: ...Hydraulic Excavator Structure and Function Shop Manual June 2013 ZX215 1002005 13 14 15 Final drive AS KYB 4 2 2 Final drive assembly ZX215 1002004 1 205 10 N m 73 3 6 N m 59 4 9 N m 157 8 N m 1 2 3 4 5 6 7 8 9 10 11 12 16 19 17 20 18 https www tractormanualpdf info ...

Page 106: ...ng 12 Travel motor 13 Fill port 14 Level port 15 Drain port Specifications Reduction ratio 12 85 12 19 85 19 1 43 246 No Check item Criteria Remedy Standard clearance Clearance limit 16 Backlash between No 2 sun gear and No 2 planetary gear 0 13 0 47 1 00 Replace 17 Backlash between No 1 planetary gear and gear hub 0 17 0 57 1 10 Replace 18 Backlash between No 1 sun gear and No 1 planetary gear 0 ...

Page 107: ...rier 5 Hub 6 Spacer 7 Planetary gear shaft 8 Planetary gear 9 Thrust washer 10 Spring pin 11 Needle bearing 12 Floating bush 13 Planetary gear shaft 14 Sun gear 15 Snap ring 16 Planetary gear 17 Needle bearing 18 Drive gear 19 Spring pin 20 End cover 21 Socket head bolt 22 Radial thrust ball bearing 23 O ring 24 Plug 25 Seal ring 26 O ring 27 Thrust washer 28 Thrust washer 29 Thrust plate 30 Gear ...

Page 108: ...95 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 ZX215 1002007 1 2 3 4 5 6 7 59 74 Nm 8 9 21 22 10 23 24 11 12 26 25 13 27 14 15 16 17 18 28 19 20 4 2 3 Swing machinery https www tractormanualpdf info ...

Page 109: ...g bearing 17 Bearing sealing 18 Swing pinion 19 Dipstick 20 Oil filling pipe No Check item Criteria Remedy Standard clearance Clearance limit 21 Backlash between swing motor shaft and No 1 sun gear 0 18 0 28 Replace 22 Backlash between No 1 sun gear and No 1 planetary gear 0 16 0 50 1 00 Replace 23 Backlash between No 1 planetary gear and ring gear 0 18 0 59 1 10 24 Backlash between No 1 planetary...

Page 110: ...l 3 Swing bearing outer race Specifications Reduction ratio 91 13 7 Amount of filled grease 13 1 Kg a Inner race soft zone S position b Outer race soft zone S position Check item Criteria Remedy Axial clearance of bearing when mounted on chassis Standard clearance Clearance limit Replace 0 5 1 6 3 2 ZX215 1002008 a 1 2 3 549 50 Nm 549 50 Nm b A A A A Unit mm https www tractormanualpdf info ...

Page 111: ... Idler 2 Track frame 3 Carrier roller 4 Sprocket 5 Track roller 6 Track shoe 7 Center guard 8 Front guard Dimension and number of track rollers may vary depending on the machine model but the basic structure is the same Model Q ty One side SY195C9 7 SY205C9 7 SY215C9 8 SY225C9 9 4 3 1 Track frame and recoil spring 4 3 Undercarriage and Frame https www tractormanualpdf info ...

Page 112: ...frame 107 Idler support 105 10 Horizontal width of idler guide Track frame 250 Idler support 247 11 Recoil spring Standard size Repair limit Replace Free length x Outside diameter Installation length Installation load Free length Installation load 598 x 247 466 157 9 kN 16112 kg 545 133 9 kN Model Item SY195C9 SY205C9 SY215C9 SY225C9 Shoe width mm 600 600 600 600 Link pitch mm 190 190 190 190 Q ty...

Page 113: ...N Y L A T I N A M E R I C A 4 16 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 4 3 2 Idler W13081901 3 5 4 6 8 7 1 2 157 255 Nm https www tractormanualpdf info ...

Page 114: ...er of protru sion Standard size Repair limit Build up welding or replace 560 2 Outside diameter of tread 520 508 3 Thickness of tread 30 24 4 Difference of tread 20 26 5 Total width 164 6 Width of tread 39 5 7 Diameter of shaft 65 Replace 8 Clearance between bush ing and support Sum of clearance at both sides Standard clearance Clearance limit 0 5 1 0 https www tractormanualpdf info ...

Page 115: ...pair limit Replace 165 2 Outside diameter of tread 140 130 3 Width of tread 44 4 Thickness of tread 41 5 34 5 Width of flange 18 6 Clearance between shaft and bushing Standard size Tolerance Standard clearance Clearance limit Shaft Hole 50 7 Interference between roller and bushing Standard size Tolerance Standard interference Interfer ence limit Shaft Hole 57 8 Axial clearance of roller Standard c...

Page 116: ...r of flange Standard clearance Repair limit Build up weld ing or replace 193 2 Outside diameter of tread 160 148 3 Thickness of tread 46 5 40 5 4 Total width 237 5 Width of tread 46 5 6 Width of flange 32 7 Inside width 80 8 Diameter of shaft 65 Replace 9 Clearance between bushing and collar Standard clearance Clearance limit 0 5 1 0 W13081902 549 59 Nm 4 5 7 9 3 6 8 2 1 https www tractormanualpdf...

Page 117: ... I C A 4 20 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 4 3 5 Track shoe W13100801 1 19 7 21 20 22 23 15 4 10 9 6 5 8 14 2 11 13 12 24 3 18 16 17 https www tractormanualpdf info ...

Page 118: ...r replace 4 Link height Standard size Repair limit 105 98 5 Shoe bolt pitch 155 57 Adjust or replace 6 119 57 7 69 8 Link Inside width 82 57 9 Overall width 40 10 Tread width 38 11 Protrusion of pin Regular 2 7 Master 2 7 12 Protrusion of bushing Regular 3 7 Master 0 0 13 Overall length of pin Regular 207 Master 209 14 Overall length of bushing Regular 136 Master 128 5 15 Thickness of spacer 16 Pr...

Page 119: ...ink Standard size Tolerance Standard interfer ence Adjust or replace Shaft Hole 59 45 0 0 05 0 25 0 32 0 20 0 32 21 Interference between regu lar pin and link 38 25 0 0 04 0 23 0 29 0 19 0 29 22 Clearance between regular pin and bushing Standard size Tolerance Standard clear ance Shaft Hole 38 25 0 0 04 0 8 0 5 0 50 0 84 23 Interference between mas ter pin and link Standard size Tolerance Standard...

Page 120: ...une 2013 4 3 6 Triple grouser shoe ZX215 1002014 1 2 3 4 5 6 7 8 Unit mm No Check item Criteria Remedy 1 Height Standard size Repair limit Build up welding or replace 26 16 2 Thickness 10 3 Length of base 29 5 4 22 5 Length at tip 20 5 6 17 7 18 8 Thickness Standard size Repair limit 36 26 https www tractormanualpdf info ...

Page 121: ... 18E Hi Lo travel speed solenoid valve 1 Bucket cylinder 2 Arm cylinder 3 Boom cylinder 4 Hydraulic tank 5 Hydraulic oil filter 6 Control valve 7 Hydraulic pump 8 Radiator 9 Accumulator 10 Left travel motor 11 Right travel motor 12 Swing motor 13 Lockout lever 14 Left pilot valve 15 Center swivel joint 16 Right pilot valve 17 Travel pilot valve 18 Solenoid valve assembly 4 4 Hydraulic System Part ...

Page 122: ...A M E R I C A 4 25 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 3 4 5 6 7 A A 8 9 10 11 12 13 14 15 16 17 18 18A 18B 18C 18D 18E W13081903 2 https www tractormanualpdf info ...

Page 123: ...7 6 A A A A 1 Hydraulic tank 2 Level gauge 3 Oil filler cap 4 Return oil filter element 5 Bypass valve 6 Breather valve 7 Oil suction filter element Specifications Tank capacity 239 L 63 US gal Available capacity 172 L 45 5 US gal Breather valve Filter fineness 10μm Ambient temperature 20 100 C Set pressure Air inlet side 0 005MPa Air outlet side 0 05MPa https www tractormanualpdf info ...

Page 124: ...Excavator Structure and Function Shop Manual June 2013 ZX215 1002018 a1 36N m a2 36N m a5 16N m a4 36N m PH1 PH2 A1 A2 A3 4 1 2 3 5 B1 B3 Psv2 DR2 170N m DR4 170N m DR3 170N m DR1 170N m a3 36N m Clockwise Type K3V112DTP1N9R 4 4 3 Hydraulic pump https www tractormanualpdf info ...

Page 125: ... port A1 F pump delivery port A2 R pump delivery port A3 Pilot gear pump delivery port Psv1 F pump regulator control port Psv2 R pump regulator control port Dr1 F pump drain plug Dr2 R pump drain plug Dr3 Air bleeder Dr4 Drain plug B1 Pump suction port B3 Pilot gear pump oil suction port 1 Front pump 2 Rear pump 3 Pilot gear pump 4 Front pump regulator 5 Rear pump regulator Outline This pump consi...

Page 126: ... Front shaft 2 Min delivery adjusting screw 3 Front casing 4 Swash plate 5 Slipper 6 Plunger 7 Cylinder block 8 Valve plate 9 End cover 10 Rear shaft 11 Rear casing 12 Gear pump 13 Piston 14 Max delivery adjusting screw 15 Gear shaft 16 Driving pin ZX215 1002019 3 5 4 1 2 13 6 7 14 9 16 10 15 8 12 11 https www tractormanualpdf info ...

Page 127: ...e 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 It is possible to change the discharge amount by changing the swash plate an gle ZX215 1002020 18 1 5 A 4 18 17 6 B 13 7 8 https www tractormanualpdf info ...

Page 128: ... is always pressed against this surface while sliding in a circular move ment Swash plate 4 conducts high pressure oil to cylinder surface B and forms a static pressure bearing when it slides Plunger 6 carries out relative movement in the axial direction inside each cylinder chamber of cylinder block 7 Cylinder block 7 seals the pressurized oil to thrust plate 8 and carries out relative rotation T...

Page 129: ... the in side of cylinder block 7 so a difference between volumes E and F is created inside cylinder block 7 A single plunger sucks and discharges the oil by the amount F E As cylinder block 7 rotates and the vol ume of chamber E becomes smaller the pressurized oil is discharged On the other hand the volume of chamber F grows larger and in this process the oil is sucked As central line X of swash p...

Page 130: ...and F becomes larger and pump delivery Q increases Piston 13 is used for changing swash plate angle a Piston 13 carries out linear alternating motion under the control of the adjustor This linear motion is transmitted to swash plate 4 via drive pin 16 The sliding of the swash plate changes the swash plate angle and changes the discharge amount of the main pump ZX215 1002024 13 4 a 16 F E https www...

Page 131: ... 310 Spring 311 Adjusting screw 312 Nut 351 Body 353 Gear shaft 354 Gear shaft 355 Filter element 361 Body 433 Screw 434 Screw 435 screw 466 Plug 700 Washer 710 O ring 725 O ring 732 O ring 850 Washer Function The engine actuates the main pump and the drive shaft of the pilot pump through the transmission case and drives the pilot pump through gear engagement NOTE For the location of the pilot pum...

Page 132: ...ent layout on page 4 24 G OE11 V KDRDE5K PSV PSV a a KDRDE5C 1 079 325 496 408 755 466 407 643 651 652 733 631 731 624 627 B A A A A 646 897 924 801 402 656 614 755 708 611 733 724 887 SKY5P 17 S ZX225 1102002 418 415 496 601 543 756 545 541 N m 402 407 408 415 418 466 496 614 801 M6 M8 M5 G1 4 G1 4 M10 NPTF1 16 12 29 6 9 16 8 8 36 29 Type s n Name plate and s n Tightening torTue Hydraulic schemat...

Page 133: ...ler 1 624 Spring seat 1 614 Plug 1 611 Feedback lever 1 601 Casing 1 545 Ball 2 543 Stopper 2 541 Valve seat 2 C 496 Embedded plug 9 C 466 VIP plug 1 D 418 Hex socket head bolt 2 JIS B 1176 M5 12 D 415 Hex socket head bolt 6 JIS B 1176 M8 50 D 408 Hex socket head bolt 1 JIS B 1176 M6 40 D 407 Hex socket head bolt 4 JIS B 1176 M6 30 D 402 Hex socket head bolt 4 JIS B 1176 M6 16 325 Valve body 1 B 0...

Page 134: ...iston 3 and changes the tilting angle of the hydraulic tank according to various command signal pressure so as to control the pump dis charge amount 4 4 5 1 Control mechanism makeup Current control The inclination output delivery amount of the pump can be controlled freely by changing of the command current I flow ing into the solenoid proportional pressure reducing valve This regulator applies po...

Page 135: ...mum flow by the adjusting screws 953 954 in the pump block side Flow control features can be adjusted with the hexagon socket head locating screw 924 on the regulator ZX215 1002028 953 806 532 548 531 808 954 PSV KDRDE5C 1 924 SKY5P 17 S ZX225 1102004 531 Inclination pin 532 Servo piston 548 Feedback pin 806 Retaining nut 808 Retaining nut 953 Adjusting screw 954 Adjusting screw https www tractorm...

Page 136: ...ow changes Minimum flow adjustment pump block side Loosen the hexagon nut 806 and tighten or loosen the hexagon socket head locat ing screw 953 Though this action is the same as the adjustment of maximum flow and all the other control features do not change power required under maximum output pressure overflow is likely to in crease if over tightened Be careful in this case ZX215 1002033 Output fl...

Page 137: ... 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 ZX215 1002037 Output flow Q Command current I ZX215 1002030 Output flow Q Command current I 4 4 5 3 Operation Flow control The output flow of the pump can be con trolled by the command current I as shown https www tr...

Page 138: ...nd tank port are intercon nected pressure of the large diameter portion of the servo piston is released and servo piston 532 moves to the left via the output pressure P1 in the shall diameter portion The inclination becomes larger Since feedback lever 611 is integrated with the servo piston and valve sleeve 651 if servo piston 632 moves to the left feedback lever swings with point A as the pivot I...

Page 139: ...o the right via are difference The inclination becomes smaller As servo piston 532 moves to the right the feedback lever swings with point A as the pivot and the valve sleeve moves to the left Through this movement the opening portion between the spool and the valve block is slowly closed The servo piston stops moving when the opening portion is completely closed P1 P1 A 808 954 643 079 652 651 62...

Page 140: ...Ba Head Bo Bs Btr Atr Dr1 As Ao PCV1 Dr3 ARM1 OPTION XAb2 XBs SWING XAtr BOOM2 XBp1 BYPASS CUT 1 XBa1 XBo TRAVEL RIGHT TRAVEL STRAIGHT TRAVEL LEFT BOOM1 BUCKET ARM2 XBa2 XAk XBb1 XAtL Pz AtL PbL Bk Rod R2 Bb Rod PCk XBk Ab Head Ak Head Aa Rod PaL BtL Py MR DR3 AoR AkR AbR AaR PG PX 4 5 Hydraulic System Part 2 4 5 1 Control valve NOTE For the location of the control valve on the machine see Hydraul...

Page 141: ...in port Pal Lock valve pilot port arm rod end PbL Lock valve pilot port boom head end XBp1 Bypass cut spool pilot port P1 side XBp2 Bypass cut spool pilot port P2 side XAb2 Boom confluence UP pilot pressure Psp Swing priority pilot port R1 Return port R2 Oil feed port Atr R travel motor port reverse Btr R travel motor port forward Ao Option Bo Option Ak Bucket cylinder head end port DIG Bk Bucket ...

Page 142: ...XBa1 HEAD Ba BaR XBp1 XBp2 P2 R1 P3 P0 CP1 LCs 4 ĭ2 1 2 ĭ1 0 2 ĭ2 0 CCb LCo AoR BoR LCa CCk CCo P5 HVa AaR LCAP2 LCAT2 AkR BkR LCk HVb AbR BbR LCb C2 CPG PTa P1 PG MR CMR2 CMR1 d1 ĭ0 7 d2 ĭ0 7 d3 ĭ0 7 Pz Px Py XBtl XAtl Btl Atl Dr1 XBb1 XAb1 Bb ROD Ab HEAD PbL PCk XBk XAk ROD Bk Ak HEAD PnA2 Dr7 XBa2 XAa2 Aa ROD PaL R2 ZX225 1102010 TRAVEL R SWING SWING PRIORITY BOOM2 ARM1 BYPASS CUT OPTION ARM2 B...

Page 143: ...1 It passes the neutral bypass 2 neutral M shaped spool mechanism of the spools of straight travel 308 L travel 301 boom 1 303 bucket 304 and arm 2 306 and flows back into the working oil tank via return port R1 Working oil supplied from the hydraulic pump Rear flows in through pump port P2 and is introduced into the main passage 3 It passes the neutral bypass 2 neutral M shaped spool mechanism of...

Page 144: ... 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 PTa XBtL XAbL PCk X8k XAa2 R1 CCk CCo XBa2 XBb1 XAtL 1 2 2 3 XAk XAtr XBs XAb2 XBo XBa1 XBp1 ZX225 1102011 P2 P3 Psp XAs XBtr XBp2 XAa1 XAo https www tractormanualpdf info ...

Page 145: ... pump front is introduced into the left travel motor via port Btl Likewise when pressure at port XBtr for the right travel spool 301 rises neutral bypass 2 at arm 1 side is closed and working oil supplied from the hydraulic pump rear is introduced into the right travel motor via port Btr On the other hand return oil from the left and right travel motor passes the left right travel spool via port A...

Page 146: ...one valve 511 of the check valve and flows into the arm 1 spool 302 via the U passage Then it flows into the periphery of arm 1 spool 302 and arm 2 spool 306 and is supplied into the arm cylinder rod end R via port As On the other hand working oil from port P1 is introduced into neutral bypass 2 via main passage 1 Neutral bypass is cut off by switching the arm 2 spool 306 There fore working oil in...

Page 147: ... Y L A T I N A M E R I C A 4 50 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 R H Aa Ba ZX225 1102013 511 511 XAa2 XAa1 256 101 https www tractormanualpdf info ...

Page 148: ... in the parallel passage pushes open the logic cone valve 256 101 of the arm 2 logic valve GP and working oil from neutral bypass pushes open the cone valve 511 of the check valve and flows into the arm 2 spool 306 via the U pas sage Then it merges with port Ba via the inner passage of arm 2 spool 306 and is supplied into the arm cylinder head end H On the other hand pressure of the return oil fro...

Page 149: ...I N A M E R I C A 4 52 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 Light load H Aa XBa1 XBa2 a b ZX225 1102014 302 317 Ba R Arm weight https www tractormanualpdf info ...

Page 150: ...A 4 53 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 When pressure at arm cylinder head end H rises R H Aa XBa1 XBa2 c 257 211 a Ba ZX225 1102015 302 317 https www tractormanualpdf info ...

Page 151: ...om 1 spool 303 via the U passage Then it flows into the periphery of boom 1 spool 303 and is supplied into the boom cylin der head end H via port Ab At the same time pilot pressure oil is also supplied to port XAb2 and boom 2 spool 307 moves to the right Working oil from port P2 is introduced into neutral bypass Neutral bypass is cut off by switching the boom 2 spool 307 Therefore working oil in t...

Page 152: ... A N Y L A T I N A M E R I C A 4 55 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 H Bb R 511 XAb1 ZX225 1102016 XAb2 511 Ab https www tractormanualpdf info ...

Page 153: ...into the parallel passage pushes open the cone valve 511 of the check valve and flows into the boom 1 spool 303 via the U passage Then it flows into the periphery of boom 1 spool 303 and is supplied into the boom cylinder rod end R via port Bb On the other hand return oil from the boom cylinder head end H passes the hole a and the periphery of boom 1 spool 303 Return oil pressure rises due to the ...

Page 154: ...passage pushes open the cone valve 511 of the check valve and flows into the bucket spool 304 via the U passage Then it flows into the periphery of bucket spool 304 and is supplied into the bucket cylinder head end H via port Ak On the other hand return oil from the buck et cylinder rod end R flows in via port Bk Then it flows to oil tank port R1 via the spool periphery and returns to working oil ...

Page 155: ...valve and flows into the bucket spool 304 via the U pas sage Then it flows into the periphery of bucket spool 304 and is supplied into the bucket cylinder rod end R via port Bk On the other hand return oil from the buck et cylinder head end H flows in via port Ak Then it flows to oil tank port R1 via the spool periphery and returns to working oil tank When bucket DIG is operated pilot pres sure oi...

Page 156: ... neutral bypass 2 via main passage 3 Neutral bypass is cut off by switching swing spool 305 Therefore working oil in the parallel passage pushes open the logic cone valve 2540 101 of the swing logic valve GP and flows into the swing spool 305 via the U passage Then it flows into the periph ery of swing spool 305 and is supplied into the swing motor via port As or Bs On the other hand return oil fr...

Page 157: ...pressure oil is supplied to port Psp and swing priority spool 311 is switch Main circuit Switch swing priority spool 311 The opening area of the swing priority reduces As a result working oil from arm 1 spool 302 flows into swing spool 305 and swing operation takes precedence 2 Swing priority function Psp ZX225 1102021 https www tractormanualpdf info ...

Page 158: ...511 of the check valve and flows into the op tion spool 309 via the U passage Then it flows into the periphery of option spool 309 and is supplied into the optional equipment via port Ao or Bo On the other hand return oil from the op tional equipment flows in via port Bo or port Ao Then it flows into tank port R1 via the spool periphery and returns to the working oil tank 2 Option confluence To ac...

Page 159: ... supplied to port PTa and straight travel spool 308 is switched Main circuit When straight travel spool 308 is switched the right left travel spool 301 are interconnected with port P2 The paral lel passage of swing boom 2 option arm 1 circuit and boom 1 bucket arm 2 circuit are interconnected with port P1 Therefore working oil supplied from port P2 flows into port Atl and port Atr and is supplied ...

Page 160: ...n neutral position The following shows when boom 1 spool 303 is in neutral position The same is with arm 2 spool 306 When boom 1 spool 303 is in neutral po sition spool 252 511 in the lock valve op tion set is pressed against the valve seat of the valve sleeve 252 541 inside the lock valve option set as shown in the illus tration via the spring force of spring 252 321 At this position working oil ...

Page 161: ...nd working oil from boom cylinder head end H does not flow into spring chamber RH In addition oil in the spring chamber RH flows into drain circuit via hole b In this way the cone valve 513 is pushed up by the pressure at boom cylinder head end H and the function of the lock valve option set 252 is released When boom DOWN is operated pilot pres sure oil is supplied to port XAb1 The cone valve 513 ...

Page 162: ...in passage P exceeds the elastic force of spring 621 cone valve 611 is pushed open Therefore working oil flows through the hole on valve sleeve 103 via the periphery of cone valve 611 and enters low pressure path R Opening of cone valve 611 causes pres sure in chamber a to drop and valve rod 512 is open In this way working oil in passage P flows into low pressure path R directly When pressure oil ...

Page 163: ...to the function as relief valve it has also the function of anti cavitation oil complement check valve Its function is described below 1 Relief valve function Working oil flows into chamber B via the hole A on plunger 301 Valve rod 511 is pressed against valve seat 541 and valve seat 541 is pressed onto the valve seat of the valve block forming a tight seal ZX225 1102027 A B P R 301 511 541 ZX225 ...

Page 164: ... Manual June 2013 When pressure in passage P exceeds the elastic force of spring 621 cone valve 611 is pushed open Therefore working oil flows through hole C via the periphery of cone valve 611 and enters low pres sure path R ZX225 1102029 C P R 611 621 ZX225 1102030 611 621 C P R https www tractormanualpdf info ...

Page 165: ...ure and Function Shop Manual June 2013 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 B P R 511 611 ZX225 1102032 B P R 511 611 https www tractormanualpdf info ...

Page 166: ...en 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 Therefore working oil is supplied from path R to path P via the periphery of valve seat 541 in order to prevent cavitation 541 P R ZX225 1102034 541 P R ZX225 1102033 https www tractormanualpdf info ...

Page 167: ...Bbl XAk XBo XBa1 XBa2 AkR AbR O O A AaR XBp1 H B PCV1 AR AoR XAb2 XBs XAtr B A 978 2 977 Dr8 PnS 273 10 273 12 XBk PCk XAa2 XBp2 210 Dr6 Pns 274 4 CCo CCk P5 P P PnA2 XBa2 XBp1 Dr3 C D E F G ZX225 1102035 Dr7 602 AaR 153 561 P5 TRAVEL R TRAVEL STRAIGHT TRAVEL L BOOM1 BUCKET ARM2 SWING BOOM2 OPTION ARM1 BYPASS CUT1 BYPASS CUT2 View O O Viw P P 4 5 3 Section view https www tractormanualpdf info ...

Page 168: ...tor Structure and Function Shop Manual June 2013 Section A A N N 101 159 541 542 N 543 166 550 PTa XBtL XAbL PCk XBk ZX225 1102036 XAa2 551 514 521 561 551 561 521 514 CCk CCo XBa2 XBb1 XAtL XAk 151 168 151 168 151 168 156 PB 2 156 N View A A View N N https www tractormanualpdf info ...

Page 169: ...ler Hydraulic Excavator Structure and Function Shop Manual June 2013 Section B B 561 R1 153 975 975 102 975 XAtr XBs XAb2 XBo 975 XBa1 XBp1 ZX225 1102037 975 165 165 165 975 975 975 975 975 P2 P3 Psp XAs XBtr XBp2 XAb1 XAo View B B https www tractormanualpdf info ...

Page 170: ...ravel right travel straight 201 336 332 335 321 320 332 261 163 314 165 163 511 521 551 561 165 163 163 163 XAtr Atr CP1 Btr 264 204 XBtr PTa 154 ZX225 1102038 164 204 264 159 159 512 522 553 CMR2 CMR1 562 562 553 522 512 Pz 601 308 261 332 332 335 323 332 336 201 164 154 MR TRAVEL RIGHT TRAVEL STRAIGHT View C C https www tractormanualpdf info ...

Page 171: ...tion Shop Manual June 2013 Section D D Swing travel left XBs XAtL 201 336 332 335 321 320 332 261 305 161 163 163 254 As 251 Bs 165 264 204 Dr2 163 163 XAs XBtl 204 ZX225 1102039 264 BtL 561 551 521 511 C2 AtL 314 261 332 320 321 335 332 336 201 SWING TRAVEL LEFT View D D https www tractormanualpdf info ...

Page 172: ...om 2 XAb2 XBb1 202 336 332 339 327 326 332 261 161 511 521 551 561 165 307 163 551 561 311 Xb2 CCb Dr1 161 261 332 320 329 339 332 336 202 Psp 163 XAb1 BbR 158 204 602 264 303 Bb 561 551 LCb 521 511 513 561 552 523 PbL CRb 158 201 336 332 335 321 320 602 332 261 L ZX225 1102040 L BOOM2 BOOM1 View E E SWING PRIORITY View L L https www tractormanualpdf info ...

Page 173: ... F Option bucket XBo 259 164 201 336 332 335 321 320 332 261 604 163 209 971 4 971 4 165 309 163 163 511 521 551 561 163 165 209 163 264 604 204 164 154 Bo LCo Ao BoR XAo PCk XBk BkR 258 ZX225 1102041 561 211 206 264 602 Bk 561 551 521 511 Ak AkR 304 261 332 602 320 321 335 332 336 201 OPTION BUCKET View F F https www tractormanualpdf info ...

Page 174: ...2013 Section G G Arm 1 arm 2 XBa1 XBa2 Dr3 AR 201 336 332 335 321 320 257 332 261 163 165 162 152 152 165 162 302 511 521 551 561 163 165 163 264 602 205 BaR XAa1 XAa2 204 ZX225 1102042 264 511 521 561 551 256 R2 LCAT2 251 552 561 523 513 158 CRa L L 306 261 332 320 321 335 332 336 201 View G G https www tractormanualpdf info ...

Page 175: ...on Shop Manual June 2013 Section H H Bypass cut 1 bypass cut 2 612 169 162 152 158 154 164 152 152 162 162 164 154158152 162 164 154 169 612 162 152 PCV2 XBp2 203 333 331 372 373 337 331 262 310 165 165 310 163 262 331 337 373 372 331333 203 ZX225 1102043 XBp1 PCV1 View H H https www tractormanualpdf info ...

Page 176: ...SEAT 4 164 O RING 7 332 SPRING SEAT 22 165 O RING 14 16 18 333 FLANGE SOCKET 2 166 O RING 1 335 STOPPER 9 168 O RING 3 16 18 336 FLANGE SOCKET 11 169 O RING 2 337 STOPPER 2 201 COVER spring 9 339 STOPPER 2 202 COVER spring 2 372 SPRING 2 203 COVER spring 2 373 SPRING 2 204 COVER spool 7 511 VALVE cone 8 205 COVER spool 1 512 VALVE cone 2 206 COVER spool 1 513 VALVE cone 2 209 FLANGE 2 514 VALVE co...

Page 177: ...G 9 562 O RING 2 25 34 273 SCREW hex S H C 44 69 78 601 VALVE main relief 1 98 120 274 SCREW hex S H C 4 69 78 602 VALVE port relief 6 301 SPOOL travel 2 120 140 604 VALVE port relief 2 302 SPOOL ASS Y arm 1 1 69 78 612 PLUG 2 303 SPOOL ASS Y boom 1 1 49 65 971 SCREW hex S H C 8 304 SPOOL bucket 1 140 180 975 SCREW hex S H C 10 305 SPOOL swing 1 977 PLATE name 1 306 SPOOL arm 2 1 978 PIN 2 307 SPO...

Page 178: ...oil port M Oil complement port PA Pressure detection port PB Pressure detection port DB Lubricating port PG Brake release port SH Brake direction port L Oil level stick IP Gear oil feed port 1 Relief valve 2 Reverse prevention valve For more technical information about the swing motor see Swing motor on page 3 6 NOTE For the location of the swing motor on the machine see Hydraulic equipment layout...

Page 179: ...ture and Function Shop Manual June 2013 ZX215 1002082 A A 12 13 8 1 5 4 3 11 2 9 6 7 10 A A 1 Spacer 2 Casing 3 Disc 4 Brake spring 5 Shell 6 Check valve spring 7 Check valve 8 Oil distribution plate 9 Cylinder 10 Brake piston 11 Plate 12 Piston 13 Drive shaft https www tractormanualpdf info ...

Page 180: ...rom chamber a be neath piston 7 Brake piston 7 is pushed down by brake spring 1 Disc 5 and plate 6 are pushed together and the brake is applied ZX215 1002084 a 5 1 6 7 M PX PG SH Pump Main valve 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 bene...

Page 181: ...e swing holding mode control valve 5 closes the motor outlet circuit but the motor rotation contin ues due to inertial force The motor output therefore is abnormally increased result ing in motor damage In order to avoid the motor damage the relief valve relieves the abnormally high pressure to port M from the motor outlet side high pressure side of the motor NOTE For the location of the relief va...

Page 182: ...ver is neutral ized the supply of pressurized oil from the pump to port A is cut off The pressurized oil from the motor outlet can t return to the tank since the return cir cuit to the tank is closed from control valve 5 Thus pressure at port B rises Swing resistance is generated on the mo tor and hence the brake starts working Pressurized oil will be relieved when the pressure on port B rises to ...

Page 183: ... 2 Spool A side 3 Spring A side 4 Plug 5 Spool B side 6 Spring B side 7 Plug 4 6 4 Reverse prevention valve 4 6 4 1 Operation drawing ZX215 1002087 T2 B T1 A 1 2 3 7 6 5 4 B A T Swing control valve Swing motor NOTE For the location of the reverse prevention valve on the swing motor see Swing motor on page 4 81 https www tractormanualpdf info ...

Page 184: ...tion valve is designed to reduce this effect The valve contributes in preventing collapsing of load when the swing is stopped and also con tributes in reducing cycle time enhances the positioning performance enabling you to proceed to the next work quicker than ever ZX215 1002088 With reversal prevention valve Without reversal prevention valve Reversal pressure Containment pressure Time Start Brak...

Page 185: ...of spring 3 spool 2 does not move and the pressurized oil is stopped by spool 2 Thus the braking force is ensured 2 When motor is stopped The motor rotation is reversed by the clos ing pressure generated at port B 1st time reverse rotation Reversing pressure is generated on port A Pressure A is conducted to chamber a and spool 2 moves spring 3 to the right side and A and B is interconnected At thi...

Page 186: ...C1 B1 D1 13 12 11 10 9 8 7 6 5 4 3 2 1 G1 1 Swing shaft 2 Dust seal 3 O ring 4 Swing body 5 Rotating seal φ100x5 6 Gasket 7 Retaining ring φ 90 8 Plug ZG3 4 9 Plug ZG1 4 10 Cover 11 Spacer 12 Gasket 13 Gasket 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 https www tractormanualpdf info ...

Page 187: ... BTR C From main valve ATL D From main valve ATR A1 To L travel motor port P1 B2 To R travel motor port P2 C3 To L travel motor port P2 D4 To R travel motor port P1 G To swing motor port DB G1 From travel motor final drive assembly oil drain port D1 D2 F From solenoid valve port A2 F1 To travel motor reducer Hi Lo speed switching port P https www tractormanualpdf info ...

Page 188: ... Speed 2 Reduction gear Gear ratio 49 95 Theoretical output torque kgf m Max 4650 4535 2767 Theoretical output speed r p m Max 60 28 45 9 Hydraulic motor Displacement cc rev Max 174 7 162 9 99 4 Continuous pressure kgf cm2 Max 350 350 Theoretical speed r p m Max 2800 1400 2294 Flow l min 250 228 Duo speed control pressure kgf cm2 20 70 Braking torque kgf m Min 50 Brake release pressure kgf cm2 8 2...

Page 189: ...ash plate 28 Cylinder block 29 Piston 30 Stopper 31 Baffle 32 Spheric bush 33 Timing plate 34 Parking piston 35 Spring 36 Cylinder block spring 37 Friction plate 38 Spacer 39 Oil seal 40 O ring 41 O ring 42 Parallel pin 43 Washer 44 Washer 45 Ball bearing 46 Ball bearing 47 Spring 48 Piston 49 Stopper 50 Pivot 51 Plunger 52 Piston seal 53 Valve body 54 Washer 55 O ring 56 O ring 57 Shim 58 Spring ...

Page 190: ...l drain port P1 Main oil port P2 Main oil port A Mounting surface with sprocket B Mounting surface with undercarriage 1 Mounting hole with sprocket 2 Mounting hole with undercarriage ZX215 1002132 P2 B A P1 Dr Tin Pm1 1 2 Pp Pm2 Ps NOTE For the location of the travel motor on the machine see Hydraulic equipment layout on page 4 24 NOTE For more technical information about the travel motor see Trav...

Page 191: ...5 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 ZX215 1002093 2 4 2 3 2 2 2 6 2 5 1 5 1 6 1 2 1 1 3 4 2 1 1 4 1 3 5 Connected to sprocket Mounted on the undercarriage Piston motor shaft https www tractormanualpdf info ...

Page 192: ...r and prevent over speed of the motor in re lation with the supplied delivery The counterbalance valve and the relief valve constitute the braking circuit The braking circuit applies braking force onto the rotating motor and stops the motor gradually This valve can serve as a shuttle valve for high pressure selection to release the brake under its own pressure The structure of a standard counterba...

Page 193: ...M2 are shut off by spool 1 and check valve 2 since no pressure is generated at port P1 and port P2 The motor is not rotating ZX215 1002094 6 2 7 2 5 2 4 2 2 2 2 1 4 1 5 1 7 1 6 1 8 2 8 8 1 3 1 M1 P1 P2 M2 Circuit B Circuit C2 Damper chamber A2 Orifice D4 Spring chamber 2 Circuit C1 Orifice D1 Damper chamber A1 Orifice D2 Spring chamber 1 Orifice D3 A Stopped state https www tractormanualpdf info ...

Page 194: ... and the hydraulic oil works on the inside of spring chamber 1 and damper chamber A1 via orifice 4 1 and check valve 5 1 The force generated in this way pushes spring 7 2 on the other side and moves piston 1 to the right At this time return oil from port M2 passes through circuit of the notch on the periph ery of piston 1 and through port P2 when pressure is generated at port M2 and en ters the ta...

Page 195: ... the left under the force of spring 7 2 closing circuit B Circuit at the suction side is also closed at the same time when the circuit at return side is closed When circuit B is closed pressure at port P1 rises due to hydraulic oil from the main pump moving piston 10 to the right again In this way when external load generates pump effect slight movement of piston 1 keep circuit B open The rotation...

Page 196: ...or does not stop rotating pump effect and pres sure at port M2 rises and serves as the braking force of motor rotation When the pressure at port M2 reaches the set pres sure of relief valve 8 cone valve 8 1 at port M1 overcomes the force of spring 8 2 and moves to the left and hydraulic oil flows the port M1 In this way the impact ing force due to inertia at port M2 is under control and vacuum at ...

Page 197: ...e ori fice and enters travel brake cylinder cham ber E to release travel brake In addition piston 1 moves to neutral position as shown in fig 5 when motor stops Circuit D is closed and drain circuit F of motor body is connected Hydraulic oil in travel brak ing cylinder chamber E is conducted to the drain circuit of motor body and travel brake is applied ZX215 1002097 1 Circuit F Circuit D Circuit ...

Page 198: ...rake is re leased 2 When travel stops As the travel lever is placed in neutral counterbalance valve spool 10 returns to the neutral position and closes the park ing brake circuit The pressurized oil in chamber A of brake piston 12 passes through the orifice of the brake piston and is drained to the motor case Brake piston 12 is pushed to the right by spring 12 Plate 13 and disc 14 are pushed to ge...

Page 199: ...ed the motor may rotate at zero load resulting in run away and inviting a very dangerous situation These valves are used to avoid such a situation by control ling the machine to travel as per the engine speed pump delivery Operation when pressurized oil is supplied Operating the travel lever conducts the pressurized oil from the control valve to port PA The pressurized oil opens suc tion safety va...

Page 200: ...esistance on the motor to prevent the machine from losing control On the other hand the spool moves to a position where the pressure on outlet port MB can be balanced against the machine s own weight and the inlet port pressure Oil flow from the outlet circuit is reduced to ensure the travel speed corresponded to the pump delivery The pressurized oil on the supply side flows to chamber S1 via orif...

Page 201: ...t damages to the equipment Operation 1 When travel is stopped or when travelling downhill Right swing Reduction of the pressure at motor inlet PA decreases the pressure in chamber S1 When it drops beyond the spool switching pressure the spool is returned to the left by spring 20 reducing the pres sure at outlet passage B1 At this time the motor continues rotating due to its iner tial force thus pr...

Page 202: ...valve is area dif ference and direct flow type It has impact damping function during starting and brak ing ZX215 1002106 PA S1 8A 19 E1 B2 8B PB MA MB Travel control valve ZX215 1002108 A Operation principle and function When the main valve makes the motor to start or brake front pressure of cone valve 2 9 2 rises above the set pressure and the force of spring 2 9 5 and moves cone valve 2 9 2 to t...

Page 203: ...rmal set loaded area S1 S2 of the relief valve So when damping piston 2 9 9 is moving the func tional pressure of relief valve is maintained at 1 3 of normal set pressure in order to absorb the impact at the high pressure circuit side due to inertia energy When the movement of damping piston stops pressure in spring chamber D rises Pres sure at both side of cone valve 2 9 2 is the same and the rel...

Page 204: ... A 4 107 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 4 6 7 Valve control system 9 8 7 6 10 4 3 2 1 5 13 12 11 1 2 3 4 5 6 7 8 9 10 11 12 ZX215 1002112 https www tractormanualpdf info ...

Page 205: ...l control lever 4 Right PPC valve 5 Right joystick 6 Accumulator 7 Transition block 8 Hydraulic pump 9 Main control valve 10 Solenoid valve 11 Left joystick 12 Left PPC valve 1 HOLD 2 Boom UP 3 Boom DOWN 4 Bucket DUMP 5 Bucket DIG 6 HOLD 7 Arm IN 8 Arm OUT 9 Right swing 10 Left swing 11 Neutral 12 Reverse travel 13 Forward travel Control lever position https www tractormanualpdf info ...

Page 206: ...nd swing pilot valve ZX215 1002113 1 2 3 4 P P P4 A P1 A P3 P2 T 64 73 5Nm 19 22Nm P From pilot pump relief valve P1 L H Pilot valve Arm OUT R H Pilot valve Boom DOWN P2 L H Pilot valve Arm IN R H Pilot valve Boom UP P3 L H Pilot valve Swing LEFT R H Pilot valve Bucket DIG P4 L H Pilot valve Swing RIGHT R H Pilot valve Bucket DUMP T To tank https www tractormanualpdf info ...

Page 207: ... Hydraulic Excavator Structure and Function Shop Manual June 2013 1 Plunger 2 Metering spring 3 Centering spring 4 Piston 5 Disc 6 Nut for lever connection 7 Joint 8 Plate 9 Retainer 10 Valve body ZX215 1002114 10 9 8 7 6 5 4 3 2 1 A A https www tractormanualpdf info ...

Page 208: ...t off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to re lease the pressure at port P1 As a result plunger 1 moves up and down until the force of metering spring 2 is balanced with the pressure at port P1 The relationship of the position of plunger 1 and body 10 orifice f is in the middle between drain chamber D and pump pressure chamber PP does not chan...

Page 209: ...he level equivalent to the lever position When the spool of the control valve re turns the oil in drain chamber D flows in from orifice f in the valve on the side that is not working The oil passes through port P2 and enters chamber B to replenish the chamber with pressurized oil 4 At full stroke Disc 5 pushes down piston 4 and re tainer 9 pushes down plunger 1 Orifice f is shut off from drain cha...

Page 210: ...ator Structure and Function Shop Manual June 2013 4 6 8 2 Travel PPC valve ZX215 1002119 1 2 4 3 P4 P3 P1 P2 T P P5 A T P P5 A P6 P From pilot pump P1 L H reverse P2 L H forward P3 R H reverse P4 R H forward P5 Travel signal P6 Travel signal T To tank https www tractormanualpdf info ...

Page 211: ...er Hydraulic Excavator Structure and Function Shop Manual June 2013 1 Plate 2 Body 3 Piston 4 Collar 5 Centering spring 6 Metering spring 7 Valve ZX215 1002120 1 2 3 4 5 6 7 C 2 4 B 1 3 C B 37 30Nm 65 45Nm 13 11Nm C C 8 6Nm 8 6Nm B B https www tractormanualpdf info ...

Page 212: ...f from pump pressure chamber PP At almost the same time it is connected to drain chamber D to re lease the pressure at port P1 As a result plunger 1 moves up and down until the force of metering spring 2 is balanced with the pressure at port P1 The relationship of the position of plunger 1 and body 10 orifice f is in the middle between drain chamber D and pump pressure chamber PP does not change u...

Page 213: ...el equivalent to the lever position When the spool of the control valve re turns the oil in drain chamber D flows in from orifice f in the valve on the side that is not working The oil passes through port P2 and enters chamber B to replenish the chamber with pressurized oil 4 At full stroke Lever 5 pushes down piston 4 and re tainer 9 pushes down plunger 1 Orifice f is shut off from drain chamber ...

Page 214: ... Pilot lockout solenoid valve T To oil tank P From accumulator and pilot pump A1 To center swivel joint port A2 To main valve port PsP A3 To main valve port Xbp2 A4 To main valve port PnA2 A6 To pilot valve block P Pilot valve lock travel speed bucket confluence swing priority 4 6 9 Solenoid valve NOTE For the location of the solenoid valve on the machine see Hydraulic equipment layout on page 4 2...

Page 215: ...15 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 4 6 10 Accumulator 1 Gas plug 2 Shell 3 Poppet 4 Holder 5 Bladder 6 Oil port Specifications Gas capacity 300 cm ZX215 1002126 1 2 3 4 5 6 https www tractormanualpdf info ...

Page 216: ...ZX215 1002127 型号压力精度 1 K K 2 3 3 4 5 6 1 Name plate 2 Head cover 3 O ring 4 Seal 5 Filter 6 Case Max delivery 40 L min Filter fineness 10 μm Operating pressure 20 Mpa Max operating pressure 40 Mpa Pressure loss 0 05 Mpa Max allowable pressure difference 1 Mpa Specification of inlet outlet port o ring 30 3 1 Specifications https www tractormanualpdf info ...

Page 217: ...oil pressure sensor 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 1 Pressure connector 2 Name plate 3 Connector 4 Vent hole ZX215 1002128 A B C 4 1 2 3 https www tractormanualpdf info ...

Page 218: ... 267 35N m 27 2 3 6kgm 56 9 10 7N m 5 8 1 1kgm 544 9 5 1kgm 5340 50N m ZX215 1002130 2 1 3 37 4 3 6kgm 367 35N m 56 9 10 7N m 5 8 1 1kgm 806 1 5 1kgm 7900 50N m ZX215 1002131 2 1 3 27 2 3 6kgm 267 35N m 5 8 1 1kgm 56 9 10 7N m 559 2 5 1kgm 5480 50N m 4 6 13 Hydraulic cylinder Boom cylinder Arm cylinder Bucket cylinder https www tractormanualpdf info ...

Page 219: ... support pin and bushing Boom 70 0 030 0 246 0 230 0 322 1 0 0 076 0 200 Arm 80 0 030 0 246 0 230 0 322 1 0 0 076 0 200 Bucket 70 0 030 0 246 0 230 0 322 1 0 0 076 0 200 Unit mm No Check item Criteria Remedy 1 Clearance between pis ton rod and bushing Cylinder Standard size Tolerance Standard clearance Clearance limit Replace bushing Shaft Hole Boom 85 0 036 0 222 0 083 0 312 0 412 0 090 0 047 Arm...

Page 220: ...95 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 ZX215 1002133 A B C D E F G H J K ZX215 1002134 1 5 6 3 4 2 A A F F G G H H C C D D E E K K J J B B 4 6 14 Work equipment https www tractormanualpdf info ...

Page 221: ...0 060 0 373 0 273 0 303 0 433 1 0 6 Clearance between pin connecting linkages and bushing 70 0 030 0 060 0 335 0 275 0 305 0 395 1 0 Unit mm No Check item Criteria Remedy 1 Clearance between pin connect ing boom and revolving frame and bushing Standard size Tolerance Standard clear ance Clearance limit Replace Shaft Hole 90 0 036 0 071 0 131 0 074 0 110 0 202 1 0 2 Clearance between pin connecting...

Page 222: ... 125 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 Arm dimension WX13060402 5 6 7 8 9 10 11 12 13 18 3 16 2 14 19 A A B B C C D D 17 15 4 1 B B A A C C D D https www tractormanualpdf info ...

Page 223: ...0 φ80 0 1 0 2 107 0 5 0 107 0 5 0 3 310 0 3 0 8 310 0 3 0 8 4 φ90 0 036 0 071 φ90 0 036 0 071 5 549 1 549 1 6 158 0 8 158 0 8 7 835 1 835 1 8 2 911 2 2 911 2 9 2 643 2 2 643 2 10 411 0 8 411 0 8 11 640 0 0 5 640 0 0 5 12 600 600 13 458 458 14 1 483 1 495 15 φ80 φ80 16 326 5 326 5 17 φ80 0 2 0 φ80 0 2 0 18 Arm itself 311 311 When press fit ting bushing 325 325 19 Min 1 680 1 680 Max 2 800 2 800 htt...

Page 224: ... A 4 127 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 Bucket dimension WX13060403 1 2 3 4 5 6 7 16 17 18 19 A A A A 15 14 9 21 10 12 11 13 15 8 8 20 22 https www tractormanualpdf info ...

Page 225: ...ndard size Tolerance Standard size Tolerance 1 457 5 0 5 457 5 0 5 2 22 0 5 22 0 5 3 91 8 91 8 4 458 458 5 1 483 1 483 6 177 177 7 45 45 8 φ80 0 2 0 φ80 0 2 0 9 348 5 0 2 0 348 5 0 2 0 10 37 37 11 107 107 12 473 5 473 5 13 φ23 5 φ23 5 14 φ190 φ190 15 φ136 φ136 16 131 131 17 125 125 18 R180 R180 19 R140 R140 20 57 57 21 326 5 0 5 326 5 0 5 https www tractormanualpdf info ...

Page 226: ... water piping 2 A C compressor DENSO 2 3 Refrigeration piping 4 Condenser SG447750 A040 5 Receiver tank DENSO 4 6 Hot water return piping 7 A C unit assembly SG443180 9320 8 Air duct A Fresh air B Recirculated air C Warm air cool air ZX215 1002137 C 8 7 6 5 4 3 2 1 C C C C A B 4 7 Air Conditioning System https www tractormanualpdf info ...

Page 227: ...Excavator Structure and Function Shop Manual June 2013 4 7 1 A C components layout drawing 1 Sunlight sensor 2 Control panel 3 Air conditioning unit 4 Condenser 5 Compressor 6 Fresh air sensor 7 Recirculated air sensor ZX215 1002138 1 2 3 4 5 6 7 https www tractormanualpdf info ...

Page 228: ...ure and Function Shop Manual June 2013 4 7 2 Control panel 1 OFF switch 2 Fan speed control switch 3 Temperature control switch 4 Air outlet mode switch 5 Auto mode switch 6 Air circulation control switch 7 LCD display 8 A C switch 6 1 2 3 4 5 7 8 CZ205 1203020G https www tractormanualpdf info ...

Page 229: ...18 21 22 25 22 24 26 25 22 20 31 30 31 32 22 22 32 32 34 34 35 35 35 24 26 M M RF GND Pt Vz REC FFE 28 G 8 6 BLCM SP HL 0 5B AC M M AM S SD TH F TH I TH W TH AM M V1 M V2 2G 2RL M R D D 1 ACC 200W 0 50 2B 2B 80W 1 25B 1 25B 0 85B 2B 40W BLC RL CH 4 3 2 1 EC C RL CH R CD BAT 40A FL Z CM B 60A 15A 20A 1 25R B RL SF G CM B RL CH RL CD RL CC SP CD M CD RL BM FU CD FU RM FL 1 D 2 SW 1 25RL 15 19 16 14 ...

Page 230: ...Y Red yellow 1 25RW Red orange 0 5BW Black white 0 85GL Green Blue 0 5LgR Light green red Code Name Code Name Code Name ACM A C amplifier FUCD Condenser fuse RLCH Condenser high speed relay BAT Battery FUM A C main fuse RLSF Protective relay BLC Speed regulating resistor G Alternator SSD Sunlight sensor CMB Battery relay MAM A M servo motor SPCD Condenser pressure switch D Diode MB Blower motor SP...

Page 231: ... Cool air Lo pressure portion Hot air Hi pressure portion Lo temp Lo press gas Air in cab Out side fresh air Cooling fan Lo temp Lo press liquid Mist Hi temp Hi press liquid Lo pres side Hi pres side Compressor Blower Evaporator Receiver Expansion valve Hi temp hi pres gas Condenser ZX215 1002142 Engine Water pump Water valve control Blower motor Internal air Low tempr water High temp water Hot ai...

Page 232: ...ssor 1 Stator 2 Front radial bearing 3 Thrust bearing 4 Front radial bearing 5 Rear cylinder head 6 Safety valve 7 Rear cylinder block 8 Swash plate 9 Slipper 10 Front cylinder block 11 Piston 12 Front cylinder head 13 Shaft seal 14 Main shaft 15 Hub 16 Rotor ZX215 1002143 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 https www tractormanualpdf info ...

Page 233: ...nsforms the refrigerant sucked from the evaporator from low tempera ture and low pressure gas state to high tem perature and high pressure state ZX215 1002144 Process 1 Process 6 Process 5 Process 3 Process 2 Process 4 HI press end pipe HI press end pipe HI press end pipe HI press end pipe LO press end pipe LO press end pipe LO press end pipe LO press end pipe HI press end pipe LO press end pipe V...

Page 234: ... controls the opera tion of the compressor only when the air conditioner is under refrigerating mode Operating principle When the A C switch is turned on the clutch coil with an electromagnet gener ates a magnetic field and attracts the metal piece The stator and rotor of the clutch are engaged and drives the main shaft of the compressor into rotation 1 Rotor 2 Stator coil 3 Snap ring 4 Ball beari...

Page 235: ... core 2 Bracket 3 Bolt with gasket 4 Refrigerant inlet 5 Refrigerant outlet ZX215 1002146 1 2 3 5 4 Function The condenser converts high temperature high pressure gas refrigerant 16Kg cm about 80 C to high temperature and high pressure liquid refrigerant 16Kg cm be low 60 C through radiating Operating principle Refrigerant from the receiver tank spurts out via the orifice turns into low temper atu...

Page 236: ... Measure the volume of refrigerant ZX215 1002149 1 2 3 4 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 Heat is absorbed and hot air turns into cold air which flows into the cab through the air ducts Evaporator surface ...

Page 237: ... the expansion valve hi pressure pipe It is a combina tion switch Hi Lo pressure combination switch When pressure is excessively high the compressor stops When pressure and temperature is very low the compressor stops Operating features ZX215 1002150 1 2 3 4 5 6 7 Pressure DIFF OFF ON DIFF 0 59 0 2 MPa 0 196 0 02 MPa 0 196 0 250 MPa 2 94 3 19 MPa ON OFF 1 23 0 1 MPa 1 52 0 08 MPa HI pressure opera...

Page 238: ... 1700 85Ω B constant 3900 195 K Allowable operating current 1 6 mA MAX ZX215 1002151 12 10 2 12 8 6 4 2 10 AT 0 10 20 30 40 Resistance value K 4 7 13 Refrigerant 1 General property High heat absorption and easy liquefaction Non flammable nonexplosive Stable chemical composition Non toxic Non corrosive No hazard to clothing WARNING Obey local material disposal regula tions Never discharge refrigera...

Page 239: ...Throttling point Gasification completed Liquefaction starts Liquefaction completed Expansion valve Liquid Evaporator Compressor Condensor Refrigerant cyclic curve Compressor IntakeėDischarge Evaporator Absorb heatėEmit cold air Condensor Via radiating Gas refri gerantėLiquid refrigerant Expansion valve Hi pressureėLo pressure Hi tempėLo temp LiquidėMist Compress HI press side outlet HI temp HI pre...

Page 240: ...nt from the low pressure end is not al lowed If feeding operation fails discharge the refrigerant that has been fed before re feeding Inspect the state of the refrigerant in the A C circulation system through the sight glass 1 Correct feeding Foam is hardly observed when the refrigerant is flowing When en gine speed increases from idling to 1500 rpm foam disappears and the refrigerant turns clear ...

Page 241: ...ng Evacuating steps Step 1 Connect the manifold pressure gauge 1 Close the high pressure valve HI and low pressure valve LO of the manifold pressure gauge 2 Connect the hoses red blue to the auxil iary valve of the compressor Red hose High pressure side Mark D Blue hose Low pressure side Mark S NOTE Connect the end of the hose with a L to the auxiliary valve of the compressor If connected inversel...

Page 242: ...se the Hi pressure valve and the Lo pressure valve on the gauge ZX215 1002156 Lo Hi Tighten pipe joint Lo press gauge returns to 0 Wait 5 min or more Lo press gauge Pointer returns to 0 Valve OFF OFF Step 3 Air proof check 1 Keep the Hi and Lo pressure valve of the manifold pressure gauge under closed state for more than 5 minutes and make sure the pointer on the gauge does not re turn to zero 2 I...

Page 243: ...frigerant Release the vent valve when you hear a squeezing sound 3 Add refrigerant until pressure reading on the Lo pressure gauge is 1kgf cm Hi pressure valve of the gauge is open at this time Close the Hi pressure valve when feeding is finished 4 Use a leak detector to check if leakage is available in the cooling system 5 Make necessary repairs tightening if leak age is observed ZX215 1002157 Lo...

Page 244: ...Fluorine cylinder Open Valve ZX215 1002160 R134a D S Lo Hi Lo Hi Open Hi press valve Lo press valve OFF Fluorine cylinder valve ON A cylinder about 600g Valve gDo not operate compressor gDo not open Lo pressure valve ON OFF OFF OFF 3 Open the hi pressure valve of the manifold pressure gauge and the cylinder valve with the engine stopped Fill about 600g of re frigerant 4 Close the hi pressure valve...

Page 245: ...e 3 Turn on the A C unit Adjust Temperature control switch to minimum 4 Adjust engine speed to 1300 1500 rpm 5 Open the Lo pressure valve of the mani fold pressure gauge and the cylinder valve Add refrigerant until no foam is observed through the sight glass Remark Manifold pressure gauge reading for refer ence HIGH pressure 13 17kgf cm when ambient temperature is 30 C LOW pressure 1 5 2kgf cm whe...

Page 246: ...ient temperature is very high cool the compressor with an electrical fan ZX215 1002163 Lo Hi Lo Hi Water less than 40 C Do not use hot water Compressor running Hi pressure valve OFF Lo pressure valve ON Cylinder valve ON ON OFF When no foam is seen Valve OFF OFF CAUTION Opening the Hi pressure valve of the pressure gauge will cause pressurized gas to counterflow and cause the hoses and the fluorin...

Page 247: ...luorine cylinder and then loosen it a bit 2 Open the Lo pressure valve of the mani fold pressure gauge a bit 3 Press the vent valve and allow a little re frigerant to come out Immediately close the valve of the cylinder and the Lo pressure valve of the manifold pressure gauge ZX215 1002164 Air hose connector Handle Gasket Needle valve Refrigerant cylinder Disc plate ZX215 1002165 Lo Hi R 134a OFF ...

Page 248: ...ssure end 1 37 1 57 Mpa 14 16 Kgf cm 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 5 Air circulation mode Recirculation ZX215 1002167 0 0 01 02 03 04 05 05 0 0 35 MPa MPa cmHg kgf cm2 cmHg kgf cm2 5 3 30 25 25 20 10 1 15 2 15 35 01 01 7...

Page 249: ...tem becomes normal again Over saturation of de hydrator Moisture in the system ices up at the expan sion valve and hinders the circulation of the refrigerating system Replace receiver dehydrator Remove the mois ture in the system through constant pumping Add proper volume of new refrigerant Moisture in the refrigerating system Symptom Intermittent refrigeration to non refrigeration ZX215 1002168 0...

Page 250: ... refrigeration Air leaks somewhere in the refrig erating sys tem Insufficient refrigerant in the system Leak of refriger ant Check for air leakage with a leak detector Make necessary re pairs Add proper amount of refriger ant When connected with the gauge if the reading is near zero set the system under vacuum state after inspection and repair ZX215 1002169 0 0 01 02 03 04 05 05 0 0 35 MPa MPa cmH...

Page 251: ...use Analysis Remedy Pressure at both Hi and Lo pressure sides very low Frosting on the pip ing between parts and reservoir Contaminant in the reservoir hinders the flow of refrigerant Blocked reservoir Replace reservoir ZX215 1002170 0 0 01 02 03 04 05 05 0 0 35 MPa MPa cmHg kgf cm2 cmHg kgf cm2 5 3 30 25 25 20 10 1 15 2 15 35 01 01 76 76 50 06 07 08 085 8 5 8 7 5 6 4 3 2 1 15 https www tractorman...

Page 252: ...e or contami nant in the refrigerant hinders the flow of refrigerant Air leak at the thermal pipe of the expansion valve hinders the flow of refrigerant Refrigerant not circulating Check the expansion valve and ERP Blow the contaminant in the expansion valve or replace the expansion valve if nec essary Replace the receiver Release internal air and add refrigerant If air leaks from thermal pipe rep...

Page 253: ...lass even when engine speed drops Over filling of refriger ant in the system Re frigerating performance inadequate Insufficient refrigera tion of condenser Over filling of refriger ant Condenser fins clogged or fan motor error Clean the condenser Check the working condition of fan mo tor If the two above items are normal check the volume of refrigerant Add refrigerant ZX215 1002172 0 0 01 02 03 04...

Page 254: ...Cause Analysis Remedy Pressure at both Hi and Lo pressure ends very high Lo pressure piping feel ing hot Foam is observed through the sight glass Air enters the re frigerating system Air enters the refriger ant system Insufficient evacuation Check if compressor oil is contaminated or inadequate Evacuate and add new refrigerant ZX215 1002173 0 0 01 02 03 04 05 05 0 0 35 MPa MPa cmHg kgf cm2 cmHg kg...

Page 255: ...ing or conden sation on Lo pres sure piping Expansion valve de fect or improper instal lation of thermal pipe Over filling of refrigerant in Lo pressure piping Expansion valve opening very wide Check the installation of thermal piping If thermal piping is normal check the expansion valve Replace defective expan sion valve if observed ZX215 1002174 0 0 01 02 03 04 05 05 0 0 35 MPa MPa cmHg kgf cm2 ...

Page 256: ...sis Remedy Pressure at Lo pressure side very high Pressure at Hi pressure side very low Compressor internal leakage Compressing fault Leaking or damaged valve loosened parts Repair or replace compressor ZX215 1002175 0 0 01 02 03 04 05 05 0 0 35 MPa MPa cmHg kgf cm2 cmHg kgf cm2 5 3 30 25 25 20 10 1 15 2 15 35 01 01 76 76 50 06 07 08 085 8 5 8 7 5 6 4 3 2 1 15 https www tractormanualpdf info ...

Page 257: ...te lubrication will result Add compressor oil according to the chart below Replaced component Compressor Condenser Evaporator Volume ml See CAUTION below 40 40 Compressor oil grade ND8 10P 10PA 10S series compressor ND9 TV series compressor CAUTION Add oil into a new compressor according to the required volume of the system When the compressor is to be replaced discharge the surplus oil in it Over...

Page 258: ...ne Start and stop the engine only with the en gine start switch 3 The controller 6 receives the signal from the fuel control dial 4 and transmits the drive signal to the throttle motor 8 to control the governor lever angle of fuel injection pump 7 and control the engine speed When engine start switch 3 is turned to the OFF position the shutdown device 9 pulls the flame out arm on the injection pum...

Page 259: ...lay Starting signal Safety relay Drive signal Potentiometer singal Throttle Off Pilot S W Start motor Starting relay ZX215 1002178 C BR P M s Lo Lo Hi Hi B P P E E E B L SW S B s Throttle On Regulating signal Governor motor Alternator Bat relay Lock relay Engine Power Controller Start switch ON signal Start motor Shutdown device Shutdown relay Starting signal Starting signal Safety relay Drive sig...

Page 260: ...ructure and Function Shop Manual June 2013 4 8 2 Components 4 8 2 1 Fuel control dial 1 Knob 2 Dial 3 Spring 4 Ball 5 Potentiometer 6 Connector ZX215 1002180 25 140 9 10 1 2 3 4 5 5V 0V VR a b c 6 a b c Yellow Blue Red Level 1 Left limit Right limit Level 10 https www tractormanualpdf info ...

Page 261: ...r 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 When throttle voltage is beyond the area the controller sends out alarm code and the engine runs at low idle The area under the sloping line is the abnormality detection area Remark The left limit is 0 and the right limit i...

Page 262: ... 165 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 4 8 2 2 Controller ZX215 1002182 TYPE USE FOR NO A ZX215 1002183 A1 A2 Controller Controller port layout https www tractormanualpdf info ...

Page 263: ... pump solenoid valve 97 Swing priority solenoid valve 98 Bucket confluence solenoid valve 99 Boom priority 1 100 Boom priority 2 104 Motor drive signal 113 Motor drive signal 114 Power ground 115 Power ground 116 Power ground 117 Power ground 118 Power supply 24V constant 119 Power supply 24V constant 120 Power supply 24V constant 121 Power supply 24V constant A1 Pin No Signal name Input output 1 ...

Page 264: ...omposite control function Pump control function Valve control function Dual travel speed control Electronic control system Auto deceleration acceleration control Engine oil under pressure alarm Engine preheating overheating alarm Engine speed calibration function Self diagnosis function NOTE For detailed information about self diagnosis function see Troubleshooting https www tractormanualpdf info ...

Page 265: ...Bucket CURL signal Bucket DUMP signal Swing signal Travel spd select signal Bucket confluence signal Controller Fuel level sensor Hydraulic oil temp sensor Hydraulic oil temperature signal Relay PPC lock signal Starting signal Starting signal Preheating signal Heater relay Engine speed Motor drive signal Throttle position feedback signal Engine oil pressure Coolant temp sensor Engine speed sensor ...

Page 266: ...e sensor Boom DOWN pressure sensor PPC Valve PPC Basic pressure PPC Lock solenoid valve Bucket confluence solenoid valve Swing priority solenoid valve Travel speed solenoid valve F Pump oil feed device Work equipment actuator Proportional valve Servo Main pump Swing motor Travel motor Servo Travel motor Proportional valve F Pressure sensor R Pressure sensor R Pump oil feed device Work equipment ac...

Page 267: ... L B Auto idle cancel Travel speed swithing Alarm output Pressure sensor Option pressure sensor Pilot oil pressure KC controller Pressure sensor Pump proportional pressure reduce solenoid valve Main control valve Throttle motor Motor Potentio meter Engine Oil feed adjustment Engine chamber Pump R Pump control angle F Pump control angle Engine speed Actual throttle position feedback Control motor F...

Page 268: ...onitor The main controller controls the pump so that it can absorb all the torque at the out put points of the engine depending on the pump absorption torque specified for each mode rotation set by the fuel control dial and actual engine speed Specifications H mode S mode L mode Engine speed 1600 1600 1800 1800 2250 Power KW 60 84 115 Engine speed 1600 1600 2250 Power KW 60 84 Engine speed 2250 Po...

Page 269: ...ntrol 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 On the contrary if pump load decreases and pump pressure drops pump controller will continue to in crease pump discharge...

Page 270: ...ne with the stabling motor curve and controls engine speed through combined control of the engine and pump Power output rate of at each working mode Mode S L B Power output rate 90 80 70 ZX215 1002193 H S L Engine torque T Engine speed N ZX215 1002194 H S L Engine power KW Engine speed N ZX215 1002195 H S L Pump output pressure P Pump delivery Q S mode B mode L mode https www tractormanualpdf info...

Page 271: ...Arm IN signal R Travel signal L Travel signal Boom UP signal Boom DOWN signal Speed sensor Engine Fuel injection pump Throttle motor Main pump Servo Servo Press sensor Press sensor Throttle position feedback signal Motor drive signal Fuel control dial Control signal Control signal Engine speed signal Proportional valve Proportional valve Monitor CAN bus Controller 4 9 4 Pump control function https...

Page 272: ...PC pressure Bucket DUMP PPC pressure L Travel PPC pressure Swing PPC pressure Arm IN PPC pressure Boom RAISE PPC pressure Pump 1 delivery amount Pump 1 delivery amount Pump 1 delivery amount Pump 1 delivery amount Pump 1 delivery amount Pump 1 delivery amount Pump 1 delivery amount Corresponding delivery output 4 9 4 1 Electrical positive flow control https www tractormanualpdf info ...

Page 273: ...amount Pump 2 delivery amount Pump 2 delivery amount Pump 2 delivery amount Pump 2 delivery amount Pump 2 delivery amount Pump 2 delivery amount Boom RAISE PPC pressure Arm IN PPC pressure Arm OUT PPC pressure Bucket CURL PPC pressure Bucket DUMP PPC pressure Boom LOWER PPC pressure R Travel PPC pressure Corresponding delivery output https www tractormanualpdf info ...

Page 274: ...oller keeps the discharge amount of the hydrau lic pump at the specified value of the cor responding pilot pressure according to the functional relation between the set hydrau lic pump discharge amount and pilot pres sure During combined operation the set discharge amount of each operation shall be added Operation When the work equipment is operating the controller collects the signal of pilot pre...

Page 275: ...wo adjustor act together hydraulically and keep two executing unit of the same speci fication and acting together in synchroni zation The change of pump discharge is determined by the sum of operating pres sure of the two hydraulic pumps P When is met the sum of the power of the two hydraulic pumps remains constant below the power of the engine Operation When the work equipment is working the cont...

Page 276: ...The engine control panel controls the target operating speed of the engine The engine controller collects the actual speed signal from the ECM and preforms a closed loop control with the target oper ating speed Then the controller involves the output of closed loop control with the calculation of the solenoid valve control signal and sends the final adjusting cur rent signal to the pump proportion...

Page 277: ...l injection pump Throttle motor Speed sensor Servo Servo Main pump Press sensor Press sensor Control signal Control signal Engine speed signal Throttle position feedback signal Motor drive signal Fuel control dial Proportional valve Proportional valve CAN bus Monitor Controller Swing signal Bucket DUMP signal Bucket DIG signal Arm OUT signal Arm IN signal R Travel signal L Travel signal Boom UP si...

Page 278: ...When the bucket control lever is operated the controller collects the signal from the bucket DUMP pressure sensor and bucket CURL pressure sensor and controls the bucket confluence proportional valve 4 9 5 1 Bucket flow control ZX215 1002201 Max Min Swash plate angle Bucket control lever PPC pressure ZX215 1002202 750mA 300mA Bucket confluence proportional valve current Bucket control lever PPC pr...

Page 279: ...ssure sensor and swing pres sure sensor meet the following conditions the controller activates the solenoid valve The solenoid valve conducts pilot pressure oil to arm flow controller and limits the al ternate circuit of arm 1 valve spool Swing valve spool first ensures swing motor power preventing the counter acting force when the arm is retracting from affecting the positioning of the upper swin...

Page 280: ...ator Travel motor Main valve Travel Speed solenoid valve L Travel pressure sensor R Travel pressure sensor Regulator Main pump Engine Throttle motor Servo Servo Injection pump Controller Monitor CAN bus Control signal Control signal Throttle position feedback signal Motor drive signal Fuel control dial 4 9 6 Duo travel speed control https www tractormanualpdf info ...

Page 281: ...chine is traveling under Hi speed mode even if work equipment is being op erated work equipment pressure sensor is switched ON travel mode remains in Hi travel mode 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 When the controller receives the signal from the travel pressure sensor under the conditions below it ac...

Page 282: ...02204 M P F R Hi Lo Heat Main valve Start switch Preheat s w Preheat relay Coolant tempe sensor Throttle motor Servo Main pump Controller Servo Monitor CAN bus Engine Control signal Control signal Motor drive signal Throttle position feedback signal Fuel control dial 4 9 7 Engine preheating overheating alarm https www tractormanualpdf info ...

Page 283: ...ination 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 When released the key will return to the OFF position automatically and preheating stops Operating condition Power ON Start key set at the HEAT posi tion Preheating switch ON 4 9 7 1 Engine preheating https www tractormanualpdf...

Page 284: ... coolant temperature rises too high alarming infor mation will be generated and transmitted to the machine monitor Operating condition Power ON Coolant temperature above 110 C 4 9 7 2 Engine overheating alarm Function The engine controller collects signal from the engine oil pressure sensor When en gine speed exceeds 600 rpm if oil pres sure is too low alarming information will be generated and tr...

Page 285: ...l Engine throttle controller Control lever signal Controller Monitor CAN bus Engine Fuel control dial Motor drive signal Potentiometer signal Right joystick Boom Bucket DOWN UP IN OUT Left joystick Swing Arm R L CURL DUMP L Travel Travel lever R Travel Forward Reverse Forward Reverse 4 9 9 Auto deceleration acceleration control https www tractormanualpdf info ...

Page 286: ... the control lever is operated again the engine speed rises instantly to the previous level If any control lever is operated while the engine speed is kept at decelerated level engine speed will rise instantly to the level set by the fuel control dial 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...

Page 287: ...ignal L Travel signal Boom UP signal Boom DOWN signal Arm IN signal Arm OUT signal Bucket DIG signal Bucket DUMP signal Swing signal Calibtator CAN bus Controller Monitor Fuel control dial Engine speed signaL Control signaL Control signaL Motor drive signaL Throttle position feedback signaL Engine Speed sensor Main pump Main valve Bucket confluence Swing pripority Pressure sensor Servo Servo Press...

Page 288: ...ing procedure for positive flow exca vators 1 Selection of fixing point of throttle motor soft shaft 2 H S L maximum speed calibration and A I speed calibration 3 Turn the dial on the calibrator counter clockwise to the end 4 Power OFF 5 Set the calibrator to Monitor mode power on and check the result Remark Memory SW up Calibration mode Memory SW down Monitor mode For more information see Engine ...

Page 289: ...ponents Operation The relationship between the pressure ap plied on the sensor P and output voltage E is shown in the right diagram ZX215 1002209 V MPa Sensor output voltage E Oil pressure P 4 9 11 1 Pump pressure sensor ZX305 1002066 A B C Terminal A Terminal B Terminal C Connection diagram Signal name PWR 5V Output No https www tractormanualpdf info ...

Page 290: ...2 Pilot pressure sensor Operation The relationship between the pressure ap plied on the sensor P and output voltage E is shown in the right diagram ZX215 1002210 V MPa Sensor output voltage E Oil pressure P ZX305 1002066 A B C Terminal A Terminal B Terminal C Connection diagram Signal name PWR 5V Output No https www tractormanualpdf info ...

Page 291: ...d value exceeds the stan dard value replace the sensor Function The engine revolution sensor is installed to the ring gear of the engine flywheel It elec trically calculates the number of the gear teeth which pass in front of it and transmits the result to the engine controller ZX215 1002211 1 2 CAUTION If the engine speed sensor is not tight ened to the specified torque the sensor may send out no...

Page 292: ...nnector 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 Standard value 50 C 80Ω Ref 60 C 56 3Ω 80 C 29 5 10Ω 100 C 16 5Ω 106 C 14 3 0 5Ω 120 C 10Ω Ref Specifications ZX215 1002212 1 2 https www tractormanualpdf info ...

Page 293: ...E R I C A 4 196 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 ZX215 1002246 1 2 3 4 4 9 11 5 Fuel level sensor 1 Float 2 Lever 3 Casing 4 Coupler https www tractormanualpdf info ...

Page 294: ...pressure switch 1 O ring 2 Sensor 3 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 Specifications Type of contact Normally closed type Operating pressure 1 9kg ZX215 1002214 1 2 3 Pressure Load https www tractormanualpdf info ...

Page 295: ...sses the signals and transmits the signals to the monitor display informing the operator of the machine condition Information on the monitor display includes primarily 1 Alert information when a machine fault is detected 2 Operating condition coolant temperature fuel level etc The machine control system can be oper ated using the switches and keys on the monitor panel W13053001 CAN signal Sensor C...

Page 296: ... or bright spots which stay on Products having 10 or less black or bright spots conform to the product specification such condition is quite normal Continuous operation of the monitor may cause the LCD to display bright blue spots on a black background it is quite normal Input and output signals No Signal name Input output 1 Digital input A Input 3 CAN high 4 CAN low 7 Digital input B 8 Trigger po...

Page 297: ...ons The front side of the machine monitor is made up of three sections A Warning and signal indicators B Display screen C Key pad F1 F2 F3 F4 F5 Esc Enter XP13031506 A B C Warning and signal indicators When a machine fault occurs the warning indicator lights up reminding the user to check and address the fault XP13031505 https www tractormanualpdf info ...

Page 298: ...ms on a normal operation display include 1 Working mode indicator 2 Coolant temperature gage 3 Fuel level gage 4 Failure code 5 Total service hours 6 Function icons 7 System time Hr Min Sec 8 Date YY MM DD 9 GPS signal 10 Engine speed level 1 to 11 Key pad The key pad is composed of 5 function keys and six navigation keys F1 F2 F3 F4 F5 Esc Enter 1 2 XP13031502 Sany Hydraulic Excavator n min AUTO ...

Page 299: ... AUTO or n min Switch between Auto idle and Non auto idle Home page Move the cursor to the right Password Entry page Enter a selected entry Information Menu page etc Increase monitor brightness Brightness Adjustment page F3 or Switch between High and Low travel speed Home page Password validation Password Entry page Confirm the validity of a password and if it s correct enter the de sired page Sav...

Page 300: ...rns to the left end digit after the right end digit 2 Navigation keys 4 10 3 Monitor operation 1 Home page The Home page is the normal operation display of the monitor Items on this page include truck load counter working mode speed level coolant temperature fuel level service hours clock fault code etc Operation Working mode selection 1 Press F1 switch between S H L and B mode NOTE S mode is the ...

Page 301: ... Press F3 to switch between high and low travel speed High travel speed is indicated by Low travel speed is indicated by NOTE Default travel speed is Low Fault Information 4 Press F4 to go to Fault Information when a fault occurs NOTE When the ECU detects an error in the machine a fault code will appear on the monitor display The tick icon on the bottom will turn red Information Menu 5 Press F5 to...

Page 302: ...r to increase or de crease the number 2 Press F2 to move the cursor to the right You can also use or to move the cursor to the left or to the right NOTE The cursor moves back to the left end side after the right end side 3 When all the five digits of the password have been entered press F3 or Enter If the password is correct the display moves to the Information Menu page if not please try again 4 ...

Page 303: ...ss F5 or ESC to return to the Home page Press F4 on this page to go to the Pass word Entry page before accessing the Sys tem Setup page NOTE Once an entry on the list is highlighted an introductory hint will appear on the bottom of the display giving a short description of the selected entry These hints include Running parameters of the engine main pup and main valve Fault code and description Thr...

Page 304: ...Pressure Signal page Press F5 or ESC to return to the Information Menu 5 Pilot Pressure Signal This page is a real time display of the pilot pressure signal of the hydraulic system Operation Press F1 to go to Main Pump and Main Valve Signal page Press F5 or ESC to return to the Information Menu XP1251203008 Engine Throttle Signal Coolant temp C Fuel level Oil press kPa Throttle gear Eng speed rpm ...

Page 305: ...tion on the Information Menu page and press F2 or Enter and the dis play moves to Fault Information page This page lists important machine fault information Operation Press F1 to go to the next page Press F5 or ESC to return to the Information Menu XP2051203010 MainPump MainValveSignal Pump1 press kg Pump2 press kg Prop valve1 current mA Prop valve2 current mA Bucket confluence valve ż Swing prior...

Page 306: ...switch between rpm blue and rpm red Press F5 or ESC to return to the Information Menu NOTE For machines equipped with SYFCS controllers when engine speed calibration is not successful a question mark will appear 9 System Language Select System Language on the Information Menu page and press F2 or Enter and the dis play moves to this page Operation Press F2 to select中文 Press F3 to select English Yo...

Page 307: ...m If system time has been adjusted it cannot be adjusted again until the system is re ener gized 11 GPS Monitoring Remark Longitude E stands for East while W for West Latitude N stands for North while S for South Altitude P means Above Sea Level while N means Below Sea Level Select GPS Monitoring on the Information Menu and press F2 or Enter to view this page Operation Press F5 or ESC to return to...

Page 308: ... changes to 0 from 15 it is either because the GPS service is not available or the SIM card charge is overdue or the GPS network is abnormal When the signal indication changes to 0 from 31 it is because the monitoring cen ter suspends 12 Brightness Adjustment Press F4 on the Information Menu Password Entry page to go to Bright Adjustment page This page is used to adjust monitor screen brightness O...

Page 309: ...e System Setup page if not please try again 3 Press F5 or ESC to return to the Home page NOTE Contact your local dealer to obtain this password 14 System Setup This page is used to set up machine configu ration Operation Press F1 to select the item below the high lighted one The highlighter returns to the top after the bottom item You can also use and to move the highlighter up and down Press F2 o...

Page 310: ...ion Menu Password Entry page 2 When all the five digits of the password have been entered press F3 or Enter If the password is correct the display moves to the Machine Configuration page if not please try again 3 Press F5 or ESC to return to the System Setup page 16 Machine Configuration You can view machine configuration informa tion on this page Operation Press F5 or ESC to return to the System ...

Page 311: ...he Service Hour Setup page if not please try again 3 Press F5 or ESC to return to the System Setup page 18 Service Hour Setup This page is used to set up machine service hours Operation Use and to change the number where the cursor blinks Use and to move the cursor Press F1 or Enter to save adjusted time Press F5 or ESC to return to the System Setup page NOTE When F1 or ENTER is pressed the screen...

Page 312: ...ss F2 or Enter and the display moves to this Password entry page Operation 1 For password entry method see Informa tion Menu Password Entry page 2 When all the five digits of the password have been entered press F3 or Enter If the password is correct the display moves to the Machine Configuration Setup page if not please try again 3 Press F5 or ESC to return to the System Setup page XP13060803 㒳䆒...

Page 313: ...ion The screen displays Setup finished Please re energize the system Press Enter to move the cursor between dif ferent parts in the machine number Use and to increase and decrease the selected machine number by 100 each time Use and to increase and decrease the selected machine number One quick pressing increase or decrease the number by 1 Long pressing increase or decrease the number in a quicker...

Page 314: ...y 1 each time or press and to increase or decrease tonnage code by 100 each time 4 When the cursor moves to Serial number press and to increase or decrease this number by 1 each time Long press ing to change the number in a quick pace Press and to increase or decrease this number by 100 each time 5 The machine number has 4 adjustable dig its Use and to switch between the four digits and use and to...

Page 315: ...Shop Manual June 2013 21 Hydraulic Oil Temperature Select Hydraulic Oil Temperature on the Sys tem Setup list and press F2 or Enter and the display moves to this page Operation Press F5 or ESC to return to the System Setup page XP2051203028 Hydraulic Oil Temp Hydraulic Oil Temp https www tractormanualpdf info ...

Page 316: ...locked NOTE Contact your local dealer to unlock the machine when the system is locked 30 Lockout Information Level 2 This display indicates that the machine has entered lockout state level 2 Operation Press F5 to enter System Unlock page XP13041504 System locked Contact manufacturer to unlock system Lockout Information Macine model Machine No Machine state Current time Lockout 1 System locked Cont...

Page 317: ...S A N Y L A T I N A M E R I C A 4 220 SY195 205 215 225C9 Crawler Hydraulic Excavator Structure and Function Shop Manual June 2013 B L A N K P A G E https www tractormanualpdf info ...

Page 318: ...Values SY195 205 215 225C9 Crawler Hydraulic Excavator Standard Values Shop Manual June 2013 5 1 5 Standard Values 5 1 Standard Values of Engine related Parts 5 3 5 2 Standard Values of Chassis related Parts 5 4 https www tractormanualpdf info ...

Page 319: ...d all safety precau tions and instructions in this manual be fore reading any other manuals provided with this machine and before operating or servicing the machine Also read the safety information on machine decals before per forming any operations Failure to do so can cause machine damage personal in jury or death https www tractormanualpdf info ...

Page 320: ...alve mm 0 51 0 381 0 762 Compression Pressure Oil Temp 40 60 C Engine Speed 250 rpm Mpa kg cm Min 2 41 Min 24 6 1 69 17 2 Blow by Pres sure Coolant Temp Working Range Arm In Overflow Max rpm kPa mmH2O Max 0 98 Max 100 1 96 200 Oil Pressure High Idling MPa kg cm Min 0 29 Min 3 0 0 25 2 5 Low Idling MPa kg cm Min 0 10 Min 1 0 0 07 0 7 Oil Temp Full Speed Range In Oil Pan C 80 110 120 Fan Belt Ten si...

Page 321: ...alve UP mm 11 5 0 5 11 5 0 5 DOWN mm 9 5 0 5 9 5 0 5 Arm control valve IN mm 11 5 0 5 11 5 0 5 OUT mm 9 5 0 5 9 5 0 5 Bucket control valve DIG DUMP mm 9 5 0 5 9 5 0 5 Swing control valve Travel L R mm 9 5 0 5 9 5 0 5 Travel control valve Forward Reverse mm 9 5 0 5 9 5 0 5 Control Lever stroke Boom control lever Engine stopped Control lever grip at center Max reading at stroke end except lever play...

Page 322: ...idle Working mode H All control levers in neutral position Hydraulic pump output pressure MPa kg cm 0 1 0 0 10 0 2 0 0 20 Boom relief Hydraulic oil temp Within operational range Operate corresponding control lever after engine runs at high idling speed Working mode H Hydraulic pump output pressure with all measurement circuits relieved 34 3 1 0 350 10 33 3 35 3 340 360 Arm relief 34 8 1 0 355 10 3...

Page 323: ...l range Engine running at high idle Working mode H Time required for 5 turns after making initial 1 turn For measuring posture see Swing 1 sec 27 3 5 Max 30 Hydraulic drift Hydraulic oil temp Within operational range Engine stopped Keeping the upper structure transverse on a grade of 15 For more information see Swing 2 Notching a mating mark on inner and outer races of the swing circle Mating mark...

Page 324: ...direction Measure the sliding distance for 5 minutes For measuring posture see Travel 4 mm 0 0 Leakage of travel motor Hydraulic oil temp Within operational range Engine running at high idle Traveling with the sprocket locked Oil leakage amount for one minute with traveling in re lief condition mm 13 6 27 2 Work Equipment Hydraulic drift Bucket tips Hydraulic oil temp Within operational range Flat...

Page 325: ...stroke end For measuring posture see Work Equipment 2 UP sec 3 4 0 4 Max 4 8 Arm Hydraulic oil temp Within operation al range Engine running at high idle Working mode H Time required from dumping stroke end to digging stroke end For measuring posture see Work Equipment 3 IN sec 2 8 0 4 Max 4 5 OUT sec 2 3 0 3 Max 3 5 Bucket Hydraulic oil temp Within operation al range Engine running at high idle W...

Page 326: ...ve For measuring posture see Work Equipment 6 sec Max 2 0 Max 2 8 Bucket Hydraulic oil temp Within operational range Engine running at low idle Working mode H Average time required for operating the con trol lever back and forth till the arm starts to move For measuring posture see Work Equipment 7 sec Max 1 0 Max 3 6 Internal Leakage Cylinders Hydraulic oil temp Within operational range Engine ru...

Page 327: ...ol value Spool stroke Travel 1 Travel speed without load Travel 2 Travel speed actual run Travel de viation ZX215 1003002 ZX215 1003005 ZX215 1003006 45 Swing 1 Swing brake angle time taken to start swing time taken to swing Travel 3 Travel deviation ZX215 1003007 x 10m ZX215 1003003 Swing 2 Hydraulic drift of swing ZX215 1003004 15 Sprocket https www tractormanualpdf info ...

Page 328: ...013 Travel 4 Hydraulic drift of Travel ZX215 1003008 12 Work equipment 1 Hydraulic drift of work equipment ZX215 1003009 Work equipment 2 Boom speed ZX215 1003010 Work equipment 3 Arm speed ZX215 1003011 Work equipment 4 Bucket speed Work equipment 5 Boom delay ZX215 1003012 ZX215 1003013 https www tractormanualpdf info ...

Page 329: ... M E R I C A 5 12 SY195 205 215 225C9 Crawler Hydraulic Excavator Standard Values Shop Manual June 2013 Work equipment 6 Arm delay Work equipment 7 Bucket delay ZX215 1003014 ZX215 1003015 https www tractormanualpdf info ...

Page 330: ...S A N Y L A T I N A M E R I C A 5 13 SY195 205 215 225C9 Crawler Hydraulic Excavator Standard Values Shop Manual June 2013 B L A N K P A G E https www tractormanualpdf info ...

Page 331: ...S A N Y L A T I N A M E R I C A 5 14 SY195 205 215 225C9 Crawler Hydraulic Excavator Standard Values Shop Manual June 2013 B L A N K P A G E https www tractormanualpdf info ...

Page 332: ...jection Timing Test and Adjust 6 13 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 6 20 6 8 2 Adjusting 6 20 6 9 Swing Bearing Clearance Measure 6 22 6 10 Track Tension Test and Adjust 6 24 6 10 1 Testing 6 24 6 10 2 Adjusting 6 25 6 11 Hydraulic Pressure in Hydrauli...

Page 333: ...machine Also read the safety information on machine decals before per forming any operations Failure to do so can cause machine damage personal in jury or death 6 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...

Page 334: ...Items 1 Engine speed at low idle 2 Engine speed at fuel control dial position 11 H and S modes 3 Engine speed at relief with fuel control dial placed at position 11 H and S modes 4 Engine speed at auto idle 6 1 2 Adjusting Adjust the fixing point of the flexible shaft of the throttle motor 1 Connect the calibrator with the chassis harness 2 Push the memory switch of the calibrator down to the OFF ...

Page 335: ...position of the flexible shaft when engine speed is higher than 1150 rpm 6 Shutdown the engine Speed calibration steps 1 Connect the calibrator with the chassis harness 2 Push the memory switch of the calibrator down to the OFF position Turn the start switch of the machine to the ON position 3 Start the engine Engine speed XXXX will be displayed on the screen display of the calibrator Press the H ...

Page 336: ...sting Shop Manual June 2013 Engine speed reference SY215C9 Level Speed rmp Level Speed rmp S1 1100 H1 1100 S2 1200 H2 1200 S3 1300 H3 1300 S4 1500 H4 1500 S5 1600 H5 1600 S6 1650 H6 1700 S7 1750 H7 1800 S8 1850 H8 1900 S9 1950 H9 2000 S10 2050 H10 2100 S11 2150 H11 2200 https www tractormanualpdf info ...

Page 337: ...e 3 Start the engine and keep the engine running until engine coolant tempera ture is within the operational range 4 When engine speed increases sudden ly or is kept at high idle direct exhaust gas through smoke meter to the filter paper 5 Remove the filter paper from the smoke meter Read the smoke value through the apparatus provided 6 Remove the testing tools after measur ing Make sure the machi...

Page 338: ... 1004003 ZX215 1004004 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 4 When engine speed increases sud denly or is kept at high idle use the opacimeter to read the smoke value of exhaust gas 5 Remove the testing tools after measur ing Make sure the machine goes back to its n...

Page 339: ... Valve clearance adjustment Carried on vehicle Check and adjust valve clearance in cold state as per the following procedure 6 3 1 Testing 1 Remove the rocker arm cover 2 Turn the No 1 piston or the No 6 piston to the top dead center of compression stroke by following the procedure below Turn the engine until the mark 16 on the flywheel aligns with the pointer on sight glass of the flywheel shell ...

Page 340: ... 2 If the feeler gauge moves easily in the clearance it is impossible to obtain ac curate result 4 If the measured value is out of specifica tion readjustment shall be performed ac cording to the following method 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...

Page 341: ...tment stop the turning motion of the adjustment screw with a screwdriver and tighten the locknut Locknut 16 24 N m 1 7 2 5 kgf m 3 Go on with the next step until all valve clearances marked with a black dot have been adjusted 4 Check the clearances again with the feeler gauge Readjustment should be made if the value is out of specification 5 When the engine is carried in vehicle us ing to turn the...

Page 342: ...re 1 Reduction of compression pressure can be an indication for engine overhaul 2 Check the compression pressure regularly and pay attention to its variation from time to time In addition in a new vehicle or when new parts are installed for replace ment the pressure may be higher due to running in of the piston ring valve seat etc The pressure will become normal as the parts wear 3 Before testing ...

Page 343: ...re the com pression pressure of each cylinder Calcu late the differential pressure between the cylinders 11 When the compression pressure and the differential pressure between cylinders de viate from their limits inject a small amount of engine oil through the fuel injector mounting hole and measure the compres sion pressure again If the compression pressure is higher it is probably due to worn or...

Page 344: ... 44 Nut used for mounting fuel injection pump 29 39 Special Tool Symbol Tool Name and Shape Part Number Application Universal Exten sion Rod A 14 A MH061099 Testing and adjusting the fuel injection timing 6 5 1 Testing 1 Remove the injection pipe lock plate lock seat retainer ring and delivery valve from the No 1 cylinder of the fuel injection pump 2 After removal of all the parts install the lock...

Page 345: ...er of compression stroke 7 Make sure that the flywheel mark and pointer are one degree before the fuel in jection timing ZX215 1004013 Injection pipe Positioning Lever Priming pump ZX215 1004012 Injection pipe ZX215 1004014 Pointer 5 The main pump is used to transfer fuel As the fuel flows out of the injection pipe turn the engine manually in the forward direc tion NOTE The engine positioning leve...

Page 346: ...nuts on the flange B 1 nut 2 Targeted at the pointer activate the injec tion pump in order to adjust injection tim ing 3 Tighten the nuts to specific torque Mea sure the injection timing again NOTE When the fuel injection timing deviates from its standard value the following steps must be followed for adjustment ZX215 1004015 A B ZX215 1004016 Injection Pump Pointer https www tractormanualpdf info...

Page 347: ...se di rection C 5 When the injection timing is fast move the injection pump away from the crankcase direction D 6 When injection timing meets the standard value install the delivery valve spring re tainer ring lock seat lock plate and injec tion pipe 7 Tighten all the parts to specific torques ZX215 1004017 D C Injection Pump ZX215 1004018 Injection pipe Lock Seat Lockplate https www tractormanual...

Page 348: ... KPa 195 KPa Tightening Torque Unit N m Symbol Part Tightened Tightening Torque Remark Engine oil pressure switch 7 8 12 Engine cold Lubricant Sealant Symbol Location Part Number Amount Threads of pressure switch A420300000032 As necessary 1 Remove the engine oil pressure switch ZX215 1004019 Engine Oil Pressure Switch 2 Mount the adaptor to where the engine oil pressure switch has been removed Mo...

Page 349: ...espectively the unloaded engine oil pressure at minimum speed and maxi mum speed 5 If the measured value is lower than the specified standard value check the entire lubrication system 6 After measuring apply sealant to the threads of pressure switch Tighten the pressure switch to specific torque NOTICE Then engine oil pressure switch must be installed when the engine is cold https www tractormanua...

Page 350: ...top Restore the sensor 1 Screw on the sensor 1 until its end con tacts with ring gear tip 2 of the flywheel 2 Unscrew the sensor some degrees Degrees 1 2 1 4 turns Adjust the clearance a between the sensor end and the flywheel edge to 2 0 2 mm 3 Tighten the sensor 1 with the nut 3 Nut 49 0 68 6 N m 5 7kg m 4 Make sure that the engine speed is dis played properly on the control panel after adjustme...

Page 351: ...y and the compressor pul ley with a finger force of about 58 8 N 6kgf and measure deflection A of the belt which shall be 5 8 mm 0 20 in 0 31in 6 8 2 Adjusting NOTE If the belt deflection is abnormal adjust it according to the following procedure 1 Loosen the bolts 1 and 2 2 Move the compressor 3 and the bracket 4 together to adjust belt tension 3 After positioning the compressor 3 tight en the bo...

Page 352: ...n 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 Cuts or cracks are found in the belt Abnormal sliding or noise When a new belt is mounted readjust the belt tension after one hour operation Reference Use a tensiometer to check the compressor belt tension New Belt...

Page 353: ...sition Raise the bucket to a height that the bucket tips and the swivel table bottom are on the same level At the moment the front of upper structure lowers while the rear rises 3 Set the dial gauge H to zero 4 Set the arm almost perpendicular to the ground and lower the boom until the front track shoe floats At the moment the front of upper structure rises while the rear lowers 5 Read the dial ga...

Page 354: ...une 2013 step 2 Check the dial gauge H to see if it reads zero ZX215 1004025 150 200mm The value indicated by the dial gauge H is the clearance of the bearing For more information see Swing bearing on page 4 13 Repeat step 3 through step 5 if the dial gauge H reads a value other than zero https www tractormanualpdf info ...

Page 355: ...ack on the ground Keep running the engine at low idle Park your machine slowly 2 Place a straight bar on the track over idler 1 and carrier roller 2 NOTE A straight angle steel bar is recom mended for this purpose as it has good resistance to bending strain 3 Measure the maximum clearance a be tween the upper surface of track and the lower edge of the straight bar Max clearance a 10 30 mm 0 4 1 2 ...

Page 356: ...on is incorrect make adjust ment as per the following instruction ZX215 1004027 b 1 2 ZXT215 1004003 1 Reduce track tension 1 Loosen the valve 1 to discharge grease Tighten the valve after dis charging 2 Check the track tension again as per the above method after adjustment 2 Increase track tension 1 Add grease through the grease fitting 2 with a grease gun 2 Check the track tension again as per t...

Page 357: ...lug 2 for measuring the hydraulic pressure Plug 1 For oil circuit of rear pump Plug 2 For oil circuit of front pump 2 Install the priming adaptor and connect it to the hydraulic tester Use an oil pressure gauge with a ca pacity of 40 MPa 408 kgf cm 3 Start the engine and keep it running until the hydraulic pressure rises to a point within the operational range ZX215 1004028 1 2 CAUTION Lower the w...

Page 358: ...re the hydraulic pressure when the engine is running at high idle and the cylinder is in relief condition NOTE The hydraulic pressure indicat ed is the pressure when the main relief valve is in relief condition 4 Measurement of swing pressure at relief 1 Start the engine Reach out the work equipment as far as possible Lower the work equipment on the ground in order to restrict swinging 2 Measure t...

Page 359: ...elief condition NOTE The hydraulic pressure indicat ed is the pressure when the main relief valve is in relief condition When the travel circuit is in relief condition the pressure indicated is always the pres sure at high relief 6 11 2 Adjusting 1 Adjustment of main relief pressure NOTE If the high relief pressure is abnor mal adjust the high pressure setting of the main relief valve 3 as per the...

Page 360: ...side is therefore to be adjusted too 2 Adjustment of swing relief pressure NOTE If the swing relief pressure is ab normal adjust the swing motor relief valve 6 as per the following 6 7 8 ZXT225 1104003 ZX215 1004030 7 8 1 Loosen the locknut 7 Turn the adjust ment screw 8 to adjust the pressure Pressure rises as the screw turns right Pressure drops as the screw turns left Each turn of the screw equ...

Page 361: ... Use an oil pressure gauge with a capacity of 6 MPa 61 kgf cm 3 Start the engine and keep it running until the hydraulic pressure rises to a point with in the operational range 4 Measure oil pressure when the engine is running at high idle and all control levers are in a neutral position 1 2 ZXT215 1004007 CAUTION Lower the work equipment to the ground and stop the engine Operate the control lever...

Page 362: ...t is less than 3 5 kgf cm loosen the retaining nut 2 and screw in adjusting stud 3 Watch the change of readings on the pressure gauge at the same time Tighten the retaining nut 2 when proper pressure value is achieved 2 Remove all the tools after measurement and make sure the machine returns to its normal condition ZX215 1004031 2 3 https www tractormanualpdf info ...

Page 363: ...e of control oil circuit is normal before measuring the output pressure of solenoid valve 1 Disconnect the hose of solenoid valve to measure the pressure at the outlet 2 Install a tee to location A on each sole noid valve and connect the hose 3 Mount the adaptor onto the tee and con nect it to the hydraulic tester Use a hydraulic tester with a capacity of 6 MPa 61 kgf cm CAUTION Lower the work equ...

Page 364: ...ze 3 0 3 9 MPa 30 39 kgf cm High speed travel Solenoid Valve Output Pressure OFF de energize 0 0 ON energize 3 9 4 1 MPa 39 41 kgf cm 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 The function of each so...

Page 365: ...MP 2 Travel right 8 Arm IN 3 Arm OUT 9 Swing 4 Bucket DIG 5 Boom DOWN 6 Boom UP 6 14 Pilot Valve Output Pressure Measure 1 2 3 4 5 6 7 8 9 ZXT225 1104005 1 Remove the pilot pressure switch 2 Install the adaptor and connect it to the hy draulic tester Use a hydraulic tester with a capacity of 6 MPa 61kgf cm 3 Start the engine and keep it running un til the hydraulic oil temperature rises to a point...

Page 366: ...Pressure Neutral 0 0 Full stroke Close to the average initial pres sure of oil control circuit See Table of Standard Values 5 Remove all measuring tools after measure ment Make sure that the machine returns to its normal condition NOTE When the measured output pres sure reads the following values the pilot valve is normal https www tractormanualpdf info ...

Page 367: ...ollowing procedure 1 Remove the work equipment and swing pi lot valve assembly 2 Remove the rubber sleeve 1 3 Loosen the locknut 2 Screw on the disc 3 until it contacts with the four heads of plunger 4 NOTE Do not move the plunger 4 When the disc 3 is fixed tighten the lock nut 2 to specified torque Locknut 98 127 N m 10 13 kgf m 5 Install the rubber sleeve 1 6 Install the work equipment and swing...

Page 368: ...sition and the bucket in the digging position If the lowering speed rises the prob lem lies in the cylinder seal If nothing changes the problem lies in the control valve Operate the control levers with engine start switch in the ON position If the pressure in accumulator drops charge the accumulator again by run ning the engine for about 10 seconds 2 Arm cylinder ZX215 1004033 NOTE If hydraulic dr...

Page 369: ...s Reference If hydraulic drift is caused by failure of the cylinder seal the reason for lowering speed increase during the above operation is de scribed below 1 If the machine is set in the above position where the holding pressure is applied to the bottom side the oil leaks from the bot tom side to the head side The pressure in the head side is increased 2 As the pressure in the head side de crea...

Page 370: ...sure in the accumulator is high set the hydraulic lockout control in the LOCKED FREE position and measure the hydraulic drift respectively Operate the control levers with engine start switch in the ON position If the pressure in accumulator drops charge the accumulator again by run ning the engine for about 10 seconds If there is a difference in hydraulic drift between the LOCKED position and the ...

Page 371: ...ure in hydraulic tank 2 Turn the engine start switch to the ON position and operate the control levers for several times The pilot lock valve must be energized Operate the control levers with the en gine start switch in the ON position The pressure in accumulator will be released after the control levers have been operated 2 or 3 times 3 Start the engine and keep the engine run ning at low idle fo...

Page 372: ...ressure in the circuits See Residual Pressure in Hydraulic Circuit Release on page 6 40 2 Disconnect the hose 1 on the cylinder head side and plug the hose end with a cap NOTE Be careful not to disconnect the hose on the cylinder bottom side 3 Start the engine and apply relief pres sure to the bottom side of the cylinder while the engine is running at high idle 4 Hold this condition for 30 seconds...

Page 373: ... circuits See Residual Pressure in Hydraulic Circuit Release on page 6 40 2 Disconnect the hose 2 on the cylinder head side and plug the hose end with a cap NOTE Be careful not to disconnect the hose on the cylinder bottom side 3 Start the engine and apply relief pres sure to the bottom side of the cylinder while the engine is running at high idle 4 Hold this condition for 30 seconds Measure oil l...

Page 374: ... the circuits See Residual Pressure in Hydraulic Circuit Release on page 6 40 2 Disconnect the hose 3 on the cylinder head side and plug the hose end with a cap NOTE Be careful not to disconnect the hose on the cylinder bottom side 3 Start the engine and apply relief pres sure to the bottom side of the cylinder while the engine is running at high idle 4 Hold this condition for 30 seconds Measure o...

Page 375: ...2 Disconnect the hose 4 and the hose 5 Plug the hose ends with caps 3 Start the engine and apply relief pres sure to the bottom side of the swing motor while the engine is running at high idle Measure oil leakage under this condition Hold the condition described in step 3 for 30 seconds Measure oil leakage for one minute After the first measurement turn the upper structure 180 and measure the leak...

Page 376: ... Start the engine and apply relief pres sure to the bottom side of the travel motor while the engine is running at high idle Measure oil leakage under this condition Hold the condition described in step 4 for 30 seconds Measure oil leakage for one minute Rotate the motor slightly Change the positions of the valve plate and the travel motor and of the cylinder and pis ton Repeat the measurement sev...

Page 377: ...ing replacing hydraulic pump Removing suction piping Repairing replacing control valve Replacing cylinder Removing cylinder piping Replacing swing motor Removing swing motor piping Replacing travel motor Removing travel motor piping NOTE Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained 1 Bleed air from hydraulic pump 1 Loosen the air bleeder 1 and che...

Page 378: ...low idle move the piston rod to the stroke end and apply relief pressure 5 Bleed air from arm cylinder and bucket cylinder by performing step 2 through step 4 NOTE When a new cylinder is in stalled for replacement bleed the air from the new cylinder before mounting it to the work equipment Especially the boom cylinder once mounted to the work equipment its piston rod is un able to reach its stroke...

Page 379: ...g Shop Manual June 2013 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 2 ZXT215 1004016 https www tractormanualpdf info ...

Page 380: ...A Current Proportional Valve Solenoid Rear pump mA Pilot Pressure Boom Raise Kg Pilot Pressure Boom Lower Kg Pilot Pressure Arm In Kg Pilot Pressure Arm Out Kg Pilot Pressure Bucket Curl Kg Pilot Pressure Bucket Dump Kg Pilot Pressure Swing Kg Pilot Pressure Travel Left Kg Pilot Pressure Travel Right Kg Solenoid Valve 1 Bucket Confluence ON OFF Swing Priority ON OFF Hi Lo Speed Switching ON OFF Vo...

Page 381: ...S A N Y L A T I N A M E R I C A 6 50 SY195 205 215 225C9 Crawler Hydraulic Excavator Testing and Adjusting Shop Manual June 2013 B L A N K P A G E https www tractormanualpdf info ...

Page 382: ... 3 2 Electrical element circuit diagram cab circuit 7 18 7 3 3 Electrical control circuit diagram engine circuit 7 20 7 3 4 Electrical control circuit diagram sensor and solenoid valve circuit 7 22 7 3 5 SWP type connector 7 23 7 3 6 A AMP type connector 7 24 7 3 7 DT type connector 7 25 7 4 Failure Symptoms and Troubleshooting Codes 7 26 7 5 Troubleshooting with an Event Code 7 28 7 6 Troubleshoo...

Page 383: ...d all safety precau tions and instructions in this manual be fore reading any other manuals provided with this machine and before operating or servicing the machine Also read the safety information on machine decals before per forming any operations Failure to do so can cause machine damage personal in jury or death https www tractormanualpdf info ...

Page 384: ... to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure 2 Points to ask user or operator 1 Have any other problems occurred apart from the problem that has been reported 2 Was there anything strange about the machine before the failure occurred 3 Did the failure occur suddenly or were there problems with the machine condition before this 4...

Page 385: ... or as a problem with the method of operation etc NOTE When operating the machine to reenact the troubleshooting symptoms do not carry out any investigation or measure ment that may make the problem worse 5 Troubleshooting Use the results of the investigation and inspection in Items 2 4 to narrow down the causes of failure then use the trouble shooting flowchart to locate the position of the failu...

Page 386: ...the operator for all information about the failure a Current working condition of machine Whether machine is operated prop erly b When troubles are found and what kind of operation does machine perform at that time c Development of troubles Whether troubles are becoming severer or occur for the first time d What kind of trouble did machine have before For example Which parts have been repaired or ...

Page 387: ... alternator terminal and wiring 3 Check for looseness corrosion of start motor terminal and wiring Tighten or replace Tighten or replace Tighten or replace Hydraulic mechanical equipment 1 Check for abnormal noise and smell 2 Check for oil leakage 3 Bleeding air Repair Repair Bleed air Electrics electrical equipment 1 Check battery voltage with engine stopped 2 Check electrolyte level 3 Check for ...

Page 388: ... running Oil and water under high pressure and high tem perature may squirt and cause personal injuries Shut off then engine when discon necting the harness and hydraulic lines Failure codes may not indicate machine trouble Temporary electrical failure can oc cur in controller memory such as low bat tery output voltage or open circuit in switch or sensor Therefore make repeated trials to erase the...

Page 389: ...T 112 Terminal 1 Preheating resistance wire terminal J 7 H 9 T 115 Terminal 1 Starting motor grounding J 6 L 3 T 119 Terminal 1 Body grounding at the sides of battery M 1 B 9 T 201 Terminal 1 Body grounding X 6 T 202 Terminal 1 Body grounding X 6 K5 R 5 Horn relay X 6 H 9 K6 R 5 Lamp relay X 6 I 9 K8 R 5 Top lamp relay X 6 J 9 K7 R 5 Parking relay X 6 J 8 KB 5 Battery relay M 2 D 1 K3 R 5 Starting...

Page 390: ... CN 113M A 2 Hydraulic oil temperature sensor I 7 F 9 CN 101M S 1 Fuel level sensor F 6 F 9 CN 152M A 2 Intermediate connector W 6 F 8 CN 613F L 6 Safety relay X 6 K 7 CN 661F S 16 Intermediate connector W 6 I 8 CN 161M S 16 Intermediate connector W 6 CN 115M DF 3 Main pressure sensor front I 7 F 4 CN 116M DF 3 Main pressure sensor rear I 7 F 4 CN 128M DF 3 Arm in pilot sensor I 6 F 5 CN 122M DF 3...

Page 391: ...solenoid valve J 6 F 3 CN 132F AMP 2 Boom priority solenoid valve 1 J 6 F 3 CN 136F AMP 2 Pilot solenoid valve J 6 L 2 CN 131F AMP 2 Hi Lo speed travel solenoid valve J 6 F 1 CN 133F AMP 2 Swing priority solenoid valve J 6 F 4 F 108 W 1 Coolant temperature sensor J 7 F 8 F 104 W 1 Horn right I 5 K 2 F 103 W 1 Horn left I 5 K 2 CN 616F AMP 81 Controller W 6 A 4 CN 615F AMP 40 Controller W 6 A 9 CN ...

Page 392: ...ulic Excavator Troubleshooting Shop Manual June 2013 Connector code Description S SWP type Yazaki A AMP AMP Japan D DT type Japan H Hebi HL Hulane Connectors L Ling Xing Electronic Equipment DF Delphi U S W AMP Japan Terminal Round terminal https www tractormanualpdf info ...

Page 393: ... A 7 12 SY195 205 215 225C9 Crawler Hydraulic Excavator Troubleshooting Shop Manual June 2013 7 3 1 Connector location layout F E D C B A 8 7 6 5 1 3 2 4 CN 104M CN 101M CN 102M CN 105M ZX215 1005033 https www tractormanualpdf info ...

Page 394: ...une 2013 M L K J I H G F 104 CN 116M CN 113M F 108 T 112 CN 801F CN 448M T 106 CN 800M CN 131F CN 132F CN 133F CN 134F CN 135F CN 136F F 103 CN 115M CN 114F CN 113F T 115 CN 112M CN 445M T 107 T 111 ZX215 1005034 CN 127M CN 128M CN 126M CN 125M CN 124M CN 123M CN 122M CN 121M CN 120M https www tractormanualpdf info ...

Page 395: ...15 225C9 Crawler Hydraulic Excavator Troubleshooting Shop Manual June 2013 N O P Q R S T 4 2 3 1 5 6 7 8 9 CN 7 707 CN 7 705 CN 301M CN 302 CN 104M CN 303M CN 304M CN 305M CN 307M CN 306M CN 131M CN 132F ZX215 1005035 https www tractormanualpdf info ...

Page 396: ...Excavator Troubleshooting Shop Manual June 2013 T U V W X Y Z CN 616F CN 615F CN 1 111 CN 1 112 CN 241M CN 121F CN 142M CN 161M CN 661F CN 152M T 201 K5 K6 K10 K3 K7 K8 CN 613F CN 204F KH CN 412F PF021 CN 106F CN 107M CN 207F T 202 ZX215 1005036 https www tractormanualpdf info ...

Page 397: ...S A N Y L A T I N A M E R I C A 7 16 SY195 205 215 225C9 Crawler Hydraulic Excavator Troubleshooting Shop Manual June 2013 https www tractormanualpdf info ...

Page 398: ...17 SY195 205 215 225C9 Crawler Hydraulic Excavator Troubleshooting Shop Manual June 2013 AF AE AD AC AB AA CN 1 110 CN 1 004M CN 1 103M CN 1 002M CN 1 001M CN 1 005 4 2 3 1 5 6 7 8 9 CN 150M ZX215 1005037 https www tractormanualpdf info ...

Page 399: ... 42 F10 29 F9 28 F7 26 25 F5 F4 24 F3 F1 506 CANL CANH 23 21 22 20 1 3 4 5 12 11 10 9 8 8 9 10 11 12 5 4 3 15A 10A 20A 5A 5A 10A 5A 15A 5A 20A 1 2 4 9 12 11 10 10 11 12 9 4 2 2 1 3 3 3 1 2 1 2 2 1 2 1 12 10 9 8 4 3 3 4 8 9 10 12 12 10 9 8 4 3 81 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 5...

Page 400: ...1 X 14 0 0 26 0 1 2 2 1 26 X 13 8 7 6 5 4 3 1 8 7 6 5 4 3 1 8 7 6 5 4 3 1 1 0 2 5 4 3 2 71 1 3 4 5 6 7 8 34 3 4 4 3 CN 102M A 2 1 2 2 1 CN 102M A 2 1 2 2 1 1 2 71 70 72 34 24 33 32 23 G L J H 7 8 9 6 4 5 3 2 1 K I X 12 X 11 X 10 X 9 X 8 X 7 X 6 X 5 X 4 X 3 X 2 X 1 1 2 3 4 5 5 4 3 2 1 1 2 3 4 5 5 4 3 2 1 1 2 3 4 5 5 4 3 2 1 1 1 2 1 28 31 32 0 1 3 4 5 M 25 36 35 L 35H CN 161F S 16 CN 661F S 12 CN 10...

Page 401: ...2 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 80 79 78 77 76 75 74 50 73 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 81 20 20 22 F1 20A F2 5A 21 10 21 20 9 9 11 11 2 1 1 2 22 X 1 16 10 11 13 22 12 X 2 X 3 X 4 X 5 X 6 X 7 2...

Page 402: ...9 9 17 10 12 12 7 7 CN 442F D 12 CN 112M 12a 12 12 a 2 1 CN 111F 1 2 2 1 21 12 65 63 64 13 CN 661M S 16 15 15 65 0 63 64 3 1 6 2 4 4 CN 121F D 12 5 5 CN 661F S 16 12 64 63 65 9 606 7 1 10 6 606 18 22 21 10 21 13 12 0 X 9 0 K7 1 2 3 4 5 5 4 3 2 1 0 17 16 18 1 2 3 4 5 5 4 3 2 1 L H M J 7 8 9 6 4 5 3 2 1 K I X 1 X 2 X 3 X 4 X 5 X 6 X 7 F13 160A 17 X 8 47 10 14 0 P B E 0 E 0 10 14 P R L R L CN 801F H ...

Page 403: ...10 9 8 7 6 5 4 3 2 1 81 CN 616F CN 615F E F ZX215 1005042 Boom lower pilot pressure sensor Arm in pilot pressure sensor Rear pump pressure sensor Front pump pressure sensor Arm out pressure sensor Boom raise pilot pressure sensor Bucket dump pilot pressure sensor Hi Lo speed travel solenoid valve Rear pump proportional solenoid valve Front pump proportional solenoid valve Boom priority 2 A4 propor...

Page 404: ...ting Shop Manual June 2013 7 3 5 SWP type connector 7222 7414 40 7222 1424 40 7222 7464 40 7222 7484 40 7222 7564 40 Male Plug Female Socket 7123 7414 40 No of pin 1 7123 1424 40 No of pin 2 7123 7464 40 No of pin 6 7123 7484 40 No of pin 8 7123 7564 40 No of pin 16 https www tractormanualpdf info ...

Page 405: ...ator Troubleshooting Shop Manual June 2013 7 3 6 A AMP type connector 282104 1 282105 1 174354 2 1473252 1 1473244 1 Male Plug Female Socket 282080 1 No of pin 2 282087 1 No of pin 3 174352 2 No of pin 2 1473255 1 No of pin 40 1473247 1 No of pin 81 https www tractormanualpdf info ...

Page 406: ... Manual June 2013 7 3 7 DT type connector DT06 2S DT04 2P A B A B DT06 3S DT06 6S DT06 8S DT06 12S B A C 1 2 3 6 5 4 8 5 1 4 12 7 1 6 A B C 1 2 3 6 5 4 8 5 4 1 7 12 6 1 Shell Plug Shell Socket DT04 3P No of pin 3 DT04 6P No of pin 6 DT04 8P No of pin 8 DT04 12P No of pin 12 https www tractormanualpdf info ...

Page 407: ...ils E 4 H 5 11 Excessive engine oil consumption or color of exhaust gas is blue S 7 12 Premature engine oil contamination S 8 13 Excessive fuel consumption S 9 14 Engine cooling water is mixed with engine oil spurts out or decreases S 10 15 Engine oil amount increases Water or fuel gets in S 11 16 Abnormal noises are heard S 12 17 Excessive vibrations are caused S 13 Failure related to work equipm...

Page 408: ...r structure overruns remarkably when stopping swinging H 21 40 Large shock is made when stopping swinging H 22 41 Large sound is made when stopping swinging H 23 42 Hydraulic drift of swing is large H 24 Monitor panel related failure 43 Monitor display is blank E 11 44 Monitor displays nothing E 12 45 Engine coolant temperature reading is incorrect E 14 46 Fuel level reading is incorrect E 15 47 A...

Page 409: ...n bucket dump pilot pressure 7 45 E328 abnormality in swing pilot pressure 7 46 E329 abnormality in left travel pilot pressure 7 47 E330 abnormality in right travel pilot pressure 7 48 E231 abnormality in fuel control dial set voltage 7 49 E237 abnormality in hydraulic oil temperature 7 50 E541 abnormality in engine speed 7 51 E450 abnormality a in front pump proportional solenoid coil current 7 5...

Page 410: ...d value in normal state and remarks on troubleshooting 1 Possible causes of trouble Given numbers are ref erence numbers which do not indi cate priority Inclusion Standard value under normal condition can be used to judge pos sible causes Reference for passing the above Good or No Good judgement Symptom of Wiring Harness Failure Open circuit Faulty contact with connector or open circuit in wiring ...

Page 411: ...n and RAM verification Response from controller Stop the operation of motor and solenoid coil Symptom of machine Engine acceleration fails and the machine acts slowly Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Internal failure of controller No troubleshooting can be done for failure occurs in the inner of controller If this ...

Page 412: ...m troubleshooting Between CN 445M and Resistance 12 2 Ω 2 Open circuit of harness Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Unplug the controller and measure the resistance between pin 113 and pin 105 Resistance 12 2 Ω 3 Short circuit of harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting U...

Page 413: ... perform troubleshooting Between CN 445M and Voltage About 5V 3 Open circuit of harness Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Unplug the controller and measure the resistance between pin 113 and pin 105 Resistance 12 2 Ω 4 Failure of throttle position sensor Turn engine start switch to OFF position Then keep it at ON position to perform troubl...

Page 414: ...5M and Voltage About 5V 3 Open circuit of harness Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Unplug the controller and measure the resistance between pin 113 and pin 105 Resistance 12 2 Ω 4 Failure of throttle position sensor Turn engine start switch to OFF position Then keep it at ON position to perform troubleshooting Between CN 445M and ground V...

Page 415: ...e Cause Standard value in normal state Remarks on troubleshooting 1 Failure of power sup ply Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Measure battery voltage Voltage 25V 2 Alternator abnormal Turn engine start switch to OFF position And Then keep the engine running to perform troubleshooting Measure the voltage between the alternator terminal B an...

Page 416: ... C for 10 sec onds when the power is on Response from controller The controller stops the motor and the solenoid coil Symptom of machine Engine acceleration fails and the machine acts slowly Possible causes and standard value in nor mal state Cause Standard value in normal state Remarks on troubleshooting 1 Internal failure of controller No troubleshooting can be done for failure occurs in the inn...

Page 417: ... causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Short circuit in harness grounded Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Measure the resistance between pin 56 pin 75 pin 74 of controller KC MB and the ground Resistance 2M Ω 2 Internal failure of controller No troubleshooting can be don...

Page 418: ...9 and Resistance 60 Ω 2 Open circuit of harness Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Unplug the controller and measure the resistance between pin 60 and CN 7 705 Resistance 1 Ω Unplug the controller and measure the resistance between pin 78 and CN 7 705 1 Ω 3 Internal failure of controller No troubleshooting can be done for failure occurs in ...

Page 419: ...een CN 115M A and B Voltage About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 115M C and pin 72 of controller Resistance 1 Ω Between CN 115M B and ground 1 Ω 3 Short circuit of signal wire grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 115M ...

Page 420: ...oting Between CN 116M A and B Voltage About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 116M C and pin 53 of controller Resistance 1 Ω Between CN 116M B and ground 1 Ω 3 Short circuit of signal wire grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Betwee...

Page 421: ...eshooting Between CN 128M A and B Voltage About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 128M C and pin 71 of controller Resistance 1 Ω Between CN 128M B and ground 1 Ω 3 Short circuit of signal wire grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Be...

Page 422: ...ubleshooting Between CN 122M A and B Voltage About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between CN 122M C and pin 52 of controller Resistance 1 Ω Between CN 122M B and ground 1 Ω 3 Short circuit of signal wire grounded Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting B...

Page 423: ...ubleshooting Between CN 126M A and B Voltage About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between CN 126M C and 70 pin of controller Resistance 1 Ω Between CN 126M B and ground 1 Ω 3 Short circuit of signal wire grounded Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting B...

Page 424: ...bleshooting Between CN 125M A and B Voltage About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between CN 125M C and pin 51 of controller Resistance 1 Ω Between CN 125M B and ground 1 Ω 3 Short circuit of signal wire grounded Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Be...

Page 425: ...bleshooting Between CN 124M A and B Voltage About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between CN 124M C and 69 pin of controller Resistance 1 Ω Between CN 124M B and ground 1 Ω 3 Short circuit of signal wire grounded Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Be...

Page 426: ...eshooting Between CN 128M A and B Voltage About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 128M C and pin 50 of controller Resistance 1 Ω Between CN 128M B and ground 1 Ω 3 Short circuit of signal wire grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Be...

Page 427: ...roubleshooting Between CN 123M A and B Voltage About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between CN 123M C and pin 68 of controller Resistance 1 Ω Between CN 123M B and ground 1 Ω 3 Short circuit of signal wire grounded Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting...

Page 428: ...orm troubleshooting Between CN 120M A and B Voltage About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between CN 120M C and pin 49 of controller Resistance 1 Ω Between CN 120M B and ground 1 Ω 3 Short circuit of signal wire grounded Turn engine start switch to OFF position Keep it at OFF position to perform troublesho...

Page 429: ...form troubleshooting Between CN 121M A and B Voltage About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between CN 121M C and pin 67 of controller Resistance 1 Ω Between CN 121M B and ground 1 Ω 3 Short circuit of signal wire grounded Turn engine start switch to OFF position Keep it at OFF position to perform troublesh...

Page 430: ... signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 302F and pin 34 of controller Resistance 1 Ω 3 Short circuit of signal wire grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 302F and ground Resistance 2M Ω 4 Short circuit of signal wire contact with power supply Turn ...

Page 431: ...ition Then keep it at OFF position to perform troubleshooting Between CN 113M and ground Voltage 0 2 4 75V 2 Open circuit of wire harness Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 113M and pin 31 of controller Resistance 1 Ω 3 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per ...

Page 432: ...ion This is normal as the en gine is not started 2 Open circuit of wire harness Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 448M and pin 38 of controller Resistance 1 Ω Between CN 448M and pin 19 of controller 1 Ω 3 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubles...

Page 433: ...n to per form troubleshooting Between CN 113F and pin 88 of controller Resistance 1 Ω Between CN 113F and ground 1 Ω 2 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 113F and wire 0 Resistance 1M Ω 3 Failure of pro portional valve coil Turn engine start switch to OFF position Keep it at OFF position to ...

Page 434: ...on to per form troubleshooting Between CN 113F and pin 88 of controller Resistance 1 Ω Between CN 113F and ground 1 Ω 2 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 113F and wire 0 Resistance 1M Ω 3 Failure of pro portional valve coil Turn engine start switch to OFF position Keep it at OFF position to...

Page 435: ...ion to per form troubleshooting Between CN 114F and pin 89 of controller Resistance 1 Ω Between CN 114F and ground 1 Ω 2 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 114F and wire 0 Resistance 1M Ω 3 Failure of pro portional valve coil Turn engine start switch to OFF position Keep it at OFF position t...

Page 436: ...ion to per form troubleshooting Between CN 114F and pin 89 of controller Resistance 1 Ω Between CN 114F and ground 1 Ω 2 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 114F and wire 0 Resistance 1M Ω 3 Failure of pro portional valve coil Turn engine start switch to OFF position Keep it at OFF position t...

Page 437: ...troubleshooting Between CN 133F and pin 98 of controller Resistance 1 Ω Between CN 133F and ground 1 Ω 2 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 133F and wire 0 Resistance 1M Ω 3 Failure of pro portional valve coil Turn engine start switch to OFF position Keep it at OFF position to per form troub...

Page 438: ...troubleshooting Between CN 133F and pin 98 of controller Resistance 1 Ω Between CN 133F and ground 1 Ω 2 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 133F and wire 0 Resistance 1M Ω 3 Failure of pro portional valve coil Turn engine start switch to OFF position Keep it at OFF position to per form troub...

Page 439: ...OFF position to per form troubleshooting Between CN 134F and 99 pin of controller Resistance 1 Ω Between CN 134F and ground 1 Ω 2 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 134F and wire 0 Resistance 1M Ω 3 Failure of pro portional valve coil Turn engine start switch to OFF position Keep it at OFF p...

Page 440: ...FF position to per form troubleshooting Between CN 134F and pin 99 of controller Resistance 1 Ω Between CN 134F and ground 1 Ω 2 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 134F and wire 0 Resistance 1M Ω 3 Failure of pro portional valve coil Turn engine start switch to OFF position Keep it at OFF po...

Page 441: ...oubleshooting Between CN 135F and pin 101 of controller Resistance 1 Ω Between CN 135F and ground 1 Ω 2 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 135F and wire 0 Resistance 1M Ω 3 Failure of pro portional valve coil Turn engine start switch to OFF position Keep it at OFF position to per form troubl...

Page 442: ...ubleshooting Between CN 135F and pin 101 of controller Resistance 1 Ω Between CN 135F and ground 1 Ω 2 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 135F and wire 0 Resistance 1M Ω 3 Failure of pro portional valve coil Turn engine start switch to OFF position Keep it at OFF position to per form trouble...

Page 443: ...nd pin 100 of controller Resistance 1 Ω Between CN 132F and ground 1 Ω 2 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 132F and wire 0 Resistance 1M Ω 3 Failure of pro portional valve coil Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Unplug the connector ...

Page 444: ...Travel speed or power is low 7 77 E 11 Blank monitor display 7 78 E 12 Monitor displays nothing 7 79 E 13 Dual speed travel not functioning 7 80 E 14 Incorrect engine coolant reading 7 81 E 15 Incorrect fuel level reading 7 82 E 16 Wiper does not work 7 83 E 17 Incorrect arm in pilot pressure reading 7 84 E 18 Incorrect arm out pilot pressure reading 7 85 E 19 Incorrect boom raise pilot pressure r...

Page 445: ... are reference numbers which do not indicate priority Description Standard value in normal state which is used to judge possible causes that might be OK or N G A reference value is used to determine OK or N G 2 3 4 5 Related circuit diagram This is part of the circuit diagram which shows the portion where the failure occurred Connector No A connector number Indicates a connector Arrow An arrow rou...

Page 446: ...ne start motor Start switch Voltage Power supply Terminal B and ground Start 20 30V Between engine input terminal S and ground 20 30V 5 Open circuit of wire har ness Turn engine start switch to OFF position Then keep it at OFF position to perform troubleshooting Wire 21 and start motor terminal B Resistance 1 Ω Wire 12 and start relay terminal SW 1 Ω Start relay terminal L and safety relay termina...

Page 447: ... 64 22 65 63 64 63 65 10 9 6 10 9 6 CN 661F S 16 CN 161F S 16 10 15 10 15 0 13 12 12a 14 47 21 1 2 4 3 1 2 4 3 12a 12a 14 14 10 10 10 47 47 10 E E 0 0 E 0 L R S P R B L P S S L SW B B 1 2 9 12 1 2 9 12 CN 613F L 6 CN 801F H 6 CN 241F D 12 TERMINAL HEAT OFF ON START B BR ACC R1 R2 C ZX215 1005095 SAFETY RELAY ALTERNATOR START MOTOR START RELAY HLR CHARGE INDICATOR PARK RELAY PARK MOTOR BATTERY BATT...

Page 448: ...and measure the resistance between pin 19 and pin 38 Resistance 2 3 0 2 K Ω 2 Internal failure in sensor Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 448M A and B Resistance 2 3 0 2 K Ω 3 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 448M B and...

Page 449: ...er cutout Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Failure of bat tery relay When engine start switch is operated if the operation of battery relay contact is heard the battery is normal Turn the start switch OFF ON OFF 2 Breakdown of surge diode Turn engine start switch to OFF position Keep it at OFF position to per form ...

Page 450: ... 64 22 65 63 64 63 65 10 9 6 10 9 6 CN 661F S 16 CN 161F S 16 10 15 10 15 0 13 12 12a 14 47 21 1 2 4 3 1 2 4 3 12a 12a 14 14 10 10 10 47 47 10 E E 0 0 E 0 L R S P R B L P S S L SW B B 1 2 9 12 1 2 9 12 CN 613F L 6 CN 801F H 6 CN 241F D 12 TERMINAL HEAT OFF ON START B BR ACC R1 R2 C ZX215 1005095 SAFETY RELAY ALTERNATOR START MOTOR START RELAY HLR CHARGE INDICATOR PARK RELAY PARK MOTOR BATTERY BATT...

Page 451: ...al transmitted Pressure 0 KG Lever in operation pressure signal transmitted 0 39 KG 5 Error of bucket curl signal Turn engine start switch to OFF position Start the engine and keep it running to perform troubleshooting Levers in NEUTRAL pressure signal transmitted Pressure 0 KG Lever in operation pressure signal transmitted 0 39 KG 6 Error of Bucket dump signal Turn engine start switch to OFF posi...

Page 452: ...FF ON OFF 3 Failure of pre heat switch Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Turn off the preheat switch and measure the resistance between wire 16 and wire 18 Resistance 1M Ω Turn on the preheat switch and measure the resistance between wire 16 and wire 18 1 Ω 4 Short circuit of wire har ness ground ed Turn engine start switch to OFF position ...

Page 453: ... Lockout control lever Resistance Between wire 105 and wire 27 LOCK 1 Ω FREE 1M Ω 2 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between 105 and ground Resistance 1M Ω 3 Failure of coil inside lockout solenoid valve Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Betw...

Page 454: ...sure 0 KG Lever in operation boom raise pressure signal 0 39 KG 2 Short circuit of harness grounded Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between harness from controller pin 70 to CN 126M A and ground Resistance 1M Ω 3 Open circuit of harness Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between con...

Page 455: ...harness grounded Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between harness from controller pin 71 to CN 128M A and ground Between harness from controller pin 52 to CN 122M A and ground Resistance 1M Ω 3 Open circuit of harness Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between controller pin 54 and...

Page 456: ... 39 KG 2 Short circuit of harness grounded Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between harness from controller pin 69 to CN 124M A and ground Between harness from controller pin 50 to CN 127M A and ground Resistance 1M Ω 3 Open circuit of harness Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Betwe...

Page 457: ...124M DF 3 CN 134F AMP 2 50 69 54 56 99 ZX215 1005100 BUCKET CONFLUENCE PROPORTIONAL VALVE 5V 5V CAB CHASSIS HARNESS SIGNAL GND WIRE BUCKET CURL PRESS SENSOR SIGNAL GND WIRE BUCKET DUMP PRESS SENSOR SIGNAL GND WIRE BUCKET CONFLUENCE SIGNAL CONTROLLER BUCKET CURL PRESS SENSOR BUCKET DUMP PRESS SENSOR SENOSR 5V SENSOR GND WIRE https www tractormanualpdf info ...

Page 458: ...ess grounded Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between harness from controller pin 49 to CN 120M A and ground Between harness from controller pin 67 to CN 121M A and ground Resistance 1M Ω 3 Open circuit of harness Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between controller pin 54 and CN 12...

Page 459: ... 7 705 pin 8 and CN 241F pin 3 Resistance 1 Ω Between CN 7 705 pin 9 and CN 241 pin 1 1 Ω Between CN 7 705 pin 10 and ground 1 Ω 3 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between harness from CN 7 705 pin 8 to CN 241 pin 3 and ground Resistance 1M Ω Between harness from CN 7 705 pin 9 to CN 241 pin 1 and gro...

Page 460: ...is tance Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between CN 1 112 1 and 2 Resistance 120 Ω 2 Open circuit of wire harness Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between CN 7 705 pin 3 and controller pin 60 Resistance 1 Ω Between CN 7 705 pin 4 and controller pin 78 1 Ω 3 Short circuit of wire h...

Page 461: ...osition to perform troubleshooting Between CN 131F A and B Resistance About 17 5 Ω 2 Open circuit of wire harness Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between CN 132F pin A and controller pin 100 Resistance 1 Ω Between CN 132F pin B and controller pin 55 1 Ω 3 Short circuit of wire harness grounded Turn engine start switch to OFF position Keep...

Page 462: ...andard values for engine coolant temperature sensor 50 C 80 Ω 60 C 56 3 Ω 80 C 29 5 Ω 100 C 16 5 Ω 106 C 14 3 Ω 120 C 10 Ω 2 Open circuit of lead Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between wire 510 and controller pin 30 Resistance 1 Ω 3 Short circuit of lead grounded Turn engine start switch to OFF position Keep it at OFF position to perform...

Page 463: ...orm troubleshooting Pin Fuel level Resistance Between wire 509 and ground FULL Upper limit Approx 10 Ω EMPTY Lower limit 85 95 Ω 2 Open circuit of lead Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between wire 509 and controller pin 11 Resistance 1 Ω 3 Short circuit of lead ground ed Turn engine start switch to OFF position Keep it at OFF position to ...

Page 464: ...tance 10 Ω 2 Open circuit of lead Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Between CN 241F 1 and CN 1 110 2 Resistance 1 Ω Between wiper switch wire 35L and CN 1 110 5 1 Ω Between wiper switch wire 35L and CN 1 110 4 1 Ω 3 Short circuit of lead ground ed Turn engine start switch to OFF position Keep it at OFF position to perform troubleshooting Ha...

Page 465: ...age Approx 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 128M and controller pin 71 Resistance Ω 3 Short circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 128M and ground Resistance 2M Ω 4 Failure of sen sor Turn engine start switch...

Page 466: ...ge About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 122M and controller pin 52 Resistance 1 Ω 3 Short circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 122M and ground Resistance 2M Ω 4 Failure of sen sor Turn engine start switch...

Page 467: ...ge About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 126M and controller pin 70 Resistance 1 Ω 3 Short circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 126M and ground Resistance 2M Ω 4 Failure of sen sor Turn engine start switch...

Page 468: ...ge About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 125M and controller pin 51 Resistance 1 Ω 3 Short circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 125M and ground Resistance 2M Ω 4 Failure of sen sor Turn engine start switch...

Page 469: ...e About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 124M and controller pin 69 Resistance 1 Ω 3 Short circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 124M and ground Resistance 2M Ω 4 Failure of sen sor Turn engine start switch ...

Page 470: ...e About 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 127M and controller pin 50 Resistance 1 Ω 3 Short circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 127M and ground Resistance 2M Ω 4 Failure of sensor Turn engine start switch t...

Page 471: ...t 5V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 123M and controller pin 68 Resistance 1 Ω 3 Short circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 123M and ground Resistance 2M Ω 4 Failure of sensor Turn engine start switch to OFF ...

Page 472: ...V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 120M and controller pin 49 Resistance 1 Ω 3 Short circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 120M and ground Resistance 2M Ω 4 Failure of sensor Turn engine start switch to OFF pos...

Page 473: ...V 2 Open circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 121M and controller pin 67 Resistance 1 Ω 3 Short circuit of signal wire Turn engine start switch to OFF position Keep it at OFF position to per form troubleshooting Between CN 121M and ground Resistance 2M Ω 4 Failure of sen sor Turn engine start switch to OFF po...

Page 474: ...ders no response in separate operation 7 105 H 10 Work equipment drifts excessively 7 106 H 11 Work equipment moves sluggishly 7 108 H 12 Other work equipment moves while single oil circuit is relieved 7 108 H 13 Travel speed drops considerably while swinging and travelling 7 109 H 14 Machine deviates during travel 7 110 H 15 Travel speed is low 7 111 H 16 Machine is not steered well or steering p...

Page 475: ...2 11 10 9 8 7 6 5 P2 P1 19 17 20 18 1 2 3 REAR FRONT M ZX225 1105039 PILOT VALVE L PILOT VALVE TRAVEL PILOT VALVE R IN OUT LEFT RIGHT LOWER RAISE BWD FWD CURL DUMP FWD BWD ARM SWING TRAVEL LEFT TRAVEL RIGHT BOOM BUCKET ACCUMULATOR LOCK PILOT VALVE BUCKET CONFLUENCE SWING PRIORITY VARIABLE SPEED TRAVEL BOOM PRIORITY REGULATOR SERVO MECHANISM REGULATOR SERVO MECHANISM https www tractormanualpdf info...

Page 476: ...S S S S Su Su Su Su S S S S 7 8 1 2 12 11 10 9 5 6 3 4 9 2 1 6 6 6X 6D SERVO MECHANISM BUCKET CYLINDER BOOM CYLINDER TRAVEL MOTOR L BALANCE VALVE SERVO MECHANISM ARM HOLD VALVE BOOM HOLD VALVE ARM 2 VALVE BUCKET VALVE BOOM VALVE BACKUP VALVE R TRAVEL VALVE BOOM 2 SWING VALVE L TRAVEL VALVE STRT TRAVEL VALVE ARM VALVE REG VALVE BUCKET CONFLUENCE BACKUP VALVE CONFLUENCE TRAVEL MOTOR R BACKUP ACTUATO...

Page 477: ... state Cause Standard value in normal state Remarks on troubleshooting 1 Possible causes of trouble Given numbers are reference numbers which do not indicate priority Description Standard value in normal state which is used to judge possible causes that might be OK or N G A reference value is used to determine OK or N G 2 3 4 5 The following information is contained in the troubleshooting table an...

Page 478: ...m troubleshooting while the engine is running at high idle Control levers Main relief pressure Arm in 33 34 3 MPa 337 350 kg cm If normal pressure cannot be restored after adjustment it is possible the fail ure of main relief valve or internal defect Check the valve directly 2 Malfunction of pilot relief valve Stop the engine Perform troubleshooting while the engine is running at high idle Control...

Page 479: ... of injection pump Injection pump may be defective Check it directly 2 Malfunction of regulator Regulator may have malfunction Check its servo mechanism 3 Clogging of oil filter ele ment Oil filter element may be clogged Check the element directly 4 Carbon buildup at fuel injection nozzle Carbon built up at fuel injection nozzle Check it directly 5 Clogging of air cleaner Air cleaner may be clogge...

Page 480: ...igh idle Pilot lockout control lever Pilot relief pressure LOCKED 0 0 FREE 3 9 4 1 MPa 40 42 kg cm 2 Failure of relief valve pilot pump Stop the engine Perform troubleshooting while the engine is run ning at high idle Control lever Pilot relief pressure All levers in NEUTRAL 3 9 4 1 MPa 40 42 kg cm 3 Failure of hydraulic pump The main pump may have malfunction or internal defect Check it by follow...

Page 481: ...hydrau lic oil Hydraulic oil probably contains air Make a visual check 3 Clogging of vent on top of hydraulic tank It is probably the clogging of the vent on top of the hydraulic tank that causes negative pressure in the hydraulic tank Press the release button of the breather valve to eliminate air Check again if the noise disappears 4 Clogging of hydraulic tank strainer It is probably the cloggin...

Page 482: ...state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of sensor Stop the engine Perform troubleshooting while the engine is running at high idle Control levers Pilot valve output pressure NEUTRAL 0 0 Operation 3 5 4 1MPa 36 42 kg cm 2 Malfunction of pilot valve Stop the engine Perform troubleshooting while the engine is running at high idle Control levers Pilot valve ...

Page 483: ...l valve spool Spool of boom control valve may have malfunction Check it directly 4 Malfunction of boom control valve re taining valve Retaining valve of boom control valve may have malfunction Check the valve directly 5 Malfunction or de fective seal of boom control valve Relief valve and makeup valve The relief valve and makeup valve in boom control valve may have mal function or defective seal C...

Page 484: ...lfunction of arm control valve spool Spool of arm control valve may have malfunction Check it directly 4 Malfunction of arm control valve regeneration valve Regeneration valve of arm control valve may have malfunction Check it directly 5 Malfunction or defective seal of arm control valve Relief valve and makeup valve The relief valve or makeup valve inside the arm control valve may have malfunctio...

Page 485: ...ssure sensor by replacing it with a new one 3 Malfunction of bucket control valve spool Spool of bucket control valve may have malfunction Check it directly 4 Malfunction or defective seal of bucket control valve relief valve and makeup valve Relief valve and makeup valve in bucket control valve may have mal function or defective seal Check the valves directly 5 Failure of bucket cylinder Stop the...

Page 486: ...rry out troubleshooting Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of pilot valve Stop the engine Perform troubleshooting while the engine is running at high idle Work equipment control lever Pilot valve output pressure NEUTRAL 0 0 DIG or DUMP 3 5MPa 36 kg cm 2 Failure of pressure sen sor Stop the engine Perform ...

Page 487: ...passage to the high pressure side of the cylinder Disconnect the cylinder from the main valve Measure the displacement of piston for 15 minutes after the cylinder becomes stable If the measured value is greater than 10 mm it is deemed that cylinder has a defec tive seal For more information on the measuring procedure refer to Testing and Adjusting Hydraulic Drift Work Equipment Test 2 Failure of b...

Page 488: ...acing it with another re lief valve or makeup valve Do not replace it with the boom down relief valve or makeup valve as their pressures are set differently 3 Failure of arm retaining valve Arm retaining valve or pilot valve may be worn or sluggish Check the valves 4 Failure of arm valve spool Arm valve spool may be worn excessively Check it directly Trouble 3 The bucket drifts excessively Related...

Page 489: ...ef valve or makeup valve of control valve may have malfunction Check it directly For arm and boom whether a valve has malfunction can be judged by replacing it with another relief valve or makeup valve Do not replace it with the boom lower relief valve or makeup valve as their pressures are set differently Trouble Other work equipment moves while single oil circuit of certain work equip ment is re...

Page 490: ...ably in swinging plus travelling operation Related information If the travel speed is low in only travelling operation check first ac cording to H 15 Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Failure of straight travel valve The straight travel valve gives no response Check the spool and the logic oil circuit drain port htt...

Page 491: ...back regulators 4 Sluggishness of proportion al solenoid valve Stop the engine Perform troubleshooting while the engine is running at high idle Travel control lever Proportional valve output pressure Operate both control levers 0 1 MPa 5 Sluggishness of travel con trol valve spool Check the valve spool to see whether it works well 6 Internal leakage of central swivel joint Check it by swapping the...

Page 492: ...t source pressure All levers in NEUTRAL 3 5 3 9 MPa 36 40 kg cm 3 Failure of sensor Stop the engine Perform troubleshooting while the engine is run ning at high idle Travel speed Travel control lever Reading on monitor Lo Operated 3 5 3 9 MPa 36 40 kg cm Hi Operated 3 5 3 9 MPa 36 40 kg cm Check the sensor by replacing it with another one 4 Malfunction of travel control valve spool Spool of travel...

Page 493: ...re sensor Stop the engine Perform troubleshooting while the engine is running at high idle Travel control lever Solenoid valve output pressure Both sides operated 3 5 3 9 MPa 36 40 kg cm Either side operated 3 5 3 9 MPa 36 40 kg cm 3 Malfunction of travel control valve spool Spool of travel control valve may have malfunction Check it direct ly 4 Malfunction of travel control valve makeup valve The...

Page 494: ...le causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of travel speed shifting solenoid valve Stop the engine Perform troubleshooting while the engine is run ning at high idle Travel speed Travel control lever Solenoid valve output pressure Lo Operated 0 0 Hi Operated 3 5 3 9 MPa 36 40 kg cm 2 Failure of travel motor in speed cha...

Page 495: ...ction Check it directly 3 Defective seat of travel motor valve makeup valve Seat of check valve in travel motor valve may have malfunction Check it directly 4 Speed of travel motor drops Stop the engine Perform troubleshooting while the engine is run ning at high idle Travel control lever Leakage from travel motor Travel relief 27 2 ml min 5 Failure of final drive Final drive may have internal def...

Page 496: ...on of swing motor relief valve Stop the engine Perform troubleshooting while the engine is run ning at high idle Swing control lever Swing relief pressure Swing relief 25 5 28 5 MPa 260 291 kg cm If oil pressure does not become normal after adjustment swing motor relief valve may have malfunction or internal defect Check the relief valve directly 3 Failure of swing motor Stop the engine Perform tr...

Page 497: ...Remarks on troubleshooting 1 Malfunction of pilot valve Stop the engine Perform troubleshooting while the engine is run ning at high idle Left control lever Pilot valve output pressure NEUTRAL 0 0 Swing 3 5MPa 36 kg cm 2 Malfunction of swing control valve spool Spool of swing control valve may have malfunction Check it directly 3 Defective seal of swing motor makeup valve Seal of makeup valve in s...

Page 498: ...rake of swing motor may have malfunction Check it directly 2 Improper adjustment or malfunction of swing motor relief valve Stop the engine Perform troubleshooting while the engine is run ning at high idle Swing control lever Swing relief valve Swing relief 25 5 28 5 MPa 260 291 kg cm If oil pressure does not become normal after adjustment swing motor relief valve may have malfunction or internal ...

Page 499: ...g control lever Pilot valve output pressure NEUTRAL 0 0 Left swing Right swing 3 5MPa 36 kg cm 2 Malfunction of swing motor pressure com pensation valve Pressure compensation valve of swing motor may have malfunction Check it directly 3 Defective seal of swing motor makeup valve Seal of makeup valve in swing motor may have defect Check it di rectly Swap the left and right makeup valves and observe...

Page 500: ...ief valve directly 2 Failure of swing motor Stop the engine Perform troubleshooting while the engine is run ning at high idle Control lever Leakage from swing motor Swing relief 10 ml min Trouble 2 Swing acceleration is only poor on one side or swing speed is low Related information Set the working mode at gear 10 of power mode S to perform troubleshooting Possible causes and standard value in nor...

Page 501: ...f valve Swing relief valve may be worn or sluggish H 23 High noise is produced when upper structure stops swinging Trouble High noise is produced when upper structure stops swinging Related information Set working mode to S and fuel control dial at position 10 to carry out troubleshooting Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshoo...

Page 502: ...irectly 2 Malfunction of swing motor parking brake Parking brake of swing motor may have malfunction Check it directly Trouble 2 Hydraulic drift of swing is large when swing holding brake is re leased Related information When swing holding brake release switch is in release position swing holding brake is released and upper structure is secured by only hydraulic pressure Possible causes and standa...

Page 503: ...S A N Y L A T I N A M E R I C A 7 122 SY195 205 215 225C9 Crawler Hydraulic Excavator Troubleshooting Shop Manual June 2013 B L A N K P A G E https www tractormanualpdf info ...

Page 504: ...Motor AS Remove and Install 8 10 8 3 1 Removal 8 10 8 3 2 Installation 8 10 8 4 Injection Pump AS Remove and Install 8 11 8 4 1 Removal 8 11 8 4 2 Installation 8 13 8 5 Engine Front Seal Remove and Install 8 15 8 5 1 Removal 8 15 8 5 2 Installation 8 15 8 6 Engine Rear Seal Remove and Install 8 16 8 6 1 Removal 8 16 8 6 2 Installation 8 17 8 7 Cylinder Head AS Remove and Install 8 18 8 7 1 Removal...

Page 505: ...ssemble and Assemble 8 58 8 14 1 Disassembly 8 58 8 14 2 Assembly 8 59 8 15 Sprocket Remove and Install 8 62 8 15 1 Removal 8 62 8 15 2 Installation 8 62 8 16 Track AS Remove and Install 8 63 8 16 1 Removal 8 63 8 16 2 Installation 8 65 8 17 Swing Bearing AS Remove and Install 8 66 8 17 1 Removal 8 66 8 17 2 Installation 8 67 8 18 Swing Platform AS Remove and Install 8 68 8 18 1 Removal 8 68 8 18 ...

Page 506: ... 8 94 8 27 1 Disassembly 8 95 8 27 2 Assembly 8 100 8 28 Work Equipment AS Remove and Install 8 105 8 28 1 Removal 8 105 8 28 2 Installation 8 107 8 29 Air Conditioner AS Remove and Install 8 108 8 29 1 Removal 8 108 8 29 2 Installation 8 112 8 30 Counterweight AS Remove and Install 8 113 8 30 1 Removal 8 113 8 30 2 Installation 8 114 8 31 Cab AS Remove and Install 8 115 8 31 1 Removal 8 115 8 31 ...

Page 507: ...l 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 8 158 8 40 2 Working principle 8 158 8 40 3 Removal 8 159 8 40 5 Installation 8 160 8 40 4 Angle adjustment of wiper arm 8 160 8 41 Relay 8 161 8 41 1 Engine relays 8 161 8 41 2 Other relays 8 162 8...

Page 508: ...ing the part 8 1 2 Disassembling and assembling an assembly Disassembly The Disassembly section contains procedure precautions and the amount of oil or water to be discharged Assembly The Assembly section contains operating procedure precautions technical specification and the amount of oil or water to be added 8 1 3 Special tools Special tools for parts disassembly and assembly are listed Necessa...

Page 509: ...he wires and the hoses in order to ensure their connecting positions By doing so mistakes can be avoided during reinstallation Count and check the number and thickness of the shims and keep them in a safe place When raising or lifting components be sure to use proper lifting equipment of ample strength and safety When forcing screws are used to remove any components tighten the screws evenly in tu...

Page 510: ...142 Plug 16 60002397 Plug 20 B210780000080 Plug 25 B210780000081 Plug B Thread connected adaptors plug and nut used in combination I D mm Code Description Code Description Light Thread Connection 6 B210780000903 Taper bore plug 23002925 Nut 8 B210780001146 Plug B210770000011 Nut 10 B210780000088 Plug B210334000011 Nut 12 B210780000089 Plug B210334000012 Nut 15 B210780000882 Plug B210334000004 Nut ...

Page 511: ... connector of oil dirt or water Make sure that the wiring connector is connected securely Before using an eyebolt check the eyebolt for deformation or deterioration Screw on the eyebolt as far as possible and align it to the direction of the hook Before tightening the split flange tighten it evenly in turn in order to prevent over tighten ing on one side NOTE After reassembling the hydraulic cylin...

Page 512: ...rough the system Check the coolant level again Add hydraulic oil to the specified level after disassembly and reinstallation of a hydraulic unit Run the engine to circulate the hydraulic oil through the system Check the oil level again Bleed the air from the system after removing and repairing the lines or hydraulic unit and reassembling the parts For more information see Air in Each Component Ble...

Page 513: ...8 2 6 kgf m Fixing bolts start motor 43 6 N m 4 4 0 6 kgf m ZX215 1006001 Starter Starter relay Terminal B Terminal S 1 2 3 4 5 6 7 ZX215T 1006002 1 Open the engine hood 2 Disconnect the cables 1 2 3 4 and 5 3 Unscrew the bolts 6 and 7 used to fix the start motor Remove the start motor as sembly CAUTION Before removing the start motor assem bly disconnect the cable from the nega tive post of the b...

Page 514: ...pen the engine hood 2 Disconnect the air intake hose 1 3 Disconnect fuel supply tube 2 fuel deliv ery hose 4 fuel return hose 3 and fuel supply tube 5 Block the hose with a cork in order to prevent flow of fuel from the hose ZX215T 1006003 1 ZX215T 1006004 3 4 2 5 ZX215T 1006005 8 4 1 Removal CAUTION Disconnect the negative post of the battery https www tractormanualpdf info ...

Page 515: ... Shop Manual June 2013 4 Disconnect the lubrication tube 6 5 Disconnect six fuel delivery tubes 7 6 Disconnect the air hose 8 7 Remove the bolt 9 fixing the electronic choke Disconnect the bolt 10 fixing the governor motor 6 ZX215T 1006006 7 ZX215T 1006007 9 10 8 ZX215T 1006008 https www tractormanualpdf info ...

Page 516: ...n pump assembly A 4 nuts on the flange B 1 nut 8 4 2 Installation Installation is to be performed in the re verse order of removal Bolts for installation of fuel supply tube 20 29 N m 2 1 3 0 kgf m Relief valve 20 29 N m 2 1 3 0 kgf m Bolts for installation of engine oil line 10 13 N m 1 0 1 3 kgf m Fuel injection tube 24 N m 2 5 kgf m Bolts for installation air hose 12 15 N m 1 2 1 5 kgf m Adjust...

Page 517: ... 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 andAdjust on page 6 13 2 Assemble the fuel injection pump assem bly and tighten the 4 nuts at position A and 1 nut at position B Nut 9 8 2 N m 10 0 2 kgf m Air bleeding Bleed the air from the fuel injection system https www tractormanualpdf info...

Page 518: ...Radiator AS Remove and Install on page 8 24 2 Remove the engine fan 1 the belt 2 and the pulley 3 3 Remove the mounting nut 4 and replace the cone 5 and the O ring 6 Remove the crankshaft belt pulley 7 8 5 2 Installation Installation is to be performed in the re verse order of removal Nut 490 N m 50 kgf m 1 3 2 ZX215 1006010 Water pump 5 6 7 Ta 4 ZX215 1006011 8 ZX215 1006012 4 Disassemble the fro...

Page 519: ... 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 3 Remove the flywheel 4 4 Remove the engine speed sensor 5 and the flywheel shell 6 5 Remove the rear seal 7 Ta 1 2 3 5 6 4 ZX215 1006013 7 ZX215 1006014 Lip https www tractormanualpdf info ...

Page 520: ...r oil seal is to be installed accord ing to the following procedure 1 Apply engine oil to the lips of the rear seal 2 Clean the oil sealing surface 3 Apply the sealant evenly and continuously align the line of the rear seal Sealant Tonsun 1596 4 The installation is to be performed 3 min utes after application of the sealant Be careful not to deviate the line while apply ing the sealant ø2mm ZX215 ...

Page 521: ... AS Remove and Install 1 Drain the engine of coolant Coolant 18 L 2 Open the engine hood 3 Disconnect the air intake hose 1 4 Remove piping 2 and piping 3 between the fuel filter and the injection pump ZX215T 1006016 1 ZX215T 1006017 2 3 ZX215T 1006018 8 7 1 Removal CAUTION Disconnect the negative post of the battery https www tractormanualpdf info ...

Page 522: ... assembly 5 6 Remove the six delivery hoses 6 7 Remove the exhaust muffler connector cover 7 8 Remove the air cleaner suction hose 8 9 Remove the air intake tube 9 and its clamps 10 between the turbocharger and the intercooler 10 Remove the engine oil delivery tube 11 and the oil return tube 12 4 5 ZX215T 1006019 6 ZX215T 1006020 7 8 9 10 ZX215T 1006021 https www tractormanualpdf info ...

Page 523: ...c Excavator Disassembly and Assembly Shop Manual June 2013 11 Remove the turbocharger assembly 12 Remove the exhaust manifold 13 13 Remove the radiator inlet hose 14 and outlet hose 15 11 12 ZX215 1006022 13 ZX215 1006023 14 15 ZX215T 1006024 https www tractormanualpdf info ...

Page 524: ...ozzle seats 16 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 Lift the cylinder head assembly in order to disassemble it 19 Remove the cylinder head gasket 21 16 ZX215T 1006025 18 21 17 19 20 ZX215 1006026 https www tractormanualpdf info ...

Page 525: ... for the maximum piston projection after measurement In ad dition even if one cylinder s piston projec tion is 0 05 mm greater than the average the gasket with a thickness one grader higher A B B C is to be used Unit mm Piston Projection Cylinder Head Gasket Average Size Thickness Tightened 0 546 0 610 A 1 3 0 610 0 674 B 1 35 0 674 0 738 C 1 4 3 The size of cylinder head gasket is deter mined acc...

Page 526: ...er 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 For more information see Valve Clearance Adjust on page 6 8 Adding coolant Add engine coolant to the specified level Start the engine to circulate the coolant in order to release all foams Check the cool ant level again https www tractormanualpdf in...

Page 527: ...lant tank Coolant approx 18 L 3 Remove the coverplate 4 Remove the two U bolts 2 5 Disconnect the hydraulic oil cooler inlet connector 3 and outlet connector 4 Block the openings to prevent leakage of hydraulic oil 6 Discharge hydraulic oil from the hydraulic cooler Hydraulic oil radiator approx 5 6 L 7 Disconnect the coolant tank hose 5 8 Disconnect the cooler inlet hose 6 and outlet hose 7 2 4 3...

Page 528: ...June 2013 10 Remove the four bolts 10 from the air conditioner radiator Remove the air condi tioner radiator and store it properly 11 Remove the radiator fan guard 11 9 Disconnect the intercooler air inlet tube 8 and outlet tube 9 6 7 8 9 ZX215T 1006031 10 10 ZX215T 1006032 11 ZX215T 1006033 https www tractormanualpdf info ...

Page 529: ...h sides of the radiator in order to hoist the radiator assembly NOTE Before the radiator assembly is hoisted move the radiator assembly axially until the fan avoids its guard 12 Remove the four mounting bolts 12 from the radiator bottom and the two mounting bolts 13 from the left and right brackets 12 13 ZX215T 1006034 ZXT335 1006029 14 https www tractormanualpdf info ...

Page 530: ... the fan Check the values a at the four measuring points in the left right top and bottom di rections which should be as the following Standard clearance a in all directions 15 1 5 mm Fan diameter b ø620 mm Fan guard inner diameter c ø650 mm Engine coolant and hydraulic oil adding Add a specific amount of coolant and hydraulic oil Start the engine to circulate the coolant and hydraulic oil Check t...

Page 531: ...raulic tank suction filter el ement and block the opening 2 Drain the engine of coolant Coolant approx 18 L 3 Open the engine hood 4 Disconnect piping 1 2 and 3 1 2 3 ZX215T 1006036 ZX215T 1006028 8 9 1 Removal CAUTION Lower the work equipment to the ground Stop the engine Disconnect the cable from the battery negative post Loosen the butterfly nut on the breather valve and press the relief button...

Page 532: ...and 8 7 Remove the clamps 9 and 10 Remove the line 11 and the cable 12 8 Unscrew the connection bolt 13 of the governor motor and the connection bolt 14 of the engine stopper 9 Disconnect the external cable from the starter 15 10 Remove the mounting bolt 16 from the hose clamp 4 6 5 7 8 ZX215T 1006037 9 10 11 12 ZX215T 1006038 14 13 15 16 ZX215T 1006039 https www tractormanualpdf info ...

Page 533: ...anual June 2013 11 Disconnect the cables 17 and 18 as well as the tubes 19 and 20 from the compressor 12 Disconnect the hoses 21 22 23 and 24 between the engine and the radiator 13 Disconnect the air intake hose 25 17 18 19 20 ZX215T 1006040 24 23 21 22 ZX215T 1006041 25 ZX215T 1006042 https www tractormanualpdf info ...

Page 534: ... the rpm sensor 15 Disconnect the external cable 27 of en gine oil pressure sensor 16 Disconnect the engine oil inlet tube 28 and outlet tube 29 17 Disconnect the wiring 30 of the engine oil pressure switch 18 Disconnect the cables 31 and 32 and remove the hose clamp 33 26 27 ZX215T 1006043 28 29 30 ZX215T 1006044 31 32 33 ZX215T 1006045 https www tractormanualpdf info ...

Page 535: ... 2013 19 Remove the hose clamp 35 20 Disconnect the wiring 34 of the water temperature sensor 21 Disconnect the cables 36 and 37 of the water temperature switch 22 Disconnect the oil return hose 38 23 Disconnect the A C water pipe 39 34 35 ZX215T 1006046 36 37 ZX215T 1006047 38 39 ZX215T 1006048 https www tractormanualpdf info ...

Page 536: ...and Assembly Shop Manual June 2013 24 Disconnect the radiator fan guard 40 25 Remove the fixing 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 40 ZX215T 1006049 41 41 ZX215T 1006050 https www tractormanualpdf info ...

Page 537: ... Also add coolant to the coolant reser voir Engine coolant approx 22 5 L Refill the hydraulic tank with hydraulic oil Hydraulic tank approx 225 L Start the engine to circulate the coolant in order release the foams and check the coolant level again Start the engine to circulate the hy draulic oil in the hydraulic system and check the oil level again Air bleeding For more information see Air in Eac...

Page 538: ...ket For more information see Sprocket Remove and Install on page 8 62 2 Remove the motor cover plate 1 3 Disconnect the four hoses 2 of the travel motor and the corresponding hose connec tors 1 ZX215 1006051 2 ZX215T 1006052 8 10 1 Removal CAUTION Lower the work equipment to the ground Stop the engine Operate the breather valve to release internal pres sure https www tractormanualpdf info ...

Page 539: ...inal drive assembly 245 309 N m 25 31 kgf m 3 ZX215 1006053 Final Drive Assembly 250 kg Hydraulic oil adding Add hydraulic oil through the filler opening to the specified level Start the engine to circulate oil in the hydraulic system and check the oil level again Air bleeding For more information see Air in Each Component Bleed on page 6 46 NOTICE Be careful not to damage the surface of mounting ...

Page 540: ...ne 2013 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 final drive tank Final drive tank approx 4 7 L 2 Cover Remove the bolts Use eyebolts to the cover 1 3 Spacer Remove the spacer 2 1 ZX215 1006054 2 ZX215 1006055 https www tractormanualpdf info ...

Page 541: ...rrier as sembly 3 2 Disassembly of No 1 planetary carrier assembly 3 Remove the screws 4 Remove the coverplate 5 from the planetary carrier assembly 6 4 Remove the thrust washer 7 gear 8 bearing 9 bearing inner race 10 and a second thrust washer 11 5 No 1 sun gear shaft Remove No 1 sun gear shaft 12 3 ZX215 1006056 9 7 4 5 10 8 11 6 ZX215 1006057 12 ZX215 1006058 https www tractormanualpdf info ...

Page 542: ...arrier assembly 22 2 Remove the bearing inner race 19 and outer race 18 Remove the plate 20 3 Remove the screw 21 to take the planetary carrier assembly 22 and the shim 23 from the body 6 Thrust washer Remove the thrust washer 13 7 No 2 sun gear Remove No 2 sun gear 14 9 Hub assembly 1 Use eyebolts to remove the hub as sembly 24 from the travel motor 13 14 ZX215 1006059 17 20 21 22 18 19 15 16 23 ...

Page 543: ...013 2 Disassemble the hub assembly as the following 3 Remove the float 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 5 Remove the float seal 29 from the travel motor 26 25 27 28 ZX215 1006062 29 30 ZX215 1006063 https www tractormanualpdf info ...

Page 544: ...ng 27 by pressing them onto the hub 28 2 Install the float seal 25 Remove any oil or dust from the O ring or O ring contact surface Dry the parts before installing the float seal After installing the float seal check that the angle of the floating seal is within 1 mm Apply a thin layer of engine oil to the sliding surface after the float seal has been installed 3 Install the float seal 29 to the t...

Page 545: ... Load 3000Kg 2 Calculation of shim thickness 1 Measure the thickness H of the raised part of No 2 carrier assembly 22 2 Measurement of raised thickness Apply 3000 Kg load to the bearing and measure the value H of the raised part of the bearing Turn the hub 2 3 times before applying a pushing force Do not use a spray gun to cushion the bearing Do not push or strike the resin retainer 3 Shim thickne...

Page 546: ... the tan gential force of hub to motor rotation Tangential force Max 294 N 30 kg Maximum tangential force occurs when the rotating direction begins to change 3 Assembly of No 2 planetary carrier as sembly 1 Assemble the No 2 planetary carrier assembly according to the following procedure NOTE Replace the plates 20 and 16 with new parts 2 Assemble the bearing 18 and bearing 19 to the gear 17 Assemb...

Page 547: ...o 2 sun gear 14 6 No 1 sun gear shaft Install No 1 sun gear shaft 12 7 No 1 planetary carrier assembly 1 No 1 planetary carrier assembly is as sembled as the following NOTE Replace the thrust washers 7 and 11 with new parts 2 Assemble the bearings 9 and 10 onto the gear 8 Assemble the top and bottom thrust washers 7 and 11 Place the gear assembly into the car rier assembly 6 3 Fix the coverplate 5...

Page 548: ...1 planetary carrier assembly 3 8 Spacer Install the spacer 2 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 10 Oil adding Tighten the drain plug and add engine oil through the filler Final drive case approx 4 7 L Check the oil level after the final drive has been successfully installed to the chassis https www tractormanualp...

Page 549: ... motor and main valve Px port port SH Between swing motor and solenoid valve block port PG 2 Remove the 11 fixing bolts 8 3 Lift the swing motor and swing drive as sembly 9 for disassembling NOTE Slowly lift the swing motor and swing drive assembly in order to avoid damaging the hoses and other parts Swing motor and swing drive as sembly 260 kg Release the residual pressure in the hy draulic circu...

Page 550: ...everse 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 filler opening to the specified level Start the engine to circulate oil in the hydraulic system and check the oil level again Air bleeding For more information see Air in Each Component Bleed on page 6 46 https www tractormanualpdf info ...

Page 551: ... drain plug to drain the oil from the swing drive Swing drive approx 4 4 L 2 Swing motor assembly 1 Place the swing motor and swing drive assembly on a suitable cribbing Be careful not to damage the drive gear or let it contact the ground 2 Unscrew the 14 bolts in order to re move the swing motor assembly 1 Swing motor assembly 70 kg 3 No 1 sun gear 1 Remove No 1 sun gear 2 2 ZX215 1006072 1 ZX225...

Page 552: ...r assembly 1 Remove No 1 carrier assembly 3 and the plate 4 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 5 Ring gear Unscrew the mounting bolts to remove the ring gear 10 3 4 ZX215 1006073 5 6 7 8 9 ZX215 1006074 10 ZX215 1006075 https www tractormanualpdf info ...

Page 553: ...Disassembly and Assembly Shop Manual June 2013 6 No 2 sun gear Remove No 2 sun gear 11 7 No 2 planetary carrier assembly 1 Remove No 2 carrier assembly 12 2 Disassemble No 2 carrier assembly as per the following procedure 11 ZX215 1006076 12 ZX215 1006077 https www tractormanualpdf info ...

Page 554: ... the shaft 4 Remove the thrust washer 16 gear 17 and a second thrust washer 19 5 Insert the pin 15 to remove the bear ing 18 from the shaft Remove the pin 15 8 Snap ring Remove the snap ring 20 9 Disassembly of main shaft 1 Place the shaft housing assembly on a press and push the shaft assembly 21 out of the shaft housing assembly 22 19 13 14 17 18 15 16 ZX215 1006078 20 ZX215 1006079 21 22 ZX215 ...

Page 555: ...mbly and Assembly Shop Manual June 2013 2 Disassemble the shaft assembly in the following procedure Remove the bearing 23 from the shaft 24 10 Bearing Remove the bearing 25 and the oil seal 26 from the housing 27 23 24 ZX215 1006081 Press 26 27 25 ZX215 1006082 https www tractormanualpdf info ...

Page 556: ...e oil to the sliding surface of the parts 1 Bearing Press the bearing 23 into the housing 27 2 Oil seal Press the oil seal 26 into the housing 27 Oil seal installation surface Gasket sealant Loctite 515 3 Housing assembly 1 Position the plate 28 on the shaft 24 2 Position the housing assembly 22 on the shaft 24 Press in the bearing 23 27 ZX215 1006083 27 26 ZX215 1006084 24 22 28 ZX215 1006085 htt...

Page 557: ...assembly 19 3 Assemble the gear 17 in the carrier assembly 19 Put the bearing 18 on the shaft 14 Slightly tap the pin 15 into the bore after alignment Use a rubber hammer to tap the pin Make sure that the pin 15 must not higher than the bearing 18 4 Push the shaft assembly into the car rier assembly 19 Be careful not to damage the gear and the plate Align the pin bore of the shaft with that of the...

Page 558: ...lant onto the ring gear 10 Mating surface Sealant Loctite 515 8 No 1 planetary carrier assembly 1 No 1 carrier assembly is assembled as per the following procedure 2 Install the plate 7 into the carrier as sembly 5 3 Install the gear 6 onto the plate after installing the bearing 9 into the gear 4 Press the shaft 8 into the gear 6 and the carrier assembly 5 Rivet one end of the shaft Check if the g...

Page 559: ...215 225C9 Crawler Hydraulic Excavator Disassembly and Assembly Shop Manual June 2013 5 Install No 1 carrier assembly 3 and the plate 4 9 No 1 sun gear assembly Install No 1 sun gear 2 3 4 ZX215 1006073 2 ZX215 1006072 https www tractormanualpdf info ...

Page 560: ...nting bolts swing motor 156 5 N m 16 0 5 kg NOTE The 14 bolt holes of the swing motor and swing drive assembly are distributed nonuniformly The mating direc tion of each hole is fixed as shown in the illustration on the right The installation of swing motor requires proper alignment of the bolt holes in order to ensure the instal lation orientation 11 Lubricant adding Screw on the drain plug and a...

Page 561: ... the shaft 5 and the support as sembly 7 NOTE The idler contains 80 ml oil which should be drained completely before disas sembling Spread a cloth on the floor to prevent smearing the floor with oil 4 Remove the float seals 6 on the other side from the idler 4 shaft 5 and sup port assembly 7 5 Remove the dowel pin 8 in order to re move the support 7 from the shaft 5 6 Remove the bushings 9 and 10 ...

Page 562: ...5 with the dowel pin 8 3 Install the float seals 6 to the idler 4 shaft 5 and support 7 assembly Float seals Completely remove the grease from the contact surfaces hatched area in the illustration on the right of O ring and float seal before installing the float seal In addition care must be taken to keep the contact surface of float seal free from dust 4 4 9 10 ZX215 1006093 6 ZX215 1006094 ZX215...

Page 563: ... Assembly Shop Manual June 2013 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 4 Install the shaft 5 and support 7 assem bly to the idler 4 a ZX215 1006095 7 5 4 ZX215 1006096 https www tractormanualpdf info ...

Page 564: ...Care must be taken to keep the sliding surface from any contaminants or dust NOTE Remove the oil and dust from the contact surfaces of the O ring and float seal 6 Install the O ring Install the support 2 with the dowel pin 1 7 Add oil and screw on the plug Oil approx 80 ml No 18 hyperbola gear oil Plug 205 8 49 N m 21 5 kgf m 4 3 3 2 ZX215 1006097 3 ZX215 1006098 13 9 3 2 1 6 11 8 12 10 7 5 4 ZX21...

Page 565: ...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 3 Remove the sprocket 1 Sprocket 58 kg 8 15 2 Installation Installation is to be performed in the re verse order of removal Threads bolt sprocket Thread sealant Tonsan 1277 Bolts sprocket 339 20 N m 35 2 kgf m 1 ZX215 1006099 https w...

Page 566: ... pin is between the idler and the carrier roller 2 Lower the work equipment Loosen the grease fitting 1 and release the track ten sion Special tools Mark Part Name Necessity Qty M Manual electric hydraulic track removing installing machine 1 3 Pull out the master pin 2 with the tool M 1 ZX215T 1006100 M 2 ZX215 1006101 WARNING The adjustment cylinder is under ex tremely high pressure Never loosen ...

Page 567: ...embly and Assembly Shop Manual June 2013 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 spread the track 3 3 ZX215 1006102 https www tractormanualpdf info ...

Page 568: ... information see Track Tension Test and Adjust on page 6 24 Installation procedure of track shoe bolts and nuts 1 Bring the R side of the track shoe nut 1 to the link seat surface Both seat surfaces should be in close contact when assem bling the track shoe NOTE If the track shoe bolts are installed from the other side the corner of nut will interfere with the link seat surface causing the nut to ...

Page 569: ...ng 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 3 Hoist the swing bearing assembly 2 Swing bearing assembly 314 kg 2 1 ZX215T 1006105 2 ZX215T 1006106 https www tractormanualpdf info ...

Page 570: ...n the bolts tighten first the four corners and mark them 2 Other bolts will be tightened clockwise or counterclockwise After one bolt is tight ened tighten the next one on the diagonal position and make a mark 3 Tighten the rest bolts in this way Let the S mark in the soft zone of the inner race of the inner ring face the right side as shown in the photo and install the swing bearing to the track ...

Page 571: ...l on page 8 105 2 Remove the counterweight assembly For more information see Counterweight AS Remove and Install on page 8 113 3 Remove the four hoses 1 of boom cylin der NOTE Plug the hoses to prevent flow of oil 4 Lift the boom cylinder assembly 2 1 ZX215T 1006108 2 ZX215T 1006109 8 18 1 Removal CAUTION Fully extend the arm and the bucket Lower the work equipment to the ground and move the hydra...

Page 572: ...quires removing other parts that interfere with the lifting of swing platform 7 Disconnect the six hoses above the swivel joint assembly Central swivel joint port A Left travel control valve port BTL Central swivel joint port C Left travel control valve port ATL Central swivel joint port F Solenoid valve Central swivel joint port G Swing motor port T Central swivel joint port D Right trav el contr...

Page 573: ... platform as sembly off the machine NOTE Remove the front and rear mount ing bolts of the platform Use a lever block to adjust the swing platform so that the platform can reach a balance both longi tudinally and laterally Remove the last two bolts finally Swing platform assembly Assembly Swing Platform Only Ref 8 427 kg 1 689 kg NOTICE Be careful not to impact the central swivel joint while removi...

Page 574: ...t Tonsun 1596 Threads bolt swing platform Thread adhesive Tonsun 1277 Mounting bolts swing platform Step 1 Tighten the bolts with a pneumatic spanner Step 2 tighten them again 490 608 N m 50 62 kgf m Hydraulic oil adding Add through the filler opening the hydraulic oil to the specified level Start the engine to circulate oil in the hydraulic system and check the oil level again Air bleeding Bleed ...

Page 575: ...rav el motor port T 3 Central swivel joint port B Left travel motor port PA 4 Central swivel joint port D Right trav el motor port PB 5 Central swivel joint port A Left travel motor port PB 6 Central swivel joint port C Right trav el motor port PA 1 2 3 4 5 6 ZX215T 1006114 8 19 1 Removal Refer to Residual Pressure in Hydraulic Cir cuit Release on page 6 40 NOTE Tag each line so as to ensure corre...

Page 576: ...1 Central swivel joint port C Left travel control valve port ATL 12 Central swivel joint port A Left travel control valve port BTL 13 Central swivel joint port D Right trav el control valve port ATR 14 Central swivel joint port B Right trav el control valve port BTR 3 Remove the fixing bolt 15 4 Remove the four mounting bolts 16 16 ZX215T 1006116 18 16 17 ZX215 1006117 Transition plate 5 Remove th...

Page 577: ...ivel joint facing the direction indicated in the illustration B D A C ZX215 1006118 Sprocket Central swivel joint Oil adding hydraulic tank Add through the filler opening the hydraulic oil to the specified level Start the engine to circulate oil in the hydraulic system and check the oil level again Air bleeding Bleed the air from the travel motor For more information see Air in Each Component Blee...

Page 578: ...emove the cover 3 3 Remove the gasket 4 O ring 5 and snap ring 6 4 Remove the rotor 13 from the housing 9 NOTE Be careful not to damage the slid ing surface of the seal of the rotor 13 5 Remove the spacer 7 and the gasket 8 from the housing 9 6 Remove the dust seal 12 from the swing shaft 13 7 Remove the O ring seal 11 and the seals 10 from the housing 9 1 2 3 4 5 6 7 8 9 10 11 12 13 ZX215 1006119...

Page 579: ... NOTE Since the clearance between the housing 9 and the rotor 13 is ap proximately 0 1 mm install the housing 9 on the rotor 13 slowly and vertically Be careful not to damage the seals 10 and the O ring seal 11 4 Use a rubber hammer to tap the housing 9 in order to match the rotor 13 properly 5 Install the spacer 7 and gasket 8 in the housing 9 6 Install the gasket 4 O ring seal 5 and snap ring 6 ...

Page 580: ...al Hydraulic oil approx 225 L 2 Open the engine hood 3 Remove the engine hood 1 cover 2 and control valve cover 3 4 Remove the cover mounting frame 4 and the screen 5 5 Remove the screen 6 and the partition frame mounting bolt 7 on the hydraulic tank side 6 Remove the screw 8 and the fuel control motor 9 7 Remove the two oil return hoses 10 from the hydraulic tank 1 2 3 4 5 ZX215T 1006122 6 7 8 9 ...

Page 581: ...rn swing motor NOTE Disconnect the oil inlet hose 18 from the hydraulic tank after disconnection of the oil inlet tube from the pump Attach each hose with an identification tag Use a sleeve nut to prevent the fitting and the cone seal from damage 9 Remove the hose clamp 19 10 Lift the hydraulic tank assembly and re move the six bolts 20 11 Lift off the hydraulic tank assembly for dis assembling Hy...

Page 582: ...ange indicated in the illustration Screw hose clamp 8 8 0 5 N m 0 9 0 05 kgf m Install the hose clamp and tighten the screw according to the illustration on the right Bolt 245 2 308 9 N m 25 31 5 kgf m ZX215 1006128 Screw Up Down ZX215 1006129 Pipe Clamp Hose Bulge Oil adding hydraulic tank Add hydraulic oil through the filler opening to the specified level Start the engine to circulate oil in the...

Page 583: ...transducer and tag them 4 XAK Bucket DIG 5 XBb1 Boom DOWN 6 XAtL Travel LEFT 7 XBa1 Arm IN 8 XBs Swing RIGHT 9 XAtr Travel RIGHT 4 7 8 9 ZXT225 1106011 5 6 1 2 ZXT225 1106009 3 ZXT225 1106010 8 22 1 Removal NOTE Tag each line so as to ensure correc tion installation WARNING Lower the work equipment to the ground Stop the engine Press the re lease button of the breather valve to re lease residual p...

Page 584: ...uence 15 XBtL Travel LEFT 16 XAb1 Boom UP 17 XBK Bucket DIG 18 XAa2 Arm OUT 6 Remove the port 19 accumulator to solenoid valve port 10 pilot filter to ac cumulator Remove hose clip 21 of the central swivel joint 7 Remove bucket hoses 22 and 23 and seal the ports 8 Remove arm hoses 24 and 25 and seal the ports 9 Remove boom hoses 26 and 27 and seal the ports ZXT225 1106012 10 11 12 13 14 15 16 17 1...

Page 585: ...ntral swivel joint hoses 28 29 30 and 31 Remove travel speed switching hose 32 and seal the ports 11 Remove swing motor hoses 33 and 34 Remove swing motor oil complement hose 35 Seal the ports properly 32 30 31 28 29 ZXT225 1106015 ZXT225 1106016 33 35 34 ZXT225 1106017 36 12 Remove pipe 36 main valve to radiator https www tractormanualpdf info ...

Page 586: ... valve to return oil tank Seal the ports properly 14 Remove hydraulic pump hoses 38 and 39 15 Remove hoses 40 to 44 on the solenoid valve and tag them properly 40 PPC lockout valve 41 Main valve PnA2 42 Main valve XBP2 43 Main valve PSP 44 Travel PT port ZXT225 1106018 37 ZXT225 1106019 38 39 WXT215 1208001G 40 41 42 43 44 https www tractormanualpdf info ...

Page 587: ...through the filler opening to the specified level Start the engine to circulate oil in the hydraulic system and check the oil level again Air bleeding Bleed the air from the circuit between the valve and the hydraulic cylinder For more information see Air in Each Component Bleed on page 6 46 ZXT225 1106021 45 46 45 16 Remove the fixing bolts 45 Lift the con trol valve assembly 46 for disassembling...

Page 588: ...e drain plug and drain the oil from the hydraulic tank and from circuits Hydraulic tank Approx 225 L 2 Lift the hood 1 ZX215 1006144 Oil stopper 1 ZX215T 1006145 8 23 1 Removal NOTE Tag each line so as to ensure correc tion installation 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 ta...

Page 589: ...ne 2013 3 Remove the pin 2 and the bolts 3 Lift the engine hood in order to remove it 4 Remove the right upper cover 4 2 ZX215T 1006146 3 4 ZX215T 1006147 5 6 ZX215T 1006148 5 Disconnect the hose 5 supplying oil to the lower proportional valve and the hose 6 delivering oil from the pilot pump https www tractormanualpdf info ...

Page 590: ...6150 10 11 12 13 14 15 ZX215T 1006151 9 Disconnect the oil drain hose 10 and seal the openings properly 10 Disconnect the high pressure hoses 11 and 12 connecting to the control valve and seal the openings properly 11 Disconnect the harness 13 of the pres sure transducer 12 Disconnect the pilot pump oil inlet hose 14 and seal the openings properly 13 Disconnect the pilot pump oil inlet tube 15 and...

Page 591: ...p Manual June 2013 16 17 18 19 ZX215T 1006152 20 21 ZX215T 1006153 14 Disconnect the solenoid valve harnesses 16 and 17 Remove the cable straps 18 and 19 15 Remove the four bolts 20 of the hydraulic pump Lift the hydraulic pump assembly 21 to remove it Hydraulic pump assembly 112 kg https www tractormanualpdf info ...

Page 592: ...0 5 N m 0 9 0 05 kgf m Install the hose clamp and tighten the screw according to the illustration on the right Mating surface hydraulic pump housing Gasket sealant Loctite 515 ZX215 1006128 Screw Up Down ZX215 1006129 Pipe Clamp Hose Bulge Oil adding hydraulic tank Add hydraulic oil through the filler opening to the specified level Start the engine to circulate oil in the hydraulic system and chec...

Page 593: ... Remove and Install on page 8 85 2 Remove the screw 2 Remove the bear ing cover 3 3 Pry the oil seal 4 out with a screwdriver NOTE Be careful not to damage the shaft while prying the oil seal 8 24 2 Installation Installation is to be performed in the re verse order of removal Seal lip Grease No 1 Calcium base grease Seal circumference Grease No 1 Calcium base grease Apply a thin layer of grease to...

Page 594: ...ket bolt 25 33 N m 2 55 3 36 kgf m 2 Insert the spring 7 into the spool hole in the valve body 8 Put the spool 6 in the spring Install the plunger 5 on the spool Push the plug 5 to the spool hole 3 Install the plate 4 on the plunger 5 Tighten the U joint 3 4 Install the plate 2 Align the position of the plate 2 and tighten the nut 1 Nut 98 133 N m 10 13 5 kgf m NOTE Location of each oil port is st...

Page 595: ...hread adhesive Ton sun 1277 to two points on the inner threads The amount of application is approximately 0 02 g U joint 3 98 133 N m 10 13 5 kgf m NOTE Tightening is to be made to the specified torque Contact surface between plung er 5 and plate 2 Grease 0 3 0 8 ml No 1 Calcium base grease 5 7 mm ZX215 1006157 https www tractormanualpdf info ...

Page 596: ...1 Install the spring 8 into the spool installation hole in the body assembly 9 Install the spool 7 Place the cover assembly 6 on the spool and press the cover assembly 6 with a hand 2 Install the cover 4 after aligning the holes Tighten the socket bolts 1 Bolt socket 98 114 N m 10 11 6 kgf m 3 Install the dust ring 3 on the plunger Install the cover 2 and fix the cover 2 with the cam shaft 5 Conta...

Page 597: ...ne 2013 8 27 Hydraulic Cylinder AS Disassemble and Assemble Special tools Application Tool Shape Necessity Quantity Pulling out pushing in the bushing 1 Press fitting the dust ring 1 O ring seal correc tion Inserting tool Correcting tool 1 Inserting the cylin der head 1 Inserting the piston 1 https www tractormanualpdf info ...

Page 598: ...er can be disassembled and assembled eas ily The pin bore in the head end can be used for fixing of the cylinder The pin roll can prevent the cylinder from turn ing Remove the tubing in case of tubing in terference while fixing the cylinder 3 Removal of cylinder head Unscrew the bolts with Allen Wrench Using an extension rod as shown in the illustration on the right will make the work easy ZX215 1...

Page 599: ...ntainer 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 Remove the piston rod 1 with the cylinder head 2 and place them on a wooden sleeper 5 Fixing the piston rod Use pin bore on the rod end or the flat part of the ear to prevent turning of the piston rod 1 2 ZX215 1006166 Sleeper 5 ZX215 1006167 Fixing https ...

Page 600: ...there are two points that have been punched against loosening After removing the riveted part with a hand drill loosen and remove the fixing screw 3 2 Remove the steel ball 4 3 Remove the piston nut 5 NOTE The piston nut 5 is very tight To loosen the piston nut 5 prepare a hydraulic jack or a spanner powered by hydraulic cylinder An extension rod should be ready when removing the piston nut 5 manu...

Page 601: ... There is an opening in the buffer seal 10 Take advantage of this opening to remove the buffer seal 10 9 Removal of piston seal 1 The slide ring 12 and the guard ring 13 can be simply removed with hands 2 The seal 14 can be removed with a hammer and a flat head screwdriver 3 Remove the O ring seal 15 with a pry bar NOTE The removed seals should not be reused 10 Removal of buffer ring 16 NOTE The b...

Page 602: ...he screwdriver to remove the dust ring 18 NOTE The removed seals should not be reused 12 Removal of bushing 19 1 Remove the elastic ring 20 from the cylinder head 2 with a screwdriver 2 Push the bushing 19 out with the help of clamps and press 13 Removal of bushing 21 1 Remove the dust ring 22 on the side of cylinder barrel and piston rod with a tool such as screwdriver 2 Remove the bushing 21 wit...

Page 603: ...raulic oil to the inside of cylinder head in advance Make sure that the bushing 19 pushed in is free from a raised shoulder 2 Use the press to push in dust ring 18 3 Install the guard ring and the U ring 17 sequentially in the U groove NOTE Install the U ring 17 in correct direc tion Make sure that the U ring is intact before installation Inverse installation will cause leak of oil Make sure that ...

Page 604: ...ing 13 on the pis ton Place the piston on the press As shown in the illustration on the right the seal 14 is installed with the tools indicated 2 Correction of seal 14 NOTE Install the seal 14 and the guard ring 13 on the other side In order to prevent the expansion of the seal 14 a corrector must be used to correct the seal 14 which has been stretched during installation The piston rod may not be...

Page 605: ... the buffer seal 10 in the groove 5 Install the buffer sleeve 8 according to the indication in the illustration on the right 6 Install the stopper ring in the groove Install the elastic ring after the buffer sleeve 8 is pushed to the bottom A rubber hammer should be used for the tapping job in order to avoid damaging the piston rod and the buffer bearing 7 If the head side of cylinder contains a b...

Page 606: ...m 632 6 kgf m NOTE Insufficient tightening can cause oil leakage loose nut and thread break age In addition excessive tightening can cause expansion of the buffer shaft on the extending side or deformation of piston on the contact side Thoroughly clean and grease with ba nana oil the threaded portions of the piston nuts and piston rod before tight ening the nuts 12 Treatment of the piston against ...

Page 607: ...d in a vertical manner the piston rod falls into the barrel under its gravity Make sure that the slide ring does not fall while the piston is inserted into the barrel 6 Tightening of cylinder head Tighten the cylinder head according to the sequence shown in the illustration on the right Bolt 267 N m 27 2 kgf m 7 Install the tubing ZX215 1006184 Tool Nylon sleeve 2 pcs type Spread the gaps by 180 8...

Page 608: ...from slipping out Put the cylinder on a bench or support Remove the grease fitting on the bottom side in the later case Remove the other boom cylinder in the same way 5 Remove the two hoses 6 of bucket cylin der and the those 7 of the arm cylinder NOTE Cork the hoses to prevent outflow of oil Secure the hoses to the valve side 6 Remove the inter connector 8 used for work lamp 1 2 3 4 5 ZX215T 1006...

Page 609: ...ual June 2013 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 8 Lift and disassemble the work equipment assembly Work equipment assembly 3451 kg 9 10 ZX215T 1006188 11 ZX215T 1006189 https www tractormanualpdf info ...

Page 610: ... more information see Air in Each Component Bleed on page 6 46 NOTE Adjust the shim thickness in order to have a desired clearance a 0 5 a 1 mm between the piston end 12 and the plate 4 Standard shim thickness 1 0 mm and 2 0 mm Greasing after assembling the pin Grease supramoly lithium base CAUTION Do not put your finger in the pin bore while aligning the pin bore Installation is to be performed i...

Page 611: ...lant approx 22 5 L 2 Recover refrigerant from the air condition ing system with the tool S S ZX215T 1006192 1 ZX215T 1006193 Special tools ID Part Name Model Necessity Qty S Refrigerant charger Robinair 34711 2K 1 Refrigerant charger Inoue Qing Hua 1 8 29 1 Removal 3 Remove the pad 1 on the cab floor CAUTION Disconnect the cable from the negative post of the battery https www tractormanualpdf info...

Page 612: ... with the ignition key Remove the outer filter ele ment 2 ZX215T 1006196 3 6 4 5 5 Remove the fuse box 3 and storage box 4 6 Remove outer covering 5 7 Remove the air conditioner cover 6 8 Remove the back air duct 7 9 Remove the left air duct 8 10 Remove the baffle 9 11 Remove the right air duct 10 7 8 9 10 ZXT225 1006205 2 W13092904 Cover https www tractormanualpdf info ...

Page 613: ...e the radio antenna 13 12 13 11 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 Remove the electrical mounting plate 19 16 Remove the air conditioner water pipes 20 and 21 as well as the dripping tube 22 20 21 22 ZX215T 1006200 14 17 16 18 19 15 ZXT215 1308207 https www tractormanualpdf...

Page 614: ...ulic Excavator Disassembly and Assembly Shop Manual June 2013 23 ZX215T 1006201 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 https www tractormanualpdf info ...

Page 615: ...w hose clamp 8 83 14 7 N m 0 9 1 5 kgf m Bolt pressure plate 13 5 1 2 N m 1 38 0 12 kgf m Refrigerant charging Charge refrigerant HFC 134a into the air condition return lines with tool S For more information see Refrigerant on page 4 141 NOTICE Keep the hoses free from contamination by dirt dust or water while installing the return hose of the air conditioner Make sure that the O ring seal is pres...

Page 616: ...emoval 1 Remove the cover 1 from the counter weight Install eyebolts to the counter weight Hold the counterweight 2 Remove the four bolts 2 1 ZX225 1106004 ZX225 1106005 2 Wire rope ZX225 1106006 3 3 Lift the counterweight levelly with wire rope or chain hoist NOTE Be careful not to damage the engine radiator or cooler Counterweight assembly 3901 kg https www tractormanualpdf info ...

Page 617: ...e the counterweight with a crane to a suitable position on the frame 2 Push the counterweight and install the bolts Adjust the position of the counter weight in such a manner that the following dimensions can be obtained Clearance with swivel 10 5 mm L R Clearance with bodywork door 10 5 mm L R Step from swivel in left to right direction b max 5 mm Step from bodywork door in left to right directio...

Page 618: ... box 2 and storage box 3 3 Remove outer covering 4 4 Remove the air conditioner cover 5 2 5 3 4 ZX215T 1006001 8 31 1 Removal CAUTION Disconnect first the cable connecting to the negative post of the battery 5 Disconnect the left wire harness 6 moni tor harness connector 7 and window washer harness 8 6 Remove the right side air duct 9 7 6 8 9 ZXT225 1006216 1 ZX215T 1006193 https www tractormanual...

Page 619: ... Hydraulic Excavator Disassembly and Assembly Shop Manual June 2013 7 Remove external air filter 10 10 ZXT225 1006217 8 Disconnect the external air duct 11 11 ZX215T 1006210 9 Remove the storage box on the armrest 12 12 ZX215T 1006211 https www tractormanualpdf info ...

Page 620: ...or Disassembly and Assembly Shop Manual June 2013 10 Remove the radio connector 13 11 Remove the radio wire harness 14 13 14 ZX215T 1006212 12 Remove the window washer reservoir 15 15 ZX215T 1006213 13 Remove the window washer pipe 16 16 ZX215T 1006214 https www tractormanualpdf info ...

Page 621: ...sassembly and Assembly Shop Manual June 2013 14 Remove the decor cover 17 17 ZX215T 1006215 15 Remove the four mounting nuts 18 and the five mounting bolts 19 20 ZX215T 1006217 16 Lift the cab assembly 20 for removal Cab assembly 450 kg 19 18 ZXT225 1006224 https www tractormanualpdf info ...

Page 622: ... 215 225C9 Crawler Hydraulic Excavator Disassembly and Assembly Shop Manual June 2013 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 https www tractormanualpdf info ...

Page 623: ...glass 8 Rear window glass 9 Roof window glass 10 Rubber sealing strip 11 Center adjusting seal 12 Front window AS Glass and frame Cab window glasses 1 2 5 7 and 9 are adhered to the window frame When replacing front window glass 2 disassemble front window assembly 12 If the cab is install with a front window assembly do not only replace the front window glass For more information about front windo...

Page 624: ...ove the sealing strip from the frame of the cab door 2 Push the glass outward carefully from inside of the cab and remove glass 4 and 6 together with the frame NOTE To avoid finger cut during when remov ing a shattered or cracked glass cover it with a piece of adhesive film or tapes 3 ZX215 1006219 4 6 ZX215 1006220 CAUTION Removing shattered or cracked window glass may cause finger cuts Wear prop...

Page 625: ... the retainer from the groove on the rubber with an ordinary screw driver 2 Put a thin bamboo chip inside part A of the retaining rubber and detach the re tainer along the edge 3 Pat the glass from inside of the cab and remove it This job may require two people 6 4 ZX215 1006221 Frame Seal 8 ZX215 1006222 A A ZX225 1006231 Rubber retainer side Glass Retainer Rubber retainer Cab side Cab https www ...

Page 626: ... 1 Remove the resin board decor strip and retainer along the edge of the glass 2 Punch a hole through the adhesive with a drill or a cutter as illustrated 3 Pull a piece of piano string or steel wire through the hole as illustrated 1 2 5 7 9 ZX215 1006223 ZX215 1006224 Adhesive Glass Cab Drill ZX215 1006225 Piano string or steel wire https www tractormanualpdf info ...

Page 627: ... screw drivers Pull the wire back and forth in order to cut the adhesive and detach the glass from the cab This job may require 2 3 people Run the string along the center of the adhesive The string may break when it becomes very hot Use different sec tions of the string while cutting the ad hesive ZX215 1006226 Cab Glass Outside Inside Adhesive https www tractormanualpdf info ...

Page 628: ...nife or scraper 5 Remove the remaining adhesive and rubber so that they will not affect the application of new adhesive Do not scrape the original paint on the surface Scraping of paint reduces the perfor mance of the adhesive 2 Clean the grease dust and dirt on the cab 8 and the glass 9 with unleaded gaso line Contaminant on the contact surface re duces the performance of adhesive Clean the black...

Page 629: ...e the adhesive paint and glass priming paint are well agitated before application If the priming paint is stored in a refrig erator keep it under ambient tempera ture for at least half a day before agita tion If the paint is unsealed immediately af ter it is taken out of a refrigerator water will condense on it 2 Always wash a used brush 11 with unleaded gasoline before using it Check the brush fo...

Page 630: ... for painted sur face Sunrise MSI Primer 24 Do not apply primer more than twice otherwise the performance of the prim er will be reduced Applying location Cover the whole area of a Dimension of a 25mm Besides the above locations apply primer also onto the right window glass and the cab door lower window glass Additional priming area on the right window glass b Additional priming area on the cab do...

Page 631: ...imer Sunrise MSI Primer 35 Do not apply the primer more than twice otherwise the performance of the primer will be reduced Priming area Apply the priming paint on the contact surface of glass 9 rubber seal 6 adhering location and along cab frame 8 Leave a 5 mm margin uncoated along the black strip adjacent to the clear area of the glass When priming paint has been coated dry it for at least 5 minu...

Page 632: ...aned area on the glass before rubber seal is adhered Be careful not to allow the rubber seal on the corners to peel off When sticking rubber seal 6 along the window frame do not overlap the two ends of the seal A 5 mm gap between the two ends of the seal is recommend ed 1 Stick rubber seal 6 onto the right cab window frame as illustrated Adhere additional rubber seal 6a onto the right cab window P...

Page 633: ...seal 6 on the left cab window as illustrated 3 Adhere rubber seal 6 onto the lower cab door window as illustrated Adhere additional rubber seal 6b onto the lower cab door window frame as il lustrated Position of additional rubber seal j 110 mm k 90 mm m 200 mm 6 ZXT225 1006248 6 ZXT225 1006249 j m k 6b ZXT225 1006250 https www tractormanualpdf info ...

Page 634: ...the clear part of the glass 5 Positioning of new window glass 1 Check the clearance between the edge of glass and the cab in 4 directions and position the glass Make sure the clearance is even 2 Put a tape 6 across the glass 9 and cab 8 and draw a line n on it for alignment Adhere tape 6 at 3 points as illustrated for precise alignment of right window glass left rear window glass and cab door lowe...

Page 635: ...June 2013 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 6 6 6 8 9 ZX215 1006246 P 4 ZX225 1006255 https www tractormanualpdf info ...

Page 636: ... Before using adhesive that has been unsealed remove the hardened part at the nozzle 1 Open the aluminum seal 13 on the head of the cylinder 12 and install the nozzle 14 Adhesive Sunrise MSI SR sealant U90 4463876 2 Cut the tip of nozzle 14 as illustrated Dimension of the cut q 10 mm r 5 mm 3 Set the cylinder 12 in the gun 7 An electrical caulking gun is more ef ficient 13 12 ZX215 1006247 q r 14 ...

Page 637: ...rface where adhesive is to be applied 5 Apply adhesive 15 along the external edge of the rubber seal 6 Adhesive 15 for rubber seal 6 on cab 8 shall be applied as illustrated Dimension of s 10 mm Dimension of t 15 mm Adhesive 15 shall be thicker that the rubber seal 6 Apply adhesive of the same thickness evenly 6 15 ZX215 1006250 s 8 t 6 15 ZX215 1006251 https www tractormanualpdf info ...

Page 638: ...lass 1 Install window glass 9 and align it with the mark on the cab See step 5 Since the glass can not be remove once installed be very careful when performing this task Install the glass properly within 5 min utes after adhesive has been applied 2 Press the perimeter of the glass 9 after is has been put in place until it is securely stuck to the rubber seal Press the corners of the glass hard 6a ...

Page 639: ...glass 4 on sec tion A A and apply the adhesive as fill ers Dimension of t 2 mm Dimension of u 5 mm Use a rubber spatula to cover the edge of the glass and trim the adhesive Remove surplus adhesive Glass primer Sunrise MSI Primer 35 Adhesive Sunrise MSI SR Sealant U90 4463876 8 Fix the glass 1 After the right window glass 1 has been adhered to the cab put position ing chips a 1 or 2 pcs beneath the...

Page 640: ...sive on the cab and on the glass Clean the adhesive with unleaded gas oline before it is hardened Do not apply impacting force onto the glass when cleaning it 10 Protection of fixed window glass 1 Remove the positioning chips foam polystyrene blocks and the rubber band after 10 hours Condition Temperature 20 humidity 60 2 Wait for another 14 hours after the re moval of positioning chips foam poly ...

Page 641: ...ate will be used in Step 6 to hang the pull rod 3 Release the rear lock of the cab 4 Lower the front window assembly carefully a bit Take out and hold the rollers 5 and 6 at the bottom of the front window from the removed parts in Step 2 5 Remove roller 5 and 6 from both sides of the bottom of the front window The front window assembly must be removed from the cab in order to replace the front win...

Page 642: ...ing of pin 7 Hang plate 8 onto the mounting bolt of left corner plate using the washer and fix it 7 Pull out the front window assembly 10 from the opened part of the guide rail and lower the assembly gradually 6 7 8 9 ZX215 1006260 9 8 ZX215 1006261 10 ZX215 1006262 NOTICE A return load of 58 8 N 6 kg is applied onto the rear of the cab Be very care ful when removing pin 7 to disconnect pull rod 9...

Page 643: ... window assembly 10 to the right and the left and remove the two upper rollers 11 and 12 from the guide rail Then remove the front window as sembly 10 8 Lower the front window assembly 10 completely Be careful not to allow the front window assembly to damage the machine mon itor 10 ZX215 1006263 10 12 11 ZX215 1006265 https www tractormanualpdf info ...

Page 644: ...olt of the roller adjusting bracket 13 and adjust the condition of the front window Tighten the mounting bolt after adjusting Mounting bolt 34 3 N m 3 5 kgf m 3 Raise the front window assemble and fix it with rear locks at both sides Check if the locks at the rear of the cab are securely fixed 4 Install the right corner plate 2 After the locked position is adjusted in Step 6 tighten the corner pla...

Page 645: ... the right corner plate 2 in a nearly correct position so that front window glass 14 is pressed closely against the adjusting seal 15 on the cab 2 Open and close the front window as sembly and check the working condi tion of left lock 16 and right lock 17 If left lock 16 and right lock 17 do not work properly Loosen the mounting bolt 19 of the lock and move the lock 16 forward Tighten the bolt aft...

Page 646: ...dow assembly is adjusted in Step 6 and Step 7 raise the assembly to the roof 2 Set the locks of the front window as sembly at the rear of the cab at the locked position and check the follow ing items Check the conditions of left lock 16 and right lock 17 The front window assembly must con tact the left and right rubber stopper 18 and the rubber stoppers must be pushed backward by 1 5 3 0 mm The fr...

Page 647: ...ate 23 ø14 5 mm 6 Adjustment of left and right rubber stop per 18 Allow front window assembly 10 to contact the left and right rubber stopper 18 when the lock is unlocked 7 Lock front window assembly 10 8 Turn the left right rubber stopper 18 to the left by one and a half round Turning the rubber stopper 18 leftward for one round is equivalent to pressing it by 1 5 mm When front window assembly is...

Page 648: ...ly contacts surface c of retainer 24 when front window assembly is raised 10 Check the locking ability of front window assembly After the adjustment from Step 6 to Step 9 is finished check the locking force of left lock 16 and right lock 17 Check the locking force at the locked side front of cab and the unlocked side rear of cab Left lower pin 27 34 N m 2 75 3 47 kgf m Mounting bolt Adhesive LT 2 ...

Page 649: ... Remove the mounting plate and the monitor assembly from the bracket 3 2 Remove the nut 1 and the gasket 2 to separate the monitor 5 from the mounting plate 1 2 3 4 5 ZX215 1006281 8 34 1 Removal 8 34 2 Installation Installation is to be performed in the re verse order of removal CAUTION Disconnect first the cable connecting to the negative post of the battery https www tractormanualpdf info ...

Page 650: ...e rear covering 3 3 Remove air conditioner cover 4 4 Remove the controller wiring connectors A1 5 and A2 6 5 Remove the four bolts Remove the con troller assembly 7 ZXT335 1006800 1 4 2 3 8 35 1 Removal 8 35 2 Installation Installation is to be performed in the re verse order of removal CAUTION Disconnect first the cable connecting to the negative post of the battery ZX215 1308283 7 6 5 https www ...

Page 651: ...e 1 Main structure 2 Wiring ZX215 1006284 ZX215 1006285 BACK PANEL POWER GROUND AND AUDIO OUTPUT AUDIO INPUT RED L SOUND TRACK INPUT RADIO ANTENNA WHITE R SOUND TRACK INPUT RED ACC IGNITION YELLOW BATT POWER SUPPLY BLACK GROUND GRAY R SOUND TRACK OUTPUT R SOUND TRACK OUTPUT WHITE L SOUND TRACK OUTPUT BLACK L SOUND TRACK OUTPUT https www tractormanualpdf info ...

Page 652: ...washers in order to remove the radio and the radio mounting brackets from the console cover 4 Remove the four screws and the washers in order to remove the radio from the radio mounting brackets 8 36 2 Removal ZX215 1006286 Radio Arm rest cover ZX215 1006287 Connector CN 003F Cab harness ZX215 1006288 Radio Mounting bracket Washer Screw Arm rest NOTICE Disconnect the power supply prior to removal ...

Page 653: ...embly Shop Manual June 2013 8 36 3 Installation Installation is to be performed in the re verse order of removal 8 36 4 Connector model and wiring 1 2 3 4 6 7 5 1 2 3 20b R L 28 0 R L 4 6 7 5 ZX215 1006289 Harness socket terminals Type Yasaki 7119 3070 Raido wiring terminals https www tractormanualpdf info ...

Page 654: ...e 2013 8 37 Battery 8 37 1 Structure 1 Spinning post 2 Charge densiometer 3 Heat sealing cover 4 PP casing 5 Central polar ear 6 Forged grid 7 Paste active material 8 Bag type screen 9 Polar group 10 Liquid gas separator 11 Central busbar ZX215 1006290 J C H G I E B D F 1 2 10 3 4 5 6 A 7 8 11 9 https www tractormanualpdf info ...

Page 655: ...attery wiring cable and the battery breaker cable VART A VARTA ZX215 1006292 Battery cable Battery Breaker cable 3 Remove the four bolts and washers Re move the battery assembly from the bot tom plate Remove the battery V A R T A ZX215 1006293 V A R T A Battery Bolt Wahser Battery box NOTICE Turn the start switch to the OFF posi tion before removal Do not remove the charge densimeter Tighten the d...

Page 656: ...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 Batteries of different types are probably charged at differ ent speeds which may cause one of them to fail due to overloading NOTICE During installation apply vaseline to battery terminals in order to prevent corrosion https w...

Page 657: ... 22 20 18 17 15 13 12 11 28 6 10 9 8 7 21 27 1 14 19 16 26 5 4 3 2 ZX215 1006294 1 Housing 2 Key 3 Ring 4 Knob 5 Nut 6 Cylinder 7 Cap 8 Shield 9 Pin 10 Spring 11 Disc 12 Spring 13 Plug 14 Rotor 15 Cover 16 Spring 17 Ball 18 Spring 19 Contact SPR B 20 Contact A 21 Seat 22 Contact SPR A 23 Contact B 24 Terminal 25 Bolt 26 O ring seal 27 Harness AS 28 Washer https www tractormanualpdf info ...

Page 658: ...r to remove the mounting plate and the start switch from the console cover 3 Remove the nut so as to remove the start switch from its mounting plate ZX215 1006295 0 0 1 67 57 21 2 2 Start swich Console cover Set screw ZX215 1006296 Mounting plate Start switch Set screw Console cover ZX215 1006297 Start switch Mounting plate Nut NOTICE Disconnect the power supply of the start switch before removal ...

Page 659: ...g of start switch 1 Working principle 2 Wiring Key Position ON OFF Battery B Battery Relay BR Accessory Preheat Plug Start Relay C R1 R2 HEAT OFF ON START 3 6 ACC BR B 1 4 R1 R2 C 3 6 13 22 1 4 16 11 ZX215 1006299 KEY SWITCH WIRING TERMINALS JACKET MODEL YAZAKI 7222 7464 30 HARNESS PLUG TERMINALS JACKET MODEL YAZAKI 7123 7464 30 https www tractormanualpdf info ...

Page 660: ... Box 8 39 1 Removal 1 Remove the cover 2 Remove the bolts and take off the back cover along with the fuse box 3 Remove the bolts so as to separate the fuse box and harness assembly from the back cover ZX215 1006300 Cover ZX215 1006301 Back cover Bolt Fuse box cover ZX215 1006302 Bolt Back cover Fuse box harness https www tractormanualpdf info ...

Page 661: ...ssembly and Assembly Shop Manual June 2013 8 40 Wiper 8 40 1 Structure ZX215 1006303 Rotating mechanism Wiper motor Blade Arm Mounting bracket Connector 8 40 2 Working principle ZX215 1006304 M YELLOW RESET GREEN LOW SPEED BLUE HIGH SPEED RED POWER BLACK POWER https www tractormanualpdf info ...

Page 662: ...nterior decoration 2 Remove the moving mechanism and the motor Unscrew the bolts to remove the wiper motor and moving mechanism from the cab ZX215 1006305 Decoration button Inner decor 3 Remove the arm and the blade Unscrew the nut to remove the wiper arm and blade from the cab ZX215 1006307 Arm bracket Cap Locknut Cab ZX215 1006306 Bolt Bolt Wiper motor Moving mechanism https www tractormanualpdf...

Page 663: ...lready stops working before the blade reaches the stopper the moving angle of wiper should be adjusted to prevent breakdown of the wiper Adjust the wiper in such a way Loosen the locknut adjust the arm working angle ac cording to actual condition Make sure that the wiper motor stops working at the mo ment that the blade reaches the mechani cal stopper 8 40 5 Installation Installation is to be perf...

Page 664: ...nduction and action Replace the relay in case of any failure 2 Mains relay check Check the conduction and action Replace the relay in case of any failure 3 Heater relay Check the conduction and action Replace the relay in case of any failure AA2A 1 S S B B SW SW L L 2 ZX215 1006309 1 1 2 4 4 3 3 2 ZX215 1006310 Battery terminal 5 1 4 5 4 1 3 2 2 3 ZX215 1006311 Fuse https www tractormanualpdf info...

Page 665: ... and terminal 3 Standard Value Approx 200Ω Check the conduction and action Replace the relay in case of any failure 3 R 2 L 1 S P 6 5 E 4 ZX215 1006312 8 41 2 Other relays 1 Function and location ZX215 1006313 Head lamp relay Shutdown delay relay Parking relay Work lamp relay Mounting plate Starter control relay Pilot control relay Horn relay Relay harness https www tractormanualpdf info ...

Page 666: ...nual June 2013 2 Removal 1 Remove relay from its seat 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 ZX215 1006314 Relay seat Screw Relay Relay harness Mounting plate https www tractormanualpdf info ...

Page 667: ...1006315 32 31 23 0 34 33 24 0 12 105 11 0 65 63 13 64 0 70 72 71 0 15 13 21 0 606 105 27 0 Relay wiring terminals Horn relay K5 Work lamp relay K6 Pilot control relay K10 Starter control relay K3 Parking relay K7 Head lamp relay K8 Shutdown delay relay K9 Relay model HELLA 4RD 007 903 027 Harness socket terminals Socket model Jacket 8JA003526 00 https www tractormanualpdf info ...

Page 668: ...fferent temperatures Standard Value 50 0 2 C 80 10Ω 60 C 56 3Ω ref 80 C 29 5Ω ref 100 C 16 5Ω ref 106 0 3 C 14 3 1 0Ω 120 C 10Ω ref Replace the sensor if the measured value exceeds the standard one 2 Engine speed sensor check Measure the resistance between terminal 1 and terminal 2 Std Value 25 C 2 3 0 2kΩ Replace the sensor if the measured value exceeds the standard one 1 ZX215 1006316 Sensor bod...

Page 669: ...ween the upper limit and the lower limit of the float should be 500 mm Move the float to its upper limit Measure the resistance between the sensor terminal R and ground with a multimeter The mea sured resistance should be Ru 9 6Ω Move the float to its lower limit Measure the resistance between the sensor terminal R and ground with a multimeter The mea sured resistance should be Rd 86Ω 3 Pressure s...

Page 670: ...3 1 Insertion 1 Hold tightly a wire terminal at a distance of about 25 mm from its end 2 Hold the connector Let the rear seal face you 3 Align the terminal with a hole on the seal and push it perpendicularly to the bottom Slightly pull back the wire in order to en sure that the terminal is locked in place ZX215 1006320 ZX215 1006321 ZX215 1006322 https www tractormanualpdf info ...

Page 671: ...old the connector with its back end fac ing you Select a suitable tool and clip on the wire 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 3 Pull out the tool to remove the wire with terminal ZX215 1006323 ZX215 1006324 ZX215 1006325 https www tractormanualpdf info ...

Page 672: ...S A N Y L A T I N A M E R I C A 8 169 SY195 205 215 225C9 Crawler Hydraulic Excavator Disassembly and Assembly Shop Manual June 2013 B L A N K P A G E https www tractormanualpdf info ...

Page 673: ...S A N Y L A T I N A M E R I C A 8 170 SY195 205 215 225C9 Crawler Hydraulic Excavator Disassembly and Assembly Shop Manual June 2013 B L A N K P A G E https www tractormanualpdf info ...

Page 674: ...nual June 2013 9 1 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 9 8 https www tractormanualpdf info ...

Page 675: ...nd all safety precau tions and instructions in this manual be fore reading any other manuals provided with this machine and before operating or servicing the machine Also read the safety information on machine decals before per forming any operations Failure to do so can cause machine damage personal in jury or death https www tractormanualpdf info ...

Page 676: ...TO PnA2 TO MAIN VALVE PbL TO MAIN VALVE XBb1 BOOM DOWN BKT DUMP TO MAIN VALVE XBk BKT DIG TO MAIN VALVE XAk R SWING TO MAIN VALVE XBs L SWING TO MAIN VALVE XAs BOOM UP TO MAIN VALVE XAb2 TO MAIN VALVE XAb1 TO MAIN VALVE XAa2 TO MAIN VALVE XAa1 ARM IN TO MAIN VALVE XBa1 TO MAIN VALVE XBa2 TO MAIN VALVE PaL ARM OUT FRONT Engine REAR A P1 B A D1 P2 P4 P4 A B P1 B1 DR As A3 B3 PT D2 P3 PT D2 P3 A B PH...

Page 677: ...4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 6 7 8 9 10 1 2 3 4 5 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 CN M30 CN M29 0 5WO 0 5BG 0 5BW 0 5LgR 0 5R 0 5BL 0 5BrW 0 5OW 0 5GW 0 5PG 0 5BY 0 5RW 0 5RY 0 5BrY 0 5LO 0 5VR A C M 0 5PB 0 5YB 0 5VW 0 5WY 0 5WR 0 5Sb 0 5BR 0 5B 0 5GO 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 1...

Page 678: ...1M CN 661F 13 2 1 2 1 0 1 2 11 13 13 105 11 105 105 31 31 33 33 72 72 71 71 23 23 24 24 27 27 70 70 0 64 63 64 65 0 12 12 65 63 32 32 34 34 606 606 1 2 3 4 5 6 7 8 16 15 14 13 12 11 10 9 9 10 11 12 13 14 15 16 8 7 6 5 4 3 2 1 1 2 3 4 5 5 4 3 2 1 1 2 3 4 5 5 4 3 2 1 1 2 3 4 5 5 4 3 2 1 1 2 3 4 5 5 4 3 2 1 1 2 3 4 5 5 4 3 2 1 1 2 3 4 5 5 4 3 2 1 N M L K J I H G F E D C B A 1 2 3 4 5 6 7 8 9 HORN REL...

Page 679: ... 302F CN 332M CN 331F CN 304M 25 CN 305M CN 303M 16 18 17 18 17 70 70 72 35 L 506 00 00 35 L 506 72 50 50 3 1 5 7 3 1 5 7 2 1 3 24 24 14 14 10 10 0 0 37 37 36 36 35 H 35 H 33 33 25 25 11 11 16 13 13 22 22 3 1 5 7 3 1 5 7 7 5 1 3 1 2 3 5 4 6 12 10 11 9 8 7 7 8 9 11 10 12 6 4 5 3 2 1 START R1 TERMINAL OFF ON HEAT B ACC BR R2 C N M L K J I H G F E D C B A 1 2 3 4 5 6 7 8 9 TO CAB HARNESS CN 131M TO C...

Page 680: ...0 00 00 00 36 36 35 H 35 H 33 25 25 25 33 CN 150M CN 207F CN 110M CN 142M CN 161F CN 121F CN 107M CN 131M CN 132F 1 2 3 4 5 6 7 8 1 4 5 6 7 8 6 5 4 3 2 1 9 10 11 12 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 12 11 10 9 9 10 11 12 13 14 15 16 8 7 6 5 4 3 2 1 7 6 5 4 3 2 1 1 2 3 4 5 6 12 11 10 9 8 7 7 8 9 10 11 12 6 5 4 3 2 1 N M L K J I H G F E D C B A 1 2 3 4 5 6 7 8 9 TO WIPER MOTOR TO HORN S W TO PILOT S W...

Page 681: ... 22 CN 1 111M 8 7 6 5 4 3 2 1 CN 442F 9 10 11 12 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 12 11 10 9 CN 441M 81 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 ...

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