SY215CCM3K

Hydraulic Excavator
Maintenance Manual

● This manual is prepared for experienced technicians and aims to provide technical information
required for maintenance and repair of the machine.
● This manual may involve work equipment and optional devices not available in your region. You
may consult local dealers authorized by Sany Heavy Machinery Co., Ltd for ordering of these parts.
Materials and technical specifications are subject to change without prior notice.
 Sany Group
Sany Heavy Machinery Limited.
SANY Industrial Park, Economic and Technological Development Zone, Kunshan, Jiangsu, China
Postcode: 215300
http://www.sany.com.cn
Sales hotline: 021-57001111
After-sale service hotline: 4008 28 2318
Consultation and complaint telephone: 4008 28 2333

Since our technologies and products are constantly updated, materials and technical specifications are
subject to change without prior notice. Copyright©2012 Sany Group No part of this manual may be
reproduced, transmitted, sold or altered without the written permission of Sany Group.
SY215CCM3K Hydraulic Excavator Table of Contents

Contents
Table of
Contents
1 Foreword .......................................................................................................................................... 1-1
2 Safety ............................................................................................................................................... 2-1
3 Technical Specifications .................................................................................................................. 3-1
4 Structure and Function..................................................................................................................... 4-1
5 Standard Values of Components ..................................................................................................... 5-1
6 Testing and Adjustment ................................................................................................................... 6-1
7 Fault Diagnosis and Troubleshooting .............................................................................................. 7-1
8 Removal and Installation.................................................................................................................. 8-1
9 Hydraulic and Electrical Diagrams ................................................................................................... 9-1

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Table of Contents SY215CCM3K Hydraulic Excavator

II Service Manual.10-2017
SY215CCM3K Hydraulic Excavator Foreword

Foreword
Contents
How to read this manual.......................................................................................................................... 1-2
1. Constitution of the manual .................................................................................................................. 1-2
2. Revision and distribution ..................................................................................................................... 1-2
Terminology note for maintenance standard .......................................................................................... 1-4
Treatment of electrical and hydraulic components ................................................................................. 1-6
Pipe connector....................................................................................................................................... 1-15
Table of Standard Tightening Torque ................................................................................................... 1-18
Bolt type ................................................................................................................................................. 1-19
Bolt tightening sequence ....................................................................................................................... 1-19
Maintenance of split flange ................................................................................................................... 1-20
Conversion table ................................................................................................................................... 1-21
Temperature .......................................................................................................................................... 1-25

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Foreword SY215CCM3K Hydraulic Excavator

How to read this manual

●Some accessories and optional parts covered in this manual may not be transported to particular
areas. Please consult your local Sany authorized distributors if required.
● Materials and technical specifications are subject to change without prior notice.

1. Constitution of the manual

This manual contains technical information necessary for maintenance in workshops. To facilitate the
understanding, this manual is divided into the following:
Foreword
This chapter introduces the main content of this manual, how to use it, contact information and the basic
reference information of other chapters.
Safety
This chapter covers the meanings of safety signs contained herein and the basic safety information
involved in equipment maintenance.
Technical Specifications
This chapter introduces the machine performance, main parameters and related information.
Structure and Function
This chapter provides a structure description of each system, and explains the operating principle of
each system or part and the maintenance standard of each part.
Standard Values of Components
This chapter lists the standard values of components of a new machine as a criteria and guidance for
testing, adjustment and troubleshooting.
Test and adjustment
This chapter introduces the methods for testing and adjustment, as well as the necessary tools and
instruments.
Fault Diagnosis and Troubleshooting
This chapter introduces the approaches to find and repair faulty parts. Fault diagnosis covers the
electrical system, the engine, the hydraulic and mechanical systems, as well as the machine monitoring
system.
Removal and refitting
This chapter describes the steps to follow and related matters needing attention in removal, installation,
disassembly or assembly of parts.
Hydraulic and Electrical Diagrams
This chapter mainly describes the hydraulic circuit diagram, electrical schematic diagram, wiring
diagram, etc.

2. Revision and distribution

Any additions, modifications or changes to other precautions will be forwarded to our designated
dealers. Make sure to obtain the latest information before you begin any work.

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3. Archive method
The manual shall indicate the reference number on the back cover according to Sany Reference Version 1
Management System, and shall be bound in a volume and kept on file in the reference room.
● Revision mark
Add 1 to the accumulated version number in the reference number when a manual is revised.
4. Symbols
Important sections relating to safety and quality are marked by the following symbols to make this
manual more practicable.
Symbol Item Remarks
Safety Special safety precautions in operation.
Special precautions for technical issues or other
CAUTION
precautions for keeping to standards in operation
Weight of parts that needs attention when selecting a
Weight hoisting wire rope, or when the working posture is of great
importance
Tightening A position for which the tightening torque requires
torque particular attention during assembly
A position that requires an application of adhesive, etc.
Coating
during assembly
A position that requires filling of oil, water, etc., and the
Oil, coolant
filling capacity
A position that requires discharge of oil, water, etc., and
Discharge
the discharge quantity
5. Units
The international system of units (SI) is used in this manual. The gravitational system of units in { } which
is used by convention is provided for reference only.

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Terminology note for maintenance standard

The standard values for maintenance of products
and parts are described as follows:
1. Standard dimension and tolerance
● To be exact, the machining dimensions
of parts are slightly different from each
other.
● To specify the machining dimension of a
part, we need to set a temporary
standard size and indicate the allowable
deviation from it.
● The abovementioned temporary
dimension is referred to as the ―standard
dimension‖, and the range of deviation
from the standard value is referred to as
the ―tolerance‖.
● The tolerance with + or - is indicated on
the right of standard size.
For example: Unit: mm
Standard size Tolerance
120 –0.022
–0.126

★ A tolerance may be indicated by a

―standard value (upper/lower limit)‖ in a
text or table. For example: 120
(-0.022/-0.126)
● Generally, the dimension of a hole and
its fitting shaft are indicated by the same
standard dimension and the tolerance Standard size Φ60
Tolerance of the hole
between them. The tightness of (upper side) + 0.046
installation is determined by the Standard clearance (max.) :
0.122
tolerance. Standard clearance (min.) :
0.030
● Dimension indication of the rotating shaft Tolerance of the shaft
(lower side): -0.076
and the hole, and dimension relation Tolerance of the shaft
diagram. (upper side): -0.030

For example: Unit: mm

Tolerance
Standard size
Shaft Hole
-0.030 +0.046
Φ60
-0.076 0

Fig. 1-1

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2. Standard clearance and standard value 5. Clearance limit 1

● The clearance occurring in assembly of a ● Parts can be used until the clearance
new part is referred to as the ―standard between them exceeds a certain limit.
clearance‖, expressed by the range from The limit at which these parts can no
the minimum to the maximum clearance. longer be used is referred to as the
―clearance limit‖.
● During repair of parts, the clearance is
generally adjusted to be a standard ● These parts must be replaced or
clearance. repaired if the clearance between them
exceeds such a limit.
● The value or an equivalent of
performance/function of a new product is 6. Limit of interference
referred to as the ―standard value‖, which
● The maximum allowable interference
is expressed by a range or target value.
between the hole of a part and the shaft
● During repair of parts, the of a part to be fitted is referred to as the
performance/function value is set as the ―limit of interference‖.
standard value.
● The limit of interference indicates the
3. Standard interference repair limit of a part with a smaller
tolerance.
● If the size of a hole is less than that of a
shaft fitted to it due to the standard value ● These parts must be replaced or
and the tolerance, such difference is repaired if the interference between them
referred to as the ―interference‖. exceeds such a limit.
● The range (A-B) from the difference (A)
between the minimum shaft size and the
maximum hole size to the difference (B)
between the maximum shaft size and the
minimum hole size is referred to as the
―standard interference‖.
● After repair or replacement of parts, it is
necessary to check the sizes of their
holes and shafts, and whether the
interference is within the standard range.
4. Repair limit and allowable value
● Changes will occur to the sizes of parts
during the use due to wear and
deformation. The limit of size change is
referred to as the ―repair limit‖.
● A part worn to the repair limit must be
replaced or repaired.
● The product performance and function
will be degraded if such a part is used.
The value below is referred to as the
―allowable value‖ at which products can
be used without problems.
● A product worn to the allowable value
must be inspected or repaired. Because
the allowable value is estimated from
tests or based on many situations.
However, no judgment can be made until
the operating conditions and customer
requirements are taken into account.

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Treatment of electrical and hydraulic components

After long-time service, it is necessary to maintain the machine performance and prevent faults or other
troubles. It is a must to carry out correct ―operation‖, ―maintenance and inspection‖, ―fault diagnosis‖ and
―repair‖. This part especially discusses correct repair procedures and aims to improve the repair quality.
For this purpose, the ―treatment of electrical components‖ and ―treatment of hydraulic components‖
(especially for gear oil and hydraulic oil) sections are provided.
Precautions for treatment of electrical
components
1. Treatment of harness and connectors
A harness consists of wires from a component
to another, connectors connecting two wires or
disconnecting a wire from another and a cover
or tube protecting wires.
Compared to electrical components in boxes or
cases, harnesses are more likely to be directly
affected by rain, water, heat or vibration.
Furthermore, they are frequently removed and
refitted during inspection and repair, so they
may be easily deformed or damaged. For this
reason, they must be treated with great care. Fig. 1-2

2. Main faults in harness

1) Poor contact between connectors (poor
contact between male and female
connectors) Incorrect insertion and
connection

Poor contact may occur when a male

connector is not inserted in a female
connector correctly, or no correct
alignment is made due to deformation, or
corrosion and oxidation appear on the
contact surface.

Fig. 1-3

2) Edge curling or brazing fault

When the pins of male and female
connectors make contact with an Edge-curling position
edge-curling terminal or welding position,
if wires come under much stress, the
plating at the connector will peel off,
thereby causing incorrect connection or
fracture.

Fig. 1-4

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3) Disconnection of wires 1
If you hold the wire while pulling out the
connector, or use a crane to lift the part
still connected to the connector, or use a
weight to strike the wire, the curled edge
of the connector may be separated, or the
welding point and the wire may be
damaged.

Fig. 1-5

4) High pressure water in the connector

The connector is of a waterproof
structure, but water may enter it when
high pressure water is directly injected
onto it and the direction of water injection
nozzle is not proper. Therefore, try to
avoid water splash onto the connector.
The connector is of waterproof
construction but hard to drain off water if
any. If water enters the connector and
therefore causes short circuit in its pin, it
is a must to immediately dry it or take
other appropriate measures before
applying power to it.
Fig. 1-6

5) Oil or sludge on the connector

Contact fault may occur when oil or
grease sticks to the connector and forms
an oil film on the mating surface between
male and female pins, making it
impossible for passage of current. When
oil or grease sticks to the connector, wipe
off with a dry cloth or dry with compressed
air which must be injected from a contact
restorer.
★ When wiping the mating part of the
connector, avoid excessive force or
deforming the pin.
★ The contact will get even dirtier if Fig. 1-7
compressed air contains oil or water,
therefore, oil and water must be
thoroughly removed from
compressed air before cleaning.

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3. Removal, installation and drying of

connector and harness
1) Disconnection of the connector
a Hold the connector when
Gently depress the locking
disconnecting it. spring during removal.

Hold the connector when Locking spring

disconnecting it. For connectors

fixed by screws, loosen the screws
and disconnect the male and female
connectors while holding them with
two hands. For connectors with a
locking spring, depress the spring
with your thumb and pull out the
connector. Fig. 1-8
★ Never pull out the connector
with one hand.
b Removal from the clamp
● Both the connector and the clamp have a
stop, and they will mesh with each other
when the connector is being installed.

Both are stops.

Fig. 1-9

● To remove a connector from a clamp, pull

it out in the direction parallel to the clamp
to take apart the stop.
★ If the connector is twisted up and
down or side to side, the housing
may be damaged.

Fig. 1-10

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c Measures to be taken after removal 1

of the connector
Before removal of any connector,
cover with a polythene bag to
prevent ingress of dust, sludge, oil or
water.
★ Poor contact may easily occur
when the machine remains
decoupled for a long time,
therefore, the connector must
be wrapped up with the bag
mouth fastened.

Fig. 1-11

2) Connection of the connector

a Visually checking the connector
Check that no oil, sludge or water
Click in place
sticks on the connector pin (mating
part). Check that the connector pin
has no deformation, contact fault,
rust or damage. Check that the
connector has no damage or cracks
on the outside.
★ If any, wipe off the oil, water or
sludge on the connector with a
dry cloth. If water enters the
connector, heat the inside of
wires with a dryer, taking care Fig. 1-12
not to make it too hot as this can
cause short circuit.
★ Replace the connector with any
damage or cracks.

b Fixing the connector

Align the connector with its location
while inserting it in place. For
connectors with a locking spring,
push the connector in until the spring
clicks in place.

Fig. 1-13

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c Correcting the bulge of shield and

misalignment of harness
For connectors with a shield, correct
its bulge. Besides, adjust the
misaligned harness or the clamp not
in place to the correct position.
★ If the connector cannot be
easily corrected, remove the
clamp and adjust the position.
● If the connector clamp is
removed, make sure to return it
to the normal position. And
check that the clamp is not
loose. Fig. 1-14

3) Connection of DT connector
Since the high-power wire connectors of
DT8 pin and 12# pin respectively have
two keys which shall be pushed in until
two clicks are heard.
• Male connector: 1
• Female connector: 2
Normally locked (horizontal): a, b, d
Partly locked (diagonal): c

Fig. 1-15

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4) Drying of harness
1
If any, wipe off oil or sludge on the
harness with a dry cloth. Avoid using
water or steam for washing. If you need to
wash the connector in water, do not apply
high pressure water or steam to the
harness. If water is directly applied to the
connector, proceed as follows.
a Disconnect the connector and wipe
off water with a cloth.
★ Remove oil and water
thoroughly before purging with
compressed air because the oil
in the air can cause contact
Fig. 1-16
fault.
b Dry the inside of the connector with a
dryer.
If water enters the connector, dry it
with a dryer.
★ You may use hot air from the
dryer, but you need to adjust the
duration to prevent the
connector or associated part
from getting too hot, as this can
cause deformation or damage
of the connector.
c Conduct connectivity test of the
connector
After drying, keep the harness
disconnected and carry out
connectivity test to check whether
short circuit occurs between pins
due to water.
Fig. 1-17
★ After drying the connector, dry it
with a contact restorer and refit
it.

T joint

Fig. 1-18

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Foreword SY215CCM3K Hydraulic Excavator

4. Treatment of controller
1) The controller contains a microcomputer
and an electronic control circuit. The
controller must be handled with great care
because it controls all the electronic
circuits in the machine.
2) Do not put items on the controller.
3) Cover the control connector with a strap or
polythene bag. Never touch the connector
contact.
4) On rainy days, do not put the controller in
a place exposed to rain splash.
5) Do not put the controller in oil, water or
soil, or any hot place even for short Fig. 1-19
periods of time. (Put it on a suitable dry
rack)
6) Precautions for arc welding
Before arc welding on the machine body,
disconnect all the harness connectors to
the controller. Install an arc welding GND
Toolbox
next to the welding spot.

Fig. 1-20
5. Considerations for diagnosis of circuit fault
1) Always turn off the power before
disconnecting or connecting the
connector.
2) Check if all related connectors are
correctly plugged before fault diagnosis.
★ Check the associated connector by
disconnecting and connecting it
several times.
3) Always connect all the disconnected
connectors before going to next step of
operation.
★ When the power is turned on with
connectors disconnected, undesired
abnormal indication will occur. Fig. 1-21
4) When circuit fault diagnosis (measurement
of voltage, resistance,connectivity or
current) is undergoing, related wires and
connectors should be moved for several
times and the meters readings checked to
be unchanged.
★ If there is a change, contact fault may
occur in the circuit.

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Precautions for treatment of hydraulic components

The most common fault cause is the sludge (foreign matter) in the hydraulic circuit due to the pressure 1
increase and accuracy improvement of hydraulic components. Special care must be taken for adding of
hydraulic oil or disassembly or assembly of hydraulic components.

1. Operating environment
Avoid adding hydraulic oil, replacing the filter or
repairing the machine in the rain or strong wind
or a dusty place.
2. On-site disassembling and maintenance
operations
On-site disassembly and maintenance of
hydraulic components may cause ingress of
dust. It is also difficult to check the
performance after repair, so you’d better
replace them with an assembly unit.
Disassembly and maintenance of hydraulic
components shall be carried out in a specially
prepared dust-proof workshop, and the Fig. 1-22
performance shall be checked by special test
equipment.

3. Sealing of openings
After removal of a pipe or component, seal the
opening with a cover, strap or polythene bag to
prevent ingress of sludge or dust. Don’t do that
because sludge may enter or the peripheral
area may be contaminated by spilled oil if
openings are left uncovered or blocked by
rags. Do not simply discharge oil to the ground,
instead, collect oil and ask the customer how to
dispose of it, or directly bring it back for proper
disposal.

Fig. 1-23

4. Prevent ingress of any sludge, pollutant or

dust during refilling.
Prevent ingress of any sludge or dust when
adding hydraulic oil. Make sure to keep
cleanliness of the oil filter and the area around
it, and use a clean pump and an oil container.
An oil cleaning device, if used, is a more
effective means for filtering out the sludge
accumulated in storage process.

Fig. 1-24

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5. Change the hydraulic oil under high

temperature
Hydraulic oil or other oil is easy to move when
kept warm. Besides, sediments may be easily
expelled from the oil circuit together with oil.
Therefore, it is best to replace the oil while hot.
During oil changing, drain the used hydraulic oil
as much as possible. (Drain oil from hydraulic
tank; and drain oil from the filter and the drain
plug in the oil circuit.) The impurities and
sediments in the used oil, if any, will be mixed
with the new oil and thereby shorten the
service life of hydraulic oil.

6. Flushing
Remove the impurities, sediments and used oil
in the hydraulic lines with flushing oil after
disassembly and assembly of devices or after
oil changing. Normally, twice flush is needed: Flushing oil

use flushing oil for primary flushing, and

designated hydraulic oil for secondary flushing.

Fig. 1-25

7. Cleaning
Use oil to remove sediments or impurities from
the hydraulic circuit after repair of hydraulic
components (pump, control valve, etc.) or
when the machine is running. The oil cleaning
device is highly effective because it is used for
removing ultra fine particles of about 3μ to
make it impossible to remove the filter built in
the hydraulic component.

Fig. 1-26

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Pipe connector 1
The pipe connector is used for connecting
small-diameter pipes. The metallic sealing surfaces
(4) and (5) of the connector (1) and the hose (2) fit
together to seal the pressure oil.

CAUTION

● The nut (3) shall not be overtightened.

The nut (3) must be tightened to the Connector
technical specification as excessive force body
will act upon the metallic sealing surfaces
(4) and (5) and may thereby make the
connector (1) broken.
Fig. 1-27
● Scratches or other damage on the sealing
surfaces (4) and (5) can cause oil leak at
the junction. Take care to avoid damaging
the sealing surfaces during
connection/removal.

Type of pipe connector

Male type Female type

Fig. 1-28

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Tightening torque of pipe connector

Wrench size, mm Wrench size, mm Tightening torque
Type
Connecting nut Hose coupler N·m（kgf·m,Ibf·ft）
19 19 59（6,44）
22 22 98（10,72）
27 27 118（12,87）
36 36 235（24,173）
24°, male type
41 41 295（30,218）
50 50 490（50,361）
60 60 670（68,494）
70 70 980（100,723）
19 17 44（4.5,32）
22 19 59（6,44）
27 22 118（12,87）
24°, female type
36 30，32 235（24,173）
41 36 295（30,218）
50 46 490（50,361）

CAUTION

● The torques in the table are for routine use only.

● Use a different torque instead of those given in the table when specified on special
occasions.

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Connection of O-ring
1
The O-ring (6) fits the end face of the connector (7)
to seal the high pressure oil.

Hose coupler

Fig. 1-29

CAUTION
• When reconnecting the pipe, be sure to replace the O-ring (6) with a new one.
• Before tightening the nut (9), check that O-ring (6) is correctly placed in its groove (8). If the
O-ring (6) moves when the nut (9) is being tightened, the O-ring (6) will be damaged, causing
oil leakage.
● Take care not to damage the O-ring groove (8) or the sealing surface (10). Damage to the
O-ring (6) will cause an oil leak.
● If the nut (9) is found loose and thus causes oil leakage, do not stop the leakage by
tightening the nut (9), instead, replace the O-ring (6) with a new one and check that it is
reliably put in place, and then tighten the nut (9).

Wrench size, mm Wrench size, mm Tightening torque

(Connecting nut) (Hose coupler) N·m（kgf·m,Ibf·ft）
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）

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Table of Standard Tightening Torque

Table of Tightening Torques of Bolts and Nuts
★ Unless a special device is provided, the nuts and bolts shall be tightened to the values below. (When
a torque wrench is used)
Hex Hex bolt Hexagon socket head bolt
Bolt Bolt Wrench
wrench
diameter grade size N·m kgf·m lbf·ft N·m kgf·m lbf·ft
size
M6 10.9 10 4 13.2 1.37 9.74 13.2 1.37 9.74
M8 10.9 13 6 31 3.16 22.87 31 3.16 22.87
M10 10.9 17 8 66 6.73 48.7 66 6.73 48.7
M12 10.9 19 10 113 11.53 83.39 113 11.53 83.39
M14 10.9 22 12 177 18.06 130.6 177 18.06 130.6
M16 10.9 24 14 279 28.47 205.9 279 28.47 205.9
M18 10.9 27 14 382 38.98 281.9 382 38.98 281.9
M20 10.9 30 17 549 56.02 405.16 549 56.02 405.16
M27 10.9 41 19 1320 134.7 974.16 1320 134.7 974.16
M10 12.9 17 6 78 7.96 57.76 78 7.96 57.76
M12 12.9 19 8 137 13.98 101.1 137 13.98 101.1
M16 12.9 24 14 339 34.6 250.18 339 34.6 250.18
M20 12.9 30 17 664 67.75 490 664 67.75 490

CAUTION

● The following items apply to fine and coarse threads.

1. Apply the lubricant (zinc white B dissolved in spindle oil) to the nuts and bolts to reduce
their friction coefficients. Lubricants are not required for thrust bolts.
2. The tolerance of torques is ±10%.
3. Be sure to use bolts of correct length. An overlong bolt cannot be screwed tight, as its
top touches the bottom of bolt hole. A too short bolt cannot achieve enough tightening
force.
4. The torques given above are only for general purpose. Use a different torque instead of
those given in the table when specified on special occasions.
5. Before installing a nut or bolt, check that the thread is clean. Remove dirt or rust if any.

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Bolt type
1
The nuts or bolts shall be correctly tightened to the
specified torque. The bolt type and grade are as
shown at right. When assembling a machine or
component, make sure to use correct bolts and
Hexagon head bolt Hexagon socket
correctly tighten them. head bolt

Fig. 1-30

Bolt tightening sequence Tighten upward and downward

alternately and equally
Tighten according to the diagonal

When tightening two or more bolts, tighten them

alternately, as shown on the right, to ensure the
force is uniform.

CAUTION Tighten from the center and according to

the diagonal
● The tools used shall be suitable for the
operation. Casual use of inappropriate
tools or rules may cause a safety hazard.
● Use a properly sized tool to loosen or
tighten the nuts and bolts, otherwise,
personal injuries can occur if the
tightening device slips. Fig. 1-31

Fig. 1-32

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Maintenance of split flange

1) Wipe clean the sealing surface and do an
inspection. Scratches/irregularities will cause a
leak or wear of seals. Unevenness will make
seals squeezed out; parts shall be replaced if
these defects cannot be removed.
2) Make sure to use a specified O-ring and check
whether it is damaged; do not file its surface
with a file, and adjust its position with
lubricating grease when placing it in its groove.

Fig. 1-33

3) Gently tighten the split flange, locating its

opening at the center to make it perpendicular
to the oil port, and tighten the bolt by hand to
keep the part in place. NG

Fig. 1-34

Table of Tightening Torques of Split Flange Bolts

★ Unless a special device is provided, the nuts of split flange shall be tightened to the values below.

Thread diameters of
Widths across flats Tightening torque
bolts
mm mm N·m kgf·m
10 14 59～74 6.0～7.5
12 17 98～123 10.0～12.5
16 22 235～285 23.5～29.5

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SY215CCM3K Hydraulic Excavator Foreword

Conversion table
1
How to use the conversion table
This part provides a conversion table for simple numeric conversion. See the following examples for the
detailed use of conversion table. Example: Conversion from mm to inch
1. Conversion of 55 mm to inch
1) Locate the number 50 in the left vertical column and denote it as (A), then draw a horizontal
line from it.
2) Locate the number 5 in the top horizontal row and denote it as (B), then draw a vertical line
down from it.
3) Denote the point where two lines intersect as (C). This point (C) shows the resultant numerical
value. So, 55 mm = 2.165 in.
2. Conversion of 550mm to inch
1) Since the number 550 is not shown in the table, we divide it by 10 (move the decimal point one
place to the left) to obtain 55 mm.
2) Convert 55 mm to 2.165 in. according to the same steps described above.
3) Since the raw value (550 mm) is divided by 10, we need to multiply 2.165 in. by 10 (move the
decimal point one place to the right) to return to the initial value. Then, 550 mm = 21.65 in.
Conversion from mm to in.
B 1mm=0.03937in
0 1 2 3 4 5 6 7 8 9
0 0.000 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0. 394 0. 433 0. 472 0. 512 0. 551 0.591 0. 630 0. 669 0. 709 0. 748
20 0. 787 0. 827 0. 866 0. 906 0. 945 0.984 1. 024 1. 063 1. 102 1. 142
30 1. 181 1. 220 1. 260 1. 299 1. 339 1.378 1. 417 1. 457 1. 496 1. 535
40 1. 575 1. 614 1. 654 1. 693 1. 732 1.772 1. 811 1. 850 1. 890 1. 929
(A) （C）
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2. 362 2. 402 2. 441 2. 480 2. 520 2.559 2. 598 2. 638 2. 677 2. 717
70 2. 756 2. 795 2. 835 2. 874 2. 913 2.953 2. 992 3. 031 3. 071 3. 110
80 3. 150 3. 189 3. 228 3. 268 3. 307 3.346 3. 386 3. 425 3. 465 3. 504
90 3. 543 3. 583 3. 622 3. 661 3. 701 3.740 3. 780 3. 819 3. 858 3. 898

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Foreword SY215CCM3K Hydraulic Excavator

Conversion from mm to in.

1mm=0.03937in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0. 394 0. 433 0. 472 0. 512 0. 551 0. 591 0. 630 0. 669 0. 709 0. 748
20 0. 787 0. 827 0. 866 0. 906 0. 945 0. 984 1. 024 1. 063 1. 102 1. 142
30 1. 181 1. 220 1. 260 1. 299 1. 339 1. 378 1. 417 1. 457 1. 496 1. 535
40 1. 575 1. 614 1. 654 1. 693 1. 732 1. 772 1. 811 1. 850 1. 890 1. 929
50 1. 969 2. 008 2. 047 2. 087 2. 126 2. 165 2. 205 2. 244 2. 283 2. 323
60 2. 362 2. 402 2. 441 2. 480 2. 520 2. 559 2. 598 2. 638 2. 677 2. 717
70 2. 756 2. 795 2. 835 2. 874 2. 913 2. 953 2. 992 3. 031 3. 071 3. 110
80 3. 150 3. 189 3. 228 3. 268 3. 307 3. 346 3. 386 3. 425 3. 465 3. 504
90 3. 543 3. 583 3. 622 3. 661 3. 701 3. 740 3. 780 3. 819 3. 858 3. 898
From kg to lb
1kg=2.2046.lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 90.39 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 112.43 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 134.48 55.12 57.32 59.52 61.73 63.93
30 66.14 68.34 70.55 72.75 156.53 77.16 79.37 81.57 83.77 85.98
40 88.18 90.39 92.59 94.80 178.57 99.21 101.41 103.62 105.82 108.03
50 110.23 112.43 114.64 116.84 200.62 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 222.66 143.30 145.50 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 244.71 165.35 167.55 169.75 171.96 174.16
80 176.37 178.57 180.78 182.98 266.76 187.39 189.60 191.80 194.00 196.21
90 198.41 200.62 202.82 205.03 288.80 209.44 211.64 213.85 216.05 218.26
From l to U.S.Gal
1l=0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.114 2.378
10 2. 642 2. 906 3. 170 3. 435 3. 699 3. 963 4. 227 4. 491 4. 756 5. 020
20 5. 284 5. 548 5. 812 6. 077 6. 341 6. 605 6. 869 7. 133 7. 398 7. 662
30 7. 926 8. 190 8. 454 8. 719 8. 983 9. 247 9. 511 9. 775 10.040 10.304
40 10.568 10.832 11.096 11.361 11.625 11.889 12.153 12.417 12.682 12.946
50 13.210 13.474 13.738 14.003 14.267 14.531 14.795 15.059 15.324 15.588
60 15.852 16.116 16.380 16.645 16.909 17.173 17.437 17.701 17.966 18.230
70 18.494 18.758 19.022 19.287 19.551 19.815 20.079 20.343 20.608 20.872
80 21.136 21.400 21.664 21.929 22.193 22.457 22.721 22.985 23.250 23.514
90 23.778 24.042 24.306 24.571 24.835 25.099 25.363 25.627 25.892 26.156

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SY215CCM3K Hydraulic Excavator Foreword

From I to U.K.Gal
1l=0.21997 U.K.Gal 1
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2. 200 2. 420 2. 640 2. 860 3. 080 3. 300 3. 520 3. 739 3. 959 4. 179
20 4. 399 4. 619 4. 839 5. 059 5. 279 5. 499 5. 719 5. 939 6. 159 6. 379
30 6. 599 6. 819 7. 039 7. 259 7. 479 7. 699 7. 919 8. 139 8. 359 8. 579
40 8. 799 9. 019 9. 239 9. 459 9. 679 9. 899 10.119 10.339 10.559 10.779
50 10.999 11.218 11.438 11.658 11.878 12.098 12.318 12.538 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.038 18.258 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
From kgm to ft.lb
1 kgm=7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7
60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.6 1048.8 1056.0 1063.3 1070.5 1077.7
150 1085.0 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1229.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.2 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

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Foreword SY215CCM3K Hydraulic Excavator

From kg/cm2 to lb/in2

1 kg/cm2=14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.3 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.0 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 996 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2133 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2390 2404
170 2418 2432 2446 2461 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2774 2788 2802 2816 2830
200 2845 2859 2873 2887 2902 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3342 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

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SY215CCM3K Hydraulic Excavator Foreword

Temperature
1
Conversion from Fahrenheit to Celsius: a simple way to convert a temperature reading from Fahrenheit
to Celsius or vice versa is to enter the center of values (in bold) in the attached table. These values
involve both Fahrenheit and Celsius temperatures. To convert from Fahrenheit to Celsius, consider the
center column as the Fahrenheit scale and read the corresponding Celsius temperature in the left
column. To convert from Celsius to Fahrenheit, consider the center column as Celsius temperatures and
read the corresponding Fahrenheit temperature in the right column.
℃ ℉ ℃ ℉ ℃ ℉ ℃ ℉
-40.0 -40 -0.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0.0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.8 146 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

Service Manual.10-2017 1-25

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1-26 Service Manual.10-2017

SY215CCM3K Hydraulic Excavator Safety

Safety

Instructions for safety decals................................................................................................................... 2-3

Safety signal terms .................................................................................................................................. 2-3
Other signal terms ................................................................................................................................... 2-3
General precautions ................................................................................................................................ 2-4
Safety Rules ............................................................................................................................................ 2-4
Keep working area tidy ............................................................................................................................ 2-5
Fluid storage ............................................................................................................................................ 2-5
Part washing ............................................................................................................................................ 2-6
Hydraulic excavator cleaning .................................................................................................................. 2-6
Decent clothing ........................................................................................................................................ 2-6
Personal protective equipment (PPE) ..................................................................................................... 2-7
Correct use of tools ................................................................................................................................. 2-7
Fire extinguisher and emergency exit ..................................................................................................... 2-7
Preparations before maintenance ........................................................................................................... 2-8
Preparations before working ................................................................................................................... 2-8
Warning sign plate................................................................................................................................... 2-9
Self-preparation ..................................................................................................................................... 2-10
Precautions for maintenance ................................................................................................................ 2-11
Work during engine running .................................................................................................................. 2-11
Dismantling accessories of hydraulic excavator ................................................................................... 2-12
Working under hydraulic excavator ....................................................................................................... 2-12
Adding or replacing fluid ........................................................................................................................ 2-12
Parts alignment...................................................................................................................................... 2-13
When a hammer is used ....................................................................................................................... 2-13
When compressed air is used ............................................................................................................... 2-13
Welding .................................................................................................................................................. 2-13
Spring for track tension ......................................................................................................................... 2-14
Safe operation for high pressure hoses ................................................................................................ 2-14
Be careful when you work with high-pressure fluid............................................................................... 2-15
Be careful when you work with hot coolant ........................................................................................... 2-15
HVAC group .......................................................................................................................................... 2-16
Electrical safety ..................................................................................................................................... 2-16

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Safety SY215CCM3K Hydraulic Excavator

Switching power off ............................................................................................................................... 2-16

Battery operation ................................................................................................................................... 2-17
Accumulator........................................................................................................................................... 2-17
Reducing fire and explosion risks ......................................................................................................... 2-18
Proper disposal for waste ...................................................................................................................... 2-18
Miscellaneous ........................................................................................................................................ 2-19
Precautions for hoisting and signaling .................................................................................................. 2-19
Precautions for using mobile crane ....................................................................................................... 2-21
Precautions for using bridge crane ....................................................................................................... 2-21
Selection of wire ropes .......................................................................................................................... 2-22

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SY215CCM3K Hydraulic Excavator Safety

Instructions for safety decals

Most accidents are usually caused by failure to follow basic process and safety rules for maintenance 2
during operation. To ensure that you safely maintain and repair the hydraulic excavator, please
familiarize yourself with and understand the maintenance and repair skills in this manual. Some of them
require special tools designed by Sany Heavy Machinery Co., Ltd. for special purpose.

Safety signal terms

The following signal terms are used to inform you of hazardous situations that may potentially cause
personal injuries or damage. In this manual and on the hydraulic excavator plate, the following signal
terms are used to indicate levels of potential danger.
Indicates a critical hazardous situation that, if not avoided, will result in death or severe
DANGER injuries.

Indicates a potential hazardous situation that, if not avoided, may result in death or
WARNING severe injuries.

Indicates a potential hazardous situation that, if unavoidable, may result in minor or

CAUTION medium damage, and may also be used to alert against, for example, unsafe operations
that may result in personal injuries, hydraulic excavator and environmental damages.

In this manual, this symbol is used to identify safety precautions. Precautions identified by these
signals must be strictly followed. If there is or might be any hazardous situation, put safety first and
take necessary actions.

For operations prohibited, use Warning as shown to warn the users.

Other signal terms

In addition to the above, the following signal terms are used to indicate conditions that should be
complied with in order to protect the hydraulic excavator, or to provide you with very useful information.
Note is used to indicate measures that must be taken to avoid shortening the service life of hydraulic
excavator.
Remarks provide very useful information.

Warning
● Incorrect maintenance operations are very dangerous and may result in severe injuries or
death.
● Always read through and understand this manual before maintaining the hydraulic
excavator.
● In no case can applications and operations prohibited in this manual be carried out. If the
operation to be carried out is not explicitly prohibited in this manual, guarantee the safety of
yourself and others.
● If fuel amount, particulate size or latitude exceeds the upper limit specified for the model and
application, it may result in injuries and is not covered by the warranty.
● Machine provided by Sany Heavy Machinery Co., Ltd. to purchasers of various countries
meet all applicable regulations and standards. If a hydraulic excavator is purchased from
another country or from someone else in another country, it may lack of some safety devices
and cannot meet the technical requirements for use in your country. If you have any
questions about the machine’s compliance with national standards and regulations for use,
contact the dealers authorized by Sany Heavy Machinery Co., Ltd before using it.

Service Manual.10-2017 2-3

Safety SY215CCM3K Hydraulic Excavator

General precautions
It is very important to develop appropriate safety rules and post or hang them in conspicuous places for
all persons visiting or using the workshop. If possible, provide the workshop staff with safety rules in
written form and discuss with them or answer related questions from them. Following safety rules for
workshop can ensure the safety of staff and create the most suitable environment for working and
learning.
Always remember that putting safety first. And you shall not keep it in mind before you start work and
forget it when you have completed the work. Most accidents are caused by negligence, operations in
haste or disregard for safety rules. Keep it in mind that if you work carefully and strictly abide by the rules
in this manual, maintenance will be safe and enjoyable.

Warning
Improper operation can be quite dangerous. Before operation, please read through section
Safety in the Operation and Maintenance Manual.

Safety Rules
Before any lubrication or repair, please read all
safety plates on the hydraulic excavator. Refer to
the safety manual for location of safety plates and
detailed precautions.
Learn the safety rules related to the work process
and apply the learning to work. Please ask for help
instead of taking risk when there is any problem.
Only authorized workers are allowed to carry out
work that requires a license or a qualification
certificate.
Figure out the work you need to do. Maintain the
hydraulic excavator without any instructions may Fig. 2-1
result in major errors. If you are not sure which
procedure should be followed during maintenance,
refer to the Maintenance Manual. If you have any
question about the content and method of work,
please ask for help from other people.
Rough-and-tumble play is strictly prohibited in the
workshop. Because temporary ―happiness‖ may
cause permanent ―sadness‖. Distraction and small
talk during maintenance increases the risk of
injuries.
If you want to smoke, please smoke in the area
designated for smokers. Smoking is strictly
prohibited in the working area.

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SY215CCM3K Hydraulic Excavator Safety

Keep working area tidy

2
Fluids such as the oil, lubricating oil, fuel and
antifreeze splashed on the ground may cause
slipping, thus they should be cleared up immediately
if found. No matter who is responsible for clearing
up, everyone in the workshop should be obliged to
clean up spilled fluid on the ground.
Keep the workshop clean. Waste and used parts
should be cleaned up in time; it is forbidden to leave
waste and used parts on the work platform or the
ground of workshop.
All equipment and tools must be placed back in
place every time you use them. Please keep the
workshop clean and tidy in order to avoid accidents.
Keep in mind that good workshop hygiene is critical Fig. 2-2
to creating a safe and comfortable working
environment.

Fluid storage
Fluids such as the fuel, lubricating oil, coolant and
detergent should be stored properly in a place away
from the working area. Keep the storage area well
ventilated.
It is forbidden to place containers with fluids
randomly without cover, otherwise spillage of fluid
may cause fire. Carefully read the information about
fluid storage and operation on each container label.
Please properly store and dispose fluids in
accordance with labels on containers. It is forbidden
to pour a fluid into the container for storing another
fluid. Disorganized storage of fluids may result in
equipment damage, fire or explosion. Fig. 2-3
Do not smoke or use open fire around the fluids,
otherwise there is a risk for fire or explosion.
Wear personal protective equipment when you work
with fluids. Work with all the fluids carefully.

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Safety SY215CCM3K Hydraulic Excavator

Part washing
It is forbidden to use gasoline, diesel or other
flammable fluids to wash parts. Please use specified
flame-retardant solvent to wash parts, otherwise
there is a risk for fire and explosion.

Fig. 2-4

Hydraulic excavator cleaning

Use high-pressure hot water, mild and
non-flammable degreasing soap or detergent when
you clean the machine's components. Do not use
any flammable or corrosive detergent.
It is forbidden to use high-pressure steam cleaning
machine to clean the hydraulic excavator. Steam
cleaning machine may damage the paint, hoses,
and electrical system of the machine.
Do not wash or flush the inside of cab with high
pressure equipment. Otherwise, the internal
electrical elements may be damaged.

Fig. 2-5

Decent clothing
Indecent clothing, loose clothing, casual clothing,
wearing jewelry, unsuitable shoes and long hair may
result in personal injuries.
Make a list of dressing codes that specifying
prohibited clothing in workshop; check each worker
individually against the list before working.

Fig. 2-6

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SY215CCM3K Hydraulic Excavator Safety

Personal protective equipment 2

(PPE)
If there are specific provisions for personal
protective equipment used in workshop, PPE must
be worn in the workshop or in other areas where it is
required.
Personnel who do not properly wear the PPE are not
allowed to stay in the workshop.
Always ensure the PPE is intact. Replace it if
necessary.

Fig. 2-7

Correct use of tools

Before the work, thoroughly check the tools,
hydraulic excavator, forklift, crane and maintenance
vehicle required for work.
Choose right tools for a work. Use of unauthorized,
wrong, defective or broken tools may result in
severe personal injuries.
Make sure all the tools are intact and properly used.
Keep the tools clean. When the work has been
completed, sort and count the tools and store them
properly to ensure that no tool is left on the hydraulic
excavator.
Fig. 2-8

Fire extinguisher and emergency

exit
If there is a fire, it is important to know where the
emergency exits and fire extinguishers are.
Before the work, spend some time wandering about
the workshop and knowing where the emergency
exits and fire extinguishers are. If maintenance is
performed on site, fire extinguishers should be
provided nearby.
Please learn how to use the fire extinguisher
correctly.

Fig. 2-9

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Safety SY215CCM3K Hydraulic Excavator

Preparations before maintenance

Preparations before working
Please park the machine on some flat stable
ground. Lower the work equipment to the ground
and place it safely and stably.
Place cushion blocks under the track to prevent the
hydraulic excavator from moving.
Turn the throttle knob to 1st position to run the
engine at a low speed with no load for 5 minutes,
and then turn the ignition switch to ―OFF‖ position to
shut down the engine.
Turn the key switch to ON position, and then move
the control lever forwards and backwards, leftwards
and rightwards for 2 to 3 times to relieve pressure
from system. Fig. 2-10
Remove the key from the key switch and pull the
safety lock control lever to the locking position.
Make sure that there is no other people and
equipment in the working area; make sure that other
workers can see you (especially when maintenance
is performed on site).

Fig. 2-11

Fig. 2-12

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SY215CCM3K Hydraulic Excavator Safety

Warning sign plate 2

If two or more workers are to carry out the same
work at the same time, they should agree on the
workflow and communication signals. Be sure to
inform your colleagues before any step begins.
Before maintenance, place a ―DO NOT OPERATE‖
warning decal or equivalent on the starting switch for
hydraulic excavator or the direction control device to
warn others that the hydraulic excavator is being
maintained.
If necessary, an additional warning decal can be
attached around the hydraulic excavator.
If someone starts the engine, touches or operates Fig. 2-13
the control lever or pedal during maintenance,
serious accidents may occur.

Fig. 2-14

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Safety SY215CCM3K Hydraulic Excavator

Self-preparation
Only approved personnel can maintain or repair the
hydraulic excavator. An observer may be assigned if
necessary.
Wear protective clothing and safety shoes required
for work.
Wear a rubber apron and a pair of rubber gloves
when you are exposed to corrosive materials. Wear
a pair of protective gloves when you work with the
wood, wire ropes or sharp metal.
Wear a protective mask when you remove springs
and elastic components or top electrolyte up to
batteries. Wear helmets and eye protection when Fig. 2-15
you weld or cut something.
Grounding, flame cutting or welding is prohibited if
there is no breather and ventilator. If it is necessary
to perform welding on the hydraulic excavator, refer
to relevant manual for correct procedures.

Fig. 2-16

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SY215CCM3K Hydraulic Excavator Safety

Precautions for maintenance

2
Work during engine running
It is forbidden to start the hydraulic excavator during
maintenance unless specified otherwise in the
Maintenance Manual. If the machine must be started
during work, observe the following rules:
1) When your work in the area around the fan, fan
belt or other rotating parts, please be very
careful because there is a risk of being caught
by them.
2) Do not drop or insert tools or other objects in
fan or fan belt, which may cause the part to
break or fly out, resulting in personal injuries.
3) Pull the safety lock control lever to the locking
position to prevent the work equipment from Fig. 2-17
moving.
4) If you perform maintenance when the engine is
running, make sure that a worker sits on the
cab seat and is always ready to stop the
engine. All personnel must keep in touch with
each other.
5) It is forbidden for the worker in cab to touch any
control lever. If a control lever must be
operated, make sure that you can always see
other workers and can warn them to move swift
to a safe place before operation.
6) When the hydraulic excavator is in operation,
the surface of most parts will become hot, and
the surface temperature on some parts will
have very high.If necessary, always wear the
PPE when you work around high-temperature Fig. 2-18
parts to avoid burns.
7) When the hydraulic excavator is in operation,
the hydraulic system, cooling system and fuel
system may under high temperature and high
pressure. Thus, be careful when you work
around these systems.

Fig. 2-19

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Safety SY215CCM3K Hydraulic Excavator

Dismantling accessories of
hydraulic excavator
When it is necessary to dismantle large accessories
from the machine, be sure to use correct hoisting
equipment and ensure that the weight of load does
not exceed the rated hoisting capacity of equipment.
Dismantled accessories or components should be
properly placed to prevent them from falling or
moving. Make sure accessories or components are
stably placed on a flat surface and they should not
obstruct the pedestrian traffic or be the obstacle on a
fire fighting access.

Fig. 2-20
Working under hydraulic excavator
Lower the work equipment onto the ground before
maintaining the machine. Never maintain the
machine without supporting it securely.
If it is necessary to lift the machine or work
equipment for maintenance, support the work
equipment or machine with the cushion blocks or
brackets that strong enough to firmly support them.
Do not support the machine with slag bricks, hollow
tires or shelves, because they will collapse under
continuous load. And do not support the machine
with a single jack.
Working under the hydraulic excavator can be very
dangerous when the track shoe is away from the Fig. 2-21
ground and the hydraulic excavator is only
supported by the work equipment because once the
hydraulics routing has been damaged or the control
lever has been accidentally hit, the work equipment
or hydraulic excavator will suddenly fall, resulting in
casualty accidents. Therefore never work under the
machine if it is not firmly supported by the cushion
blocks or brackets.
Adding or replacing fluid
When you add or replace fluids for system,
remember that these systems may be under high
temperature and high pressure.
The engine should be switched off during operation.
The filler cap can only be unscrewed when the
system has been cooled down, otherwise it may
cause severe burns or the fluid to splash.
Slowly unscrew the filler cap, drain plug, or pressure
relief plug to prevent fluid from spraying.

Fig. 2-22

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SY215CCM3K Hydraulic Excavator Safety

Parts alignment 2
Be very careful when you install or align parts.
Align holes or bonding surfaces without the help of
your hands or fingers, for fear of crushing.
Use proper tools to align the parts with each other to
prevent injury to your hands or fingers.

Fig. 2-23

When a hammer is used

When you hit hard metallic parts such as the pins,
loading buckets teeth, cutting edges or bearings with
a hammer, there might be parts and metallic
fragments flying off and resulting in injuries. Thus,
always wear eye protection and protective gloves
and make sure that there are no people around.
Try to avoid installing parts or pins with the metallic
hammer to avoid part damage. Try to use soft or
non-iron hammer whenever possible.

When compressed air is used

When you do cleaning with the compressed air,
particles may fly off and result in personal injuries. Fig. 2-24
Thus, it is important to wear the eye protection, dust
masks, protective gloves and other PPE.

Welding
There is a risk of fire or electric shock during
welding, therefore, welding must be carried out by
qualified welders with appropriate equipment.
Unqualified personnel are not allowed for welding.
Switch off the power before welding. See pages
2-16.

Fig. 2-25

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Safety SY215CCM3K Hydraulic Excavator

Spring for track tension

Be very careful during track maintenance because
springs for track tension may pose a danger.
Springs for track tension are always under high
pressure. Improper operation during dismantling
may cause the springs to fly out, which may result in
severe personal injuries.
Do not hit the springs for track tension, because
these springs may be subject to great pressure.
Otherwise, explosive breakage from springs may
result in personal injuries.
Be very careful when you remove and install the
tracks. When the main track link is dismantled, the
track assembly may suddenly break and cause Fig. 2-26
personal injuries. When you detach the main track
link, keep away from the traveling path of track.

Safe operation for high pressure

hoses
If leakage is found in the high-pressure hose, it may
cause an operational failure and even lead to a fire.
If bolts on the hose come loose, stop working and
tighten the bolts to specified torque. Stop working
immediately and replace the hoses when:
1) Damage or leakage has been found on any
hydraulic pipe fitting.
2) The covering has been worn or broken, or the
reinforcement layer of steel wire is exposed.
3) Swelling has been partly found on the cover.
Fig. 2-27
4) Impurities have been found in the cover.
5) Disorder or indentation has been found on any
movable part.

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SY215CCM3K Hydraulic Excavator Safety

Be careful when you work with 2

high-pressure fluid
Pressure always exists in the hydraulic system.
When you check or replace the hose, always check
if pressure in the hydraulic oil line has been relieved.
If there is remaining pressure in the hydraulic oil line,
serious accidents will occur. Therefore, it is
important to observe following rules:
1) Press the vent button for breather valve to
relieve system pressure before maintenance of
hydraulic system.
2) Open fire is forbidden around the hydraulic
system. Spilled hydraulic oil, if any, should be
removed immediately.
3) Diesel or pressurized hydraulic oil can
penetrate the skin or eyes, which may result in
severe injuries, blindness or even death. It is
difficult to check if the pressurized hydraulic oil
leaks with naked eyes. You need to find
leakage with a piece of cardboard or wood chip
instead of touching leaked oil directly. Wear a
face mask or protective goggles to protect your
eyes. If oil penetrates your skin, rinse it with
water and seek medical attention as soon as
possible.
Fig. 2-28
4) When the engine is running, pressure builds up
in the fuel line. If the fuel line system is to be
checked or maintained, wait until the engine
has been shut down for at least 30 seconds
and the internal pressure has decreased.

Be careful when you work with hot

coolant
As temperature of engine increases, pressure in
cooling system builds up. Stop the engine to allow
the system to cool down before removal of radiator
cap. You should not remove it until the coolant cools
down.

Fig. 2-29

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Safety SY215CCM3K Hydraulic Excavator

HVAC group
● Keep away from fire during maintenance of
HVAC group;
● When you add refrigerant, always select a
correct refrigerant, which should be refrigerant
R134a. Any other refrigerants are not available
because they will damage the HVAC group;
● If the refrigerant enters eyes, it may cause
blindness; if it splashes on skin, it will cause
cold frostbite.
● It is strictly forbidden to discharge the
refrigerant directly into the atmosphere,
instead, a refrigerant circulation system should Fig. 2-30
be used.

CAUTION
R134a refrigerant is a non-toxic gas at room
temperature, but it turns into a highly toxic
gas when it exposes to fire.

Electrical safety
When the hydraulic excavator circuits are tested,
always get to know the components to be tested.
High voltage and strong current both can cause
equipment damage, electric sparks, explosion and
even fire.
Before maintaining or testing the electrical system,
always get to know the system voltage. Be sure to
check the electric circuits and make sure the circuits
are disconnected before maintenance.
When you work around flammable fluids or
explosive systems, you are allowed to use the
specified explosion-proof light only. Using
unapproved light may cause an explosion or fire. Fig. 2-31

Switching power off

Before any maintenance, be sure to disconnect the
battery cables or switch off the master power switch
(e.g. for the equipment).
When the battery is to be disconnected, disconnect
the negative (-) connector before disconnecting the
positive (+) connector.
When the battery is to be connected, ensure that all
the switches for electrical system are switched OFF,
and then connect the positive (+) connector before
connecting the negative (-) connector.

Fig. 2-32

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SY215CCM3K Hydraulic Excavator Safety

Battery operation 2
Working around the batteries can be dangerous,
especially when the batteries have been used for a
long time. Here are some precautions you should
know when you maintain the batteries or work
around the batteries:
1) Always wear the PPE when you work around
the batteries.
2) Gas can be easily explosive when it is released
from the battery. When the battery box has
been opened, allow enough time for gas
spreading in the box, and then perform
maintenance.
3) Be sure to choose a well-ventilated place for Fig. 2-33
handling the batteries.
4) If the batteries have been corroded, rinse them
with a mixture of sodium bicarbonate and warm
water.
5) In case of skin, eye contact with battery
electrolyte, rinse the skin or eye immediately
with plenty of clean water and see a doctor as
soon as possible.
Accumulator
As accumulator is filled with high pressure nitrogen,
improper operation may lead to explosion and
severe accident. Therefore, it is important to
observe the following rules:
1) Do not disassemble the accumulator;
2) Do not place the accumulator close to a fire or
expose it to a flame;
3) Do not punch, weld, or use gas cutting to the
accumulator;

Fig. 2-35
4) The accumulator should not be hit, rolled or
subject to any impact;
5) If the accumulator is to be disposed, it must be
bled first. Please contact dealers authorized by
Sany Heavy Machinery Co., Ltd for this
operation.

Fig. 2-34

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Safety SY215CCM3K Hydraulic Excavator

Reducing fire and explosion risks

The engine must be shut down and the electrical
equipment must be switched off during fuel tank
refueling. Take extra care when you refuel a hot
engine with fuel. No spark should occur around a
grounded fuel nozzle.
Dispose all solvents and dry chemicals at a
well-ventilated area according to the steps indicated
on the containers.
Remove all the dust and residue from the hydraulic
excavator where rags or any other flammable
materials should not be placed on.
Clean the parts with non-flammable solvents instead
of the gasoline, diesel or any other flammable fluid. Fig. 2-36
Store the flammable fluids and materials in suitable
containers according to safety regulations.
Check and maintain fire extinguishers regularly to
ensure that they are always ready to be used.
Proper disposal for waste
Improper disposal for waste may lead to
environmental and ecological perils. Consult your
local environmental collection center or Sany Heavy
Machinery Co., Ltd. authorized distributor about
collection or disposal methods.
1) Potential hazardous wastes in Sany heavy
machinery equipment include the hydraulic oil,
fuel, coolant, refrigerant, filter and battery.
2) Discharge the fluid with a leak-proof container
instead of the container for food or beverage,
otherwise contents in the container may be
ingested by people accidentally;
3) Do not pour the fluid waste on the ground, in Fig. 2-37
the sewer or any source of water;
4) Leakage of HVAC refrigerant may damage the
atmosphere. Thus, collection or regeneration of
HVAC refrigerant should comply with relevant
laws.

Fig. 2-38

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SY215CCM3K Hydraulic Excavator Safety

Miscellaneous
2
Precautions for hoisting and signaling
1) Only one designated worker can signal and
co-workers must frequently communicate with
each other.The designated signaler must
distinctly signal as specified where the driver
and other signaler(s) can see the operating

Hoisting capacity (kN(kg))

conditions clearly. The signaler must stand in
front of the load and safely guide the driver.
● Do not stand beneath the load.
● Do not step on the load.
2) Before hoisting, check the wire rope slings.
3) Wear gloves all the way during hoisting. (Wear Angle for hoisting (°)
a pair of leather gloves, if available.)
4) Visually measure the weight of load and check Fig. 2-39
its center of gravity.
5) Use suitable wire rope slings according to the
load weight and hoisting method. If the wire
ropes used to hoist load are too thick, the load
may slip or fall down.
6) Do not hoist the load with a single wire rope.
Otherwise, the load will rotate and may slip out
of the wire rope. Use two or more wire ropes
symmetrically.
7) In general, the angle for hoisting does not
exceed 60°. Do not hoist heavy loads with large
angle for hoisting. When the load is hoisted with
two or more wire ropes, force exerted on each
wire rope increases with the angle for hoisting.
The following table shows the permissible load
change in kN at various angles for hoisting
when 2 wire ropes are used for hoisting and the
permissible vertical hoisting limit of each wire
rope is 9.8 kN{1,000 kg}. When 2 wire ropes are
used to hoist a load vertically, the permissible
total hoisted weight is 19.6 kN{2,000 kg}, and
when the 2 steel wire ropes are at a hoisting
angle of 120°, the weight is reduced to 9.8
kN{1,000 kg}. If a load of 19.6kN{2,000kg} is
hoisted with 2 wire ropes when the angle for
hoisting is 150°, the force exerted on each wire
rope is 39.2kN{4,000kg}.

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Safety SY215CCM3K Hydraulic Excavator

8) When the wire ropes are installed to an angular

load, use a pad to protect them. If the load is
smooth, use suitable material to prevent the
wire ropes from slipping.
9) Secure the wire ropes and sling chains to the
load with specified eyebolts and U-shaped rings
with pins.
10) Install wire ropes in the middle of the hooks.
● If the wire rope slings are too close to the
top of hooks during hoisting, the wire
ropes may slip off the hooks. The wire
ropes have the maximum strength when
they are in the middle of the hooks.
11) Do not use twisted or kinked wire ropes. Fig. 2-40

12) Observe the following rules when a load is

hoisted:
● Lift the load slowly until the wire ropes are
tensioned. Do not grasp the wire ropes
when you handle them with hands,
otherwise your fingers may easily be
pinched.
● When the wire ropes have been stretched,
stop the crane and check status of hoisted
load, wire ropes and pad.
● If the load is unsteady or the wire ropes or
sling chains are twisted, lower the load
and hoist it again.
● Do not hoist the load at an angle.
13) Observe the following rules when a load is
lowered:
● When a load is lowered, steady it at 30 cm
above the ground and slowly lower it.
● Check if the load is steady before
removing the wire rope slings.
● Eliminate the kinks and sludge from wire
ropes and sling chains for hoisting and
store the wire ropes and sling chains in the
designated position.

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SY215CCM3K Hydraulic Excavator Safety

Precautions for using mobile crane

2
CAUTION
Read the operation and maintenance manual for crane in advance and operate the crane safely.

Precautions for using bridge crane

1) Before working, check the wire ropes, brake, clutch, controller, rail, overhoist protection device,
earth leakage circuit breaker, anti-collision device for crane and alarm lamp for power application,
and check the safety.
2) React to the hoisting signal.
3) Operate the crane at a safe place.
4) Be sure to check the direction of the indicator board (east, west, south and north) and the direction
of control buttons.
5) Do not lift the load in tilt posture. Do not move the crane when the hoisted load rotates.
6) Do not lift or lower the load while the crane is moving horizontally or vertically.
7) Do not drag wire rope slings.
8) When a load is to be lifted, you can lift it only after it has been above the ground and safety check
has been done.
9) Arrange the path for traveling in advance, and then lift the load to a safe level.
10) Place the control switch to a position where crane will not obstruct working or be an obstacle on any
passage.
11) Do not turn the control switch after crane operation.
12) Remember the position of main power switch so that power can be switched off immediately in any
emergency.
13) If the crane stops due to a power failure, switch the power switch to OFF position. When a switch,
which has been switched off via the earth leakage circuit breaker, is switched on, check whether
devices related to the switch are in operation.
14) If any obstacle is found around the crane, stop operation.
15) After the work, stop the crane at the specified position and lift the hooks to a place at least 2 m
above the ground. Do not leave wire rope slings on the hooks.

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Safety SY215CCM3K Hydraulic Excavator

Selection of wire ropes

According to the weight of parts to be hoisted, select the appropriate wire rope (see the table below).
Wire rope
("Z” (right regular lay) or "S" (left regular lay) wire rope, not galvanized)
Nominal diameter of wire rope Permissible load
mm kN t
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
Permissible load is 1/6 of breaking force of used wire rope. (Safety factor: 6)

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SY215CCM3K Hydraulic Excavator Technical Specifications

Technical Specifications

Specified dimension figures .................................................................................................................... 3-2

Dimension ....................................................................................................................................... 3-2
Working range ................................................................................................................................. 3-3
Technical Specifications .......................................................................................................................... 3-4
Weight Table ........................................................................................................................................... 3-6
Engine oil, fuel and coolant ..................................................................................................................... 3-7
Engine graph ........................................................................................................................................... 3-8

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Technical Specifications SY215CCM3K Hydraulic Excavator

Specified dimension figures

Dimension

Fig. 3-1
Item SY215CCM3K
A Overall length (for transportation) 9680
B Overall width 2980
C Overall height (for transportation) 3440
D Width of superstructure 2710
E Overall height (top of the cab) 3080
F Standard track shoe width 600
G Track gauge 2380
Min. ground clearance (excluding the
H 440
flange height of the track shoe)
I Tail swing radius 2900
J Ground contact length of track 3445
K Track length 4250
Ground clearance of superstructure
L (excluding the flange height of the track 1130
shoe)

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SY215CCM3K Hydraulic Excavator Technical Specifications

Working range
3

Fig. 3-2
Name SY215CCM3K
a Max. digging height 9570
b Max. dumping height 6700
c Max. digging depth 6600
d Max. vertical wall digging depth 5800
e Max. digging reach 9950
f Min. swing radius 3595
g Max. height at min. swing radius 7665

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Technical Specifications SY215CCM3K Hydraulic Excavator

Technical Specifications
Machine model SY215CCM3K
Bucket capacity m3 0.93
Overall weight kg 22000
Max. digging height mm 9570
Max. dumping height mm 6700
Max. digging depth mm 6600
Working
Max. vertical wall digging depth mm 5800
range
Max. digging depth mm 9950
Min. swing radius mm 3595
Performance Max. height at min. swing radius mm 7665
Max. bucket digging force kN 138
Max. arm digging force kN 103
Swing speed rpm 11
Traveling speed (high/low) km/h 5.4/3.3
Climbing ability degree 35
Ground pressure kPa 47
Overall length (for transportation) mm 9680
Overall width (for transportation/operation) mm 2980
Overall height (for transportation) mm 3440
Width of superstructure mm 2710
Overall height (top of the cab) mm 3080
Dimension
Standard track shoe width mm 600
Track gauge (for transportation/operation) mm 2380
Min. ground clearance mm 440
Tail swing radius mm 2900
Ground contact length of track mm 3445

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SY215CCM3K Hydraulic Excavator Technical Specifications

Machine model SY215CCM3K 3

MITSUBISHI 4M50
Model
4-cylinder, 4-stroke, water
Type
cooling, in-line, DFI
Number of cylinders - cylinder bore × stroke
Mm 4-Φ114 mm×120mm
Total displacement
L 4.899
Rated power
kW/rpm 118/ 2000
Engine Max. torque
N·m/rpm 580/ 1600
Max. speed without load rpm
Performance 2150±25
Min. speed without load rpm 975±25
Fuel consumption (rated g/kWh 200
power)
Starting motor 24V/5.0 KW
Battery 24V/50A
Carrier roller (each side) Piece 2
Lower
Track roller (each side) Piece 8
structure
Number of track shoes (each side) Piece 47
Model K7V125 (swash plate piston
Hydraulic Maximum flow rate of the pump)
pump main pump L/min 2×210
Rated pressure Mpa 34.3
Control Type × number KMX15RB/B45229 ×1
valve Control method Hydraulic
2 × MAG-170VP swash plate
variable displacement piston
motor
Hydraulic Travel motor
(w/brake)
motor Swing motor
Hydraulic 1 × M5X180 swash plate variable
system displacement piston motor
(hydraulic brake)
Type Double-acting piston type
Inner diameter of cylinder 120 (boom), 135 (arm), 115
Hydraulic (boom/arm/bucket) (bucket)
cylinder Diameter of piston rod mm 85 (boom), 95 (arm), 80 (bucket)
(boom/arm/bucket) 1285 (boom), 1490 (arm), 1120
Stroke (boom/arm/bucket) (bucket)
Hydraulic tank Sealed type
Hydraulic oil filter element Oil return filter
Hydraulic oil cooler Air cooling

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Technical Specifications SY215CCM3K Hydraulic Excavator

Weight Table
Unit: kg
Machine model SY215CCM3K
Engine 481
Radiator assembly 175
Hydraulic tank assembly (without hydraulic oil) 171
Fuel tank assembly (without fuel) 164
Upper structure frame 1894
Cab 409
Cab seat 41
Counterweight 3955
Hydraulic pump 120
Multi-way valve 185
Swing reducer assembly 200
Travel reducer assembly 300×2
Track frame 2748
Swing bearing 286
Idler 116×2
Tensioner 135×2
Carrier roller 25.5×4
Track roller 40×16
Boom assembly 1590
Arm assembly 709
Bucket assembly 781
Boom cylinder assembly 206×2
Arm cylinder hose 262
Bucket cylinder hose 188
Link 88
Rocker 22×2
Note: This table is only used as the reference for operating components or transportation.
Capacity table (L):
Swing
Hydraulic Cooling
Engine oil pan mechanism Final gearbox Fuel tank
tank system
box
17 4.0 5.5 260 25 390

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SY215CCM3K Hydraulic Excavator Technical Specifications

Engine oil, fuel and coolant

3
Environmental temperature
Liquid
Vessel
type -22 -4 14 32 50 68 86 104 122 ℉
-30 -20 -10 0 10 20 30 40 50℃

SAE 30

SAE 10W
Engine oil pan
SAE 10W-30
Engine oil
SAE 15W-40

Carrier roller
Idler SAE 30
Track roller
Swing gearbox: Gear oil 85W-140
Gear oil
Travel gearbox

SAE 10W

Engine oil SAE 10W-30

SAE 15W-40
Hydraulic
system
HDZ32 Low temperature anti-wear
hydraulic oil
Hydraulic
oil HDZ46 Anti-wear hydraulic oil

HDZ68 Anti-wear hydraulic oil

GB252 Premium-No.0 Diesel

GB252
Premium-No.20
Fuel tank Diesel
Diesel

GB252 Premium-No.35
Diesel

Lubricating
Grease fitting NLGI No.2
grease
Cooling system Coolant TEEC-L35

● Note: 1) Recommended engine oil: API CF-4 or above, at least API CD.
2) Recommended gear oil: GL-5.
3) Please buy genuine SANY oil from Sany Heavy Machinery Co., Ltd or dealers authorized
by Sany Heavy Machinery Co., Ltd to ensure oil quality.

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Technical Specifications SY215CCM3K Hydraulic Excavator

Engine graph
Mitsubishi 4M50
Test conditions:
1) Temperature: 298K, at standard atmospheric pressure;
2) No fan.

Fig. 3-3

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SY215CCM3K Hydraulic Excavator Structure and Function

Structure and Function

Contents
Engine and cooling system ..................................................................................................................... 4-3
Engine-related parts ........................................................................................................................ 4-3
Radiator and intercooler.................................................................................................................. 4-4
Powertrain ............................................................................................................................................... 4-5
Powertrain ....................................................................................................................................... 4-5
Traveling reducer assembly (T40D43BF1H1U) ............................................................................. 4-6
Reducer (Sauter)............................................................................................................................. 4-8
Swing reducer mechanism............................................................................................................ 4-10 4
Swing bearing ............................................................................................................................... 4-12
Lower structure ...................................................................................................................................... 4-14
Track frame and tension mechanism............................................................................................ 4-14
Idler ............................................................................................................................................... 4-16
Carrier roller .................................................................................................................................. 4-18
Track roller .................................................................................................................................... 4-19
Crawler .......................................................................................................................................... 4-20
Layout of hydraulic parts ....................................................................................................................... 4-24
Hydraulic tank and filler ......................................................................................................................... 4-26
Hydraulic pump...................................................................................................................................... 4-28
Regulator (KR7G-0E05-V) ............................................................................................................ 4-35
Control valve.......................................................................................................................................... 4-42
Hydraulic circuit diagram............................................................................................................... 4-44
Swing motor........................................................................................................................................... 4-78
Central swivel joint ................................................................................................................................ 4-84
Travel motor .......................................................................................................................................... 4-86
Control system..................................................................................................................................... 4-104
Pilot valve ............................................................................................................................................ 4-105
Solenoid valve ..................................................................................................................................... 4-113
Accumulator......................................................................................................................................... 4-114
Pilot oil filter ......................................................................................................................................... 4-115
Hydraulic cylinder ................................................................................................................................ 4-116
Work equipment .................................................................................................................................. 4-118
HVAC group ........................................................................................................................................ 4-124

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Structure and Function SY215CCM3K Hydraulic Excavator

Layout of A/C elements............................................................................................................... 4-125

A/C control panel......................................................................................................................... 4-126
Schematic circuit diagram ........................................................................................................... 4-127
Working principles of A/C............................................................................................................ 4-129
Compressor ................................................................................................................................. 4-130
Clutch .......................................................................................................................................... 4-132
Condenser ................................................................................................................................... 4-133
Expansion valve .......................................................................................................................... 4-134
Evaporator ................................................................................................................................... 4-134
Dryer............................................................................................................................................ 4-135
Pressure switch ........................................................................................................................... 4-136
Refrigerant .................................................................................................................................. 4-137
Compressor oil ............................................................................................................................ 4-150
Engine control...................................................................................................................................... 4-151
System operation ........................................................................................................................ 4-152
System components ................................................................................................................... 4-153
Electrical control system...................................................................................................................... 4-157
Control functions ......................................................................................................................... 4-157
System parts ............................................................................................................................... 4-170
Display system .................................................................................................................................... 4-176
Display......................................................................................................................................... 4-177

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SY215CCM3K Hydraulic Excavator Structure and Function

Engine and cooling system

Engine-related parts

Fig. 4-4

1. Fan
2. Starter motor Technical Specifications
3. Engine outrigger Oil capacity: 22 L

Service Manual.10-2017 4-3

Structure and Function SY215CCM3K Hydraulic Excavator

Radiator and intercooler

Fig. 4-5

1. Radiator inlet hose Technical Specifications

2. Fan cover Radiator assembly:
3. Radiator outlet hose ZH860×385×1050－S70Y75Z20Q/SY015
4. Intercooler air outlet Aluminum tube-and-fin radiator
5. Intercooler air intake Water cooler is connected in parallel with the oil
6. Water radiator radiator, and then they are connected in series
with the intercooler.
7. Hydraulic oil cooler
Radiator capacity: 8.9 L (engine coolant capacity:
8. Intercooler 9.5 L)

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SY215CCM3K Hydraulic Excavator Structure and Function

Powertrain
Powertrain

Fig. 4-6

1. Swing motor 7. Multi-way valve (KMX15RB)

(M5X180CHB-12A-51A/260-169)
8. Reducer assembly (GT40D43B-F1H1U)
2. Swing reducer (RG14D20A5)
9. Piston pump (K7V125DTP)
3. Swing bearing
10. Engine (Mitsubishi 4M50)
4. Guide wheel
5. Swing joint
6. Accumulator

Service Manual.10-2017 4-5

Structure and Function SY215CCM3K Hydraulic Excavator

Traveling reducer assembly (T40D43BF1H1U)

Fig. 4-7

Fig. 4-8

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SY215CCM3K Hydraulic Excavator Structure and Function

1. Piston cylinder subassembly 9. 2# sun gear (number of teeth: 19)

2. Shaft 10. 2# planetary gear (number of teeth: 36)
3. Gear hub (number of teeth: 85) 11. Seal ring
4. 2# planetary carrier 12. Travel motor
5. 1# planetary carrier 13. Oil filler
6. 1# planetary gear (number of teeth: 36) 14. Check port
7. 1# sun gear (number of teeth: 12) 15. Oil drain port
8. End cover

Technical Specifications
Reduction ratio: ((12+85)/12)×((19+85)/19))-1= 43.246
Unit: mm
S/N Inspection Item Criterion Measures
Clearance between 2# sun Standard clearance Clearance limit 4
16 Replacement
gear and 2# planetary gear 0.13 ～ 0.47 1.00
Clearance between 1#
17 0.17 ～ 0.57 1.10
planetary gear and gear hub
Clearance between 1# sun
18 0.14 ～ 0.46 1.00
gear and 1# planetary gear
Clearance between 2# Replacement
19 0.16 ～ 0.56 1.10
planetary gear and gear hub
Clearance between 1#
20 planetary carrier and 2# sun 0.38 ～ 0.66 1.00
gear

Service Manual.10-2017 4-7

Structure and Function SY215CCM3K Hydraulic Excavator

Reducer (Sauter)

Fig. 4-9

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SY215CCM3K Hydraulic Excavator Structure and Function

1. Motor casing 12. Wear retaining plate II gear 23. Roller P6×29.8
carrier
2. Floating seal 24. Shaft end retaining plate Ⅰ
13. Planetary gear II
3. Bearing BA246-2T11 NSK 25. Sun gear Ⅰ
14. Roller P6×49.8
4. Inner ring gear 26. Planetary carrier plate I
5. Pin 15. Bushing Ⅱ
27. Screw M12× 25
6. Adjusting shim I mandrel 16. Shaft end retaining plate Ⅱ
28. Rear wear cover
7. Adjusting shim II 17. Bolt M20×130
29. O-ring 355×4
8. Adjusting shim III 18. Sun gear Ⅱ 30. O-ring 23.7×3.5
GT40D43-5
19. Wear retaining plate Ⅰ 31. Box cover
9. Washer
20. Planetary carrier body I 32. Screw M10× 25
10. Planetary carrier body II
21. Bushing Ⅰ 33. Plug
11. Screw M20× 65
22. Planetary gear I
4

Service Manual.10-2017 4-9

Structure and Function SY215CCM3K Hydraulic Excavator

Swing reducer mechanism

Fig. 4-10

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SY215CCM3K Hydraulic Excavator Structure and Function

1. Plug 11. 2# planetary gear subassembly

2. Oil seal 12. 2# planetary gear (number of teeth: 17)
3. Self-alignment bearing 13. Spring pin
4. Ring gear (number of teeth: 52) 14. Swing reducer plug
5. 2# planetary carrier 15. Grease fitting
6. 1# planetary carrier 16. Self-alignment bearing
7. 2# sun gear (number of teeth: 16) 17. Bearing seal
8. 1# sun gear (number of teeth: 14) 18. Swing pinion
9. Swing motor 19. Oil dipstick
10. 1# planetary gear (number of teeth: 18) 20. Filler pipe

Technical Specifications
Reduction ratio: (14+25)/14×(16+25)/14= 20.04
Unit: mm 4
S/N Inspection Item Criterion Measures
Clearance between swing motor Standard clearance Clearance limit
21 Replacement
shaft and 1# sun gear 0.18～ 0.28 —
Clearance between 1# sun gear and
22 0.16～ 0.50
1# planetary gear 1.00
Clearance between 1# planetary
23 0.18～ 0.59 1.10
gear and ring gear
Clearance between 1# planetary
24 0.39～ 0.71 1.20
carrier and 2# sun gear
Clearance between 2# sun gear and Replacement
25 0.16～ 0.50 0. 90
2# planetary gear
Clearance between 2# planetary
26 0.18～ 0.59 1.00
gear and ring gear
Clearance between 2# planetary
27 0.07～ 0.23 —
carrier and swing pinion
Clearance between swing pinion
28 0.22～ 1.32 2.00
and swing bearing

Service Manual.10-2017 4-11

Structure and Function SY215CCM3K Hydraulic Excavator

Swing bearing

Fig. 4-11

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SY215CCM3K Hydraulic Excavator Structure and Function

1. Swing bearing cone (number of teeth: 91) Technical Specifications

2. Steel ball Reduction ratio: 91/13=7
3. Swing bearing outer ring Grease replenishment quantity: 13±1 kg

a. ―S‖ part in the soft area of cone

b. ―S‖ part in the soft area of the cup

Unit: mm
Inspection Item Criterion Measures
Axial clearance of bearing Standard clearance Clearance limit
Replacement
(mounted on the chassis) 0.5～1.6 3.2

Service Manual.10-2017 4-13

Structure and Function SY215CCM3K Hydraulic Excavator

Lower structure
Track frame and tension mechanism

Fig. 4-12

1. idler ● The track rollers are of different sizes and

numbers depending on the specific model, but
2. Track frame
all of them are the same basic structure.
3. Carrier roller
● Number of track rollers
4. Sprocket
Model Qty. (on one side)
5. Track roller
SY215CCM3K 8
6. Track
7. Central guard board
8. Front guard board

4-14 Service Manual.10-2017

SY215CCM3K Hydraulic Excavator Structure and Function

Standard track shoe

Model
SY215CCM3K
Item
Track shoe width (mm) 600
Link pitch (mm) 190
Number of track shoes (on one side) 47
Unit: mm
S/N Inspection Item Criterion Measures
Standard Repair
Tolerance
Vertical width of size limit Perform
9
idler guide groove Track frame 107 — — overlay
welding or
Idler bearing 105 — —
replace the
Horizontal width of Track frame 250 — — part
10
idler guide groove Idler bearing 247 — —
Standard size Repair limit 4
Free
Mounting Mounting Free Mounting
length×Outer
Spring for track length load length load
11 diameter Replacement
tension
157.9 kN
598 x 247 466 {16112 545 133.9 kN
kg}

Service Manual.10-2017 4-15

Structure and Function SY215CCM3K Hydraulic Excavator

Idler

Fig. 4-13

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SY215CCM3K Hydraulic Excavator Structure and Function

Unit: mm
S/N Inspection Item Criterion Measures
Outer diameter of Standard size Repair limit
1
protrusion 560 —
Outer diameter of
2 520 508 Perform
wheel face
overlay
Thickness of wheel
3 30 24 welding or
face
replace the
Difference of wheel part
4 20 26
face
5 Total width 164 —
6 Width of wheel face 39.5 —
7 Diameter of shaft 65 —
Clearance between the Standard clearance Clearance limit
bushing and the Replacement 4
8 bearing
(sum of clearances on 0.5～1.0 —
both sides)

Service Manual.10-2017 4-17

Structure and Function SY215CCM3K Hydraulic Excavator

Carrier roller

Fig. 4-14
Unit: mm
S/N Inspection Item Criterion Measures
Standard size Repair limit
1 Outer diameter of flange
165 —
Outer diameter of wheel
2 140 130
face
3 Width of wheel face 44 —
4 Thickness of wheel face 41.5 34
5 Width of flange 18 —
Standard Tolerance Standard Clearance Replacement
Clearance between the size clearance Limit
6 Shaft Hole
shaft and the bushing
50 — — — —

Interference between the Standard Tolerance Standard Interference

7 carrier roller and the size Shaft Hole interference Limit
bushing 57 — — —
Axial clearance of carrier Standard clearance Clearance limit
8
roller 0.44～0.76 —

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SY215CCM3K Hydraulic Excavator Structure and Function

Track roller

Fig. 4-15
Unit: mm
S/N Inspection Item Criterion Measures
Outer diameter of Standard clearance Repair limit
1
flange 193 —
Outer diameter of wheel Perform
2 160 148 overlay
face
welding or
3 Thickness of wheel face 46.5 40.5
replace the
4 Overall width 237 — part
5 Width of wheel face 46.5 —
6 Width of flange 32 —
7 Width of inner side 80
8 Diameter of shaft 65 —
Clearance between the Standard clearance Clearance limit
bushing and the collar
9 Replacement
(sum of clearances on 0.5~1.0 —
both sides)

Service Manual.10-2017 4-19

Structure and Function SY215CCM3K Hydraulic Excavator

Crawler

Fig. 4-16

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SY215CCM3K Hydraulic Excavator Structure and Function

Unit: mm
S/N Inspection Item Criterion Measures
Standard size Repair limit
1 Link spacing Put the part
190 193
upside down or
Standard size Upside down replace it
2 Outer diameter of bushing
59.45 53.7
3 Thickness of bushing metal 10.75 5.75
Repair or replace
Standard size Repair limit
4 Link height the part
105 98
5 155.57
6 Track shoe bolt spacing 119.57
7 69
8 Inner width 82.57
9 Overall width 40
Link
Width of wheel 4
10 38
face
Common 2.7 Adjust or replace
11 Pin protrusion
Main 2.7 the part
Bushing Common 3.7
12
protrusion Main 0.0
Total pin Common 207
13
length Main 209
Total bushing Common 136
14
length Main 128.5
15 Thickness of spacer bushing —
16 Bushing 88.2～245 kN {9～25 t}
17 Press fit force Common pin 127.4～274.4 kN {13～28 t}
—
18 Main pin 78.4～147 kN {8～15 t}

Service Manual.10-2017 4-21

Structure and Function SY215CCM3K Hydraulic Excavator

Unit: mm
S/N Inspection Item Criterion Measures
Tightening torque
a. Re-tightening angle (°)
(N·m{kgf·m})
Common
link Three-teeth 750±22.5
120±10
Track track shoe {62.5±2.3} Re-tighten
shoe bolt Tightening Lower limit of the part
19 Re-tightening angle
b. Main torque torque
(°)
link (N·m{kgf·m}) （N·m{kgf·m}）
— — —
Number of track shoes
SY215CAM3K —
(each side)
Tolerance Standard
Interference between Standard size
Shaft Hole interference
20 the bushing and the
link 0 -0.25
59.45 0.20～0.32
-0.05 -0.32
Interference between 0 –0.23
21 the common pin and 38.25 0.19～0.29
the link -0.04 –0.29

Tolerance Standard
Clearance between Standard size
Shaft Hole clearance
22 the pin and the Adjust or
bushing 0 0.8 replace
38.25 0.50～0.84
-0.04 0.5 the part
Tolerance Standard
Interference between Standard size
Shaft Hole interference
23 the common pin and
the link -0.08 -0.23
38.25 0.12～0.21
-0.11 -0.29
Tolerance Standard
Clearance between Standard size
Shaft Hole clearance
24 the main pin and the
bushing -0.5 1
38.25 1～1.7
-0.7 0. 5

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SY215CCM3K Hydraulic Excavator Structure and Function

Three-teeth track shoe

4
Fig. 4-17
Unit: mm
S/N Inspection Item Criterion Measures
Standard size Repair limit
1 Height
26 16
2 Thickness 10
3 29.5
Base length Perform overlay
4 22
welding or
5 20.5 replace the part
6 Top length 17
7 18
Standard size Repair limit
8 Thickness
36 26

Service Manual.10-2017 4-23

Structure and Function SY215CCM3K Hydraulic Excavator

Layout of hydraulic parts

1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Hydraulic tank
5. Hydraulic oil filter
6. Multi-way valve
7. Piston pump
8. Radiator
9. Accumulator
10. Left travel motor
11. Right travel motor
12. Swing motor
13. Safety lock rod
14. Left pilot valve
15. Central swivel joint
16. Right pilot valve
17. Traveling pilot valve
18. Solenoid valve assembly
18A. Pilot lockout solenoid valve
18B. Boom priority solenoid valve
18C. Bucket converging solenoid valve
18D. Swing priority solenoid valve
18E. High/low speed traveling solenoid valve

Fig. 4-18

4-24 Service Manual.10-2017

SY215CCM3K Hydraulic Excavator Structure and Function

Fig. 4-19

Service Manual.10-2017 4-25

Structure and Function SY215CCM3K Hydraulic Excavator

Hydraulic tank and filler

Fig. 4-20

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SY215CCM3K Hydraulic Excavator Structure and Function

1. Hydraulic tank Technical Specifications

2. Liquid level meter Capacity of hydraulic tank: 260L
3. Oil filler cap Effective capacity: 172 L
4. Oil return filter element Breather valve
5. Bypass valve Filter precision: 10 μm
6. Breather valve Ambient temperature: -20~100℃
7. Oil suction filter element Pressure setting: intake side→ 0.005 MPa
discharge side 0.05MPa

Service Manual.10-2017 4-27

Structure and Function SY215CCM3K Hydraulic Excavator

Hydraulic pump
Model: K7V125DTP1N9R

Clockwise rotation

Fig. 4-21

4-28 Service Manual.10-2017

SY215CCM3K Hydraulic Excavator Structure and Function

Overview
● The pump consists of 2 variable swashplate type piston pumps, 2 regulators and 1 pilot gear pump.

a1： Front pump main pressure Psv1: Front pump regulator 1: Front pump
check port control port
2: Rear pump
a2： Rear pump main pressure Psv2: Rear pump regulator
3: Pilot gear pump
check port control port
4: Front pump regulator
a3 ： Front pump regulator Dr1： Front pump drain plug
pressure check port 5: Rear pump regulator
Dr2： Rear pump drain plug
a4： Regulator control pressure Dr3： Bleeder plug
check port
Dr4： Oil drain port
a5 ： Pilot gear pump output
pressure check port B1： Pump oil suction port
PH1: Front pump pressure B3： Pilot gear pump oil suction
sensor mounting port port
PH2: Rear pump pressure
sensor mounting port 4
A1： Front pump oil delivery port
A2： Rear pump oil delivery port
A3： Pilot gear pump output oil
port

Service Manual.10-2017 4-29

Structure and Function SY215CCM3K Hydraulic Excavator

Fig. 4-22

1. Front shaft 9. End cover

2. Minimum displacement adjusting screw 10. Rear shaft
3. Front case 11. Rear case
4. Swashplate 12. Gear pump
5. Slipper 13. Piston
6. Piston 14. Maximum displacement adjusting screw
7. Cylinder 15. Gear shaft
8. Port plate 16. Drive pin

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SY215CCM3K Hydraulic Excavator Structure and Function

Fig. 4-23

Function ● The swashplate (4) has a plane (A), and the

slipper (5) always presses against this plane
● The engine torque is transferred to the shaft
when it makes a circular motion.
(1) to drive the cylinder (7) to rotate, and the 9
pistons (6) slide along the surface of the port ● The swashplate (4) guides the high-pressure
plate (8). The piston (6) reciprocates within oil to the surface (B) and forms a static
the cylinder (7) to alternately suck the pressure bearing when it slides.
low-pressure oil and discharge the
● The piston (6) makes an axial relative
high-pressure oil.
movement inside each cavity of the cylinder
● The displacement is changed through change (7).
of the inclination angle of the swashplate
● The cylinder (7) seals the pressurized oil to
Structure the port plate (8) and makes a relative
rotation.
● The cylinder (7) is supported on the shaft (1)
by the spline (17). ● This surface is so designed that the oil
pressure balance is maintained at a suitable
● The shaft (1) is supported by the front and
level.
rear bearings (18).
● The oil inside each cavity of the cylinder (7) is
● The piston (6) top is made into a concave
sucked and discharged through the port plate
sphere which is filled with the slipper (5) to
(8).
form a device.
● The piston (6) and slipper (5) form a spherical
bearing.

Service Manual.10-2017 4-31

Structure and Function SY215CCM3K Hydraulic Excavator

Working process
● The cylinder (7) rotates with the shaft (1), and
the slipper (5) slides on the plane (A).
● In this case, the swashplate (4) moves along
the cylindrical surface (B). Therefore, the
angle (a) between the center line (X) of the
swashplate (4) and the axial direction of the
cylinder block (7) may change.
● (a) is the inclination angle of the swashplate.

Fig. 4-24

● When the centerline (X) of the swashplate (4)

is at an inclination angle of the swashplate
relative to the axial direction of the cylinder
(7), the plane (A) will act as a cam relative to
the slipper (5).
● In this way, the piston (6) will slide inside the
cylinder (7) so that the difference between
capacities (E) and (F) will be generated inside
the cylinder (7).
● The oil suction/discharge quantity of a piston
is equal to (F) - (E). Fig. 4-25
● When the cylinder (7) rotates and the
capacity of the cavity (E) becomes smaller,
the pressurized oil will be discharged.
● On the other hand, the capacity of the cavity
(F) becomes larger during which the oil is
sucked.

● When the centerline (X) of the swashplate (4)

coincides with the axial direction of the
cylinder (7) (the inclination angle (a) of the
swashplate = 0), the difference between
capacities (E) and (F) inside the cylinder (7)
will become 0.
● In this state, the suction and discharge of
pressurized oil won’t be performed, i.e. there
will be no oil pumping action. (However, the
inclination angle of the swashplate angle isn’t
set to 0 actually.)
Fig. 4-26

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SY215CCM3K Hydraulic Excavator Structure and Function

Oil delivery control

● If the inclination angle (a) of the swashplate
becomes larger, the difference between
capacities (E) and (F) becomes larger and
the pump oil delivery quantity (Q) increases.
● The piston (13) is used to change the
inclination angle (a) of the swashplate.
● The piston (13) makes a reciprocating motion
in a straight line under the control of the
regulator.
● The straight motion is transferred to the
swashplate (4) via the drive pin (16) to drive
the swashplate to slide and change the
inclination angle of the swashplate, thus
changing the displacement of the main pump. Fig. 4-27

Service Manual.10-2017 4-33

Structure and Function SY215CCM3K Hydraulic Excavator

Pilot pump

Fig. 4-28

307: Valve stem 361: Body

308: Valve seat 433: Screw
309: Retaining ring 434: Screw
310. Spring pin 435: Screw
311: Adjusting screw 466: Plug
312: Nut 700: Washer
351: Body 710: O-ring
353: Gear shaft 725: O-ring
354: Gear shaft 732: O-ring
355: Filter element 850: Washer

Function
● The engine drives the drive shafts of the main
pump and pilot pump via the transmission
and then drives the pilot pump through gear
engagement.

4-34 Service Manual.10-2017

 Fig. 4-29
Regulator (KR7G-0E05-V)
SY215CCM3K Hydraulic Excavator

Mounting torque of the bolt•plug•nut•servo piston Nameplate and serial

Service Manual.10-2017
number

Part number Thread Size Mounting torque

Model

Serial number

Direction B

Hydraulic
schematic diagram
Structure and Function

4-35
4
Structure and Function SY215CCM3K Hydraulic Excavator

Class Code Product name Quantity Remarks

C 924 Hexagon socket head setscrew 1
/ 897 Pin 1
/ 887 Pin 1
D 801 Hexagon nut 1 JIS B 1181 N-M10
D 756 O-ring 2
D 755 O-ring 2
D 733 O-ring 2
D 731 O-ring 1
D 724 O-ring 5
D 708 O-ring 1
/ 656 Cover plate 1
/ 652 Slide valve 1
/ 651 Valve sleeve 1
/ 646 Pilot spring 1
/ 643 Pilot piston 1
/ 631 Pf pilot sleeve 1
/ 627 Regulating wheel 1
/ 624 Spring seat 1
/ 614 Pivot plug 1
/ 611 Feedback rod 1
/ 601 Shell 1
/ 545 Steel ball 2
/ 543 Stop block 2
/ 541 Valve seat 2
C 496 Countersunk plug 9
C 466 VIP plug 1
D 418 Hexagon socket head bolt 2 JIS B 1176 M5-12
D 415 Hexagon socket head bolt 6 JIS B 1176 M8-50
D 408 Hexagon socket head bolt 1 JIS B 1176 M6-40
D 407 Hexagon socket head bolt 4 JIS B 1176 M6-30
D 402 Hexagon socket head bolt 4 JIS B 1176 M6-16
/ 325 Valve 1
Proportional reducing solenoid
B 079 1
valve
B — Regulator assembly 1

Class description:
B Subassemblies that can be purchased from the agent (with individual parts not sold separately)
/ Individual parts contained in class B subassemblies (not sold separately)
C Parts that can be purchased from the agent
D Parts that can be purchased on the market

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SY215CCM3K Hydraulic Excavator Structure and Function

Functional principles

● The regulator controls the flow of the main

pump based on the command signal pressure
so that the pump driving power doesn’t exceed
the engine power.
● Pumps 1 and 2 are equipped with a regulator
respectively. The main parts of the regulator
include the solenoid proportional reducing
valve (1), positive flow regulator (2), servo
piston (4) and servo reversing valve (3). The
regulator opens or closes the oil circuit of the
servo piston (3), changes the inclination of
hydraulic cylinder block, and controls the pump
flow based on the command signal pressure.

4
Fig. 4-30

Control mechanism composition

Current control
● Through change of the command current I
flowing into the solenoid proportional reducing
valve, the inclination angle (output flow) of the
pump can be controlled steplessly. The
regulator is adopted with a positive flow control
(or positive control) mode in which the output
flow Q increases with the increase of the
command current I. This mechanism can
ensure that the current at a required flow
corresponding to the operation is input, so that
the pump only outputs the required flow,
therefore, the useless power won’t be wasted.

Service Manual.10-2017 4-37

Structure and Function SY215CCM3K Hydraulic Excavator

Adjustment of the regulator

Fig. 4-31

531: Tilting pin

532: Servo piston
548: Feedback pin
806: Fixing nut
808: Fixing nut
953: Adjusting screw
954: Adjusting screw
● The maximum and minimum flow rates can be
adjusted with the adjusting screws (953, 954)
on the pump body side, and the flow control
characteristics can be adjusted with the
hexagon socket head setscrew (924) on the Fig. 4-32
regulator.

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SY215CCM3K Hydraulic Excavator Structure and Function

Adjustment of the maximum flow (on the pump

body side)
● Loosen the hexagon nut (808) and tighten (or
loosen) the hexagon socket head setscrew

Output flow Q
(954). The control characteristics except the
maximum flow are not changed.

Command current I

Fig. 4-33

Adjustment of the minimum flow (on the pump

body side) 4
Output flow Q
Loosen the hexagon nut (806) and tighten (or
loosen) the hexagon socket head setscrew
(953). Although the case in which other control
characteristics aren’t changed is the same as
that of adjustment of the maximum flow, it shall
be noted that the required power may increase
under the maximum output pressure (overflow)
condition if excessive tightening occurs.

Command current I

Fig. 4-34

Adjustment of the flow control characteristic

● Loosen the hexagon nut (801), and then
tighten (or loosen) the hexagon socket head
setscrew (924). When the hexagon socket
Output flow Q

head setscrew (924) is tightened, the control

line graph will move to the right as shown in the
right figure.

Command current I

Fig. 4-35

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Structure and Function SY215CCM3K Hydraulic Excavator

Action description
Flow control
● The output flow of the pump can be controlled

Output flow Q
steplessly through the command current I
(when the pump is at a constant speed) as
shown in the right figure.

Command current I

Fig. 4-36

Flow increase action

● When the command current I increases and
the pressure of the solenoid proportional
reducing valve rises twice, the slide valve (652)
will move to the right by means of the pilot
piston (643). When the hydraulic pressure
pushed to the right and the elastic force of the
pilot spring (646) are in the balance position,
the slide valve (652) will stop moving.
● In case that the slide valve (652) moves to the
right, the pressure of the large-diameter part of
servo piston will be discharged because the cl Inclination angle Large
port and tank port are connected so that the
servo piston (532) will move to the left by
means of the output pressure P1 of the Fig. 4-37
small-diameter part, therefore, the inclination
angle will increase.
● As the feedback rod (611) is connected with
the servo piston and valve sleeve (651), the
feedback rod will swing with the point A as the
pivot if the servo piston (632) moves to the left,
therefore, the valve sleeve will move to the
right.
● Through such movement, the opening between
the slide valve/valve body will be slowly closed,
and the servo piston will stop until the opening
is fully closed.

Fig. 4-38

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SY215CCM3K Hydraulic Excavator Structure and Function

Flow decrease action

● When the command current I decreases and
the pressure of the solenoid proportional
reducing valve declines twice, the slide valve
(652) will move to the left. In case that the slide
valve (652) moves, the output pressure P1 will
be conducted through the cl port of the slide
valve and guided into the large-diameter
chamber of the servo piston. On the other
hand, the output pressure P1 will be usually
introduced into the small-diameter chamber of
the servo piston so that the servo piston will Small inclination angle
move to the right by means of the area
difference, thereby, the inclination angle will
decrease. Fig. 4-39
● In case that the servo piston (532) moves to
the right, the feedback rod will swing with the
point A as the pivot, therefore, the valve sleeve
will move to the left. Through such movement,
the opening between the valve spool and the
4
valve body will move to be closed, and the
servo piston (532) will stop until the opening is
fully closed.

Fig. 4-40
List of Adjustment Quantities of the Regulator
Regulator model KR7G-0E05-V
Speed (min-1) 2000
Screw-in (rotation) quantity of the adjusting
Adjustment of the +1/4
screw (954)
maximum flow
Flow variation quantity (L/min) -5.9
Screw-in (rotation) quantity of the adjusting
Adjustment of the +1/4
screw (953)
minimum flow
Flow variation quantity (L/min) +4.7

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Structure and Function SY215CCM3K Hydraulic Excavator

Control valve
Type: KMX15RB

Fig. 4-41

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SY215CCM3K Hydraulic Excavator Structure and Function

XAtr ： Right traveling (reverse) pilot port XBp2 ： Bypass cutoff valve spool pilot port (on
the P2 side)
XBtr ： Right traveling (forward) pilot port XAb2 ： Boom converging (lifting) pilot port
pressure
(XAo)： (reserved pilot port) Psp ： Swing priority pilot port
(XBo)： (reserved pilot port) R1 ： Oil return port
XAk ： Bucket (digging) pilot port R2 ： Oil replenishment port
XBk ： Bucket (unloading) pilot port Atr ： Left travel motor port (reverse)
XAb1 ： Boom 1 (lifting) pilot port Btr ： Right travel motor port (forward)
XBb1 ： Boom 1 (lowering) pilot port (AO)： Reserved port
XAa2 ： Arm 2 (extension) pilot port (Bo)： Reserved port
XBa2 ： Arm 2 (retraction) pilot port Ak ： Bucket cylinder piston head side port
(digging)
XAtL ： Left traveling (reverse) pilot port Bk ： Bucket cylinder piston rod side port
(unloading)
XBtL ： Left traveling (forward) pilot port Ab ： Boom cylinder piston head side port
(lifting)
XAs ： Swing (leftward) pilot port Bb ： Boom cylinder piston rod side port
(lowering) 4
XBs ： Swing (rightward) pilot port AtL ： Left travel motor port (reverse)
XAa1 ： Arm 1 (extension) pilot port BtL ： Left travel motor port (forward)
XBa1 ： Arm 1 (retraction) pilot port As ： Swing motor port (leftward)
Dr1 ： Leaky oil port Bs ： Swing motor port (rightward)
Px ： Signal port for work equipment Aa ： Arm cylinder piston rod side port
(extension)
Py ： Traveling signal port Ba ： Arm cylinder piston head side port
(retraction)
Pz ： Pilot pressure for charge air pressure of the P1 ： Pump port (on the P1 side)
main relief valve
PG ： Pilot pressure source port P2 ： Pump port (on the P2 side)
Pns ： Swing logic control valve pilot port MR ： Main relief valve
PCK ： Bucket (digging) stroke limit pilot port AR ： Arm regeneration cutoff valve
PnA2 : Arm 2 logic control valve pilot port AbR ： Port relief valve
Dr2 ： Leaky oil port BbR ： Port relief valve
Dr3 ： Leaky oil port AkR ： Port relief valve
Dr6 ： Leaky oil port BkR Port relief valve
Dr7 ： Leaky oil port AoR ： Port relief valve
Pal ： Locking valve pilot port (on the arm piston BoR ： Port relief valve
rod side)
PbL ： Locking valve pilot port (on the boom piston AaR ： Port relief valve
head side)
(XBp1)： Bypass cutoff valve spool pilot port (on the BaR ： Port relief valve
P1 side)

Technical parameters
Item Specification
Standard flow (equivalent to 1 pump) 234L/min
Main relief valve under the common
34.3MPa
condition
Maximum pressure
Main relief valve under the charge air
37.3MPa
pressure condition
Port relief valve under the common
Maximum pressure 39.2MPa
condition
Hydraulic oil temperature -20~90℃
Maximum pressure of leaky oil 0.3MPa

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Structure and Function SY215CCM3K Hydraulic Excavator

Hydraulic circuit diagram

(with the bucket converging function)

Traveling Straight
(right) traveling

Swing
Traveling (left)

Swing priority

Boom 1

Boom 2

Standby Bucket

Arm 2
Arm 1

Bypass
cutoff

Fig. 4-42

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SY215CCM3K Hydraulic Excavator Structure and Function

Working principles
(1) Valve spool in the neutral position
[Main circuit]
When all valve spools are in the neutral position, the hydraulic oil from the hydraulic pump (front) will flow
in from the pump port P1. It will be introduced into the main passage (1), flow into the neutral bypass (2)
(M-shaped slide valve function) of straight traveling (308), left traveling (301), boom 1 (303), bucket
(304) and arm 2 (306) valve spools, and then return to the hydraulic tank from the oil return port (R1).
The hydraulic oil from the hydraulic pump (rear) will flow in from the pump port P2. It will be introduced
into the main bypass (3), flow into the neutral bypass (2) (M-shaped slide valve function) of right traveling
(301), swing (305), boom converging (boom 2:307) ), standby (309) and arm 1 (302) valve spools, and
then return to the hydraulic tank from the oil return port (R1).

Fig. 4-43

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Structure and Function SY215CCM3K Hydraulic Excavator

(2) Traveling
[Pilot circuit]
When the left and right traveling valve spools are switched, the side bypass will be closed, thus the
pressure at the port Py (traveling signal port) will increase.
[Main circuit]
When the pilot port XBtL for the left traveling valve spool (301) is pressurized, the neutral bypass (2) on
the boom 1 side will be closed, and the hydraulic oil from the hydraulic pump (front) will be supplied into
the left travel motor from the port BtL.
Similarly, when the pilot port XBtr for the right traveling valve spool (301) is pressurized, the neutral
bypass (2) on the arm 1 side will be closed, and the hydraulic oil from the hydraulic pump (rear) will be
supplied into the right travel motor from the port Btr.
On the other hand, the oil returned from the left and right travel motors will pass through the left traveling
(right traveling) valve spool from the port AtL (Atr). Then, it will return to the hydraulic tank from the oil
return port (R1).
When the travel motor on the opposite side is operated (i.e. when the pilot ports XAtr and XAtL are
pressurized), the above procedures will be followed.

Travel motor

Fig. 4-44

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SY215CCM3K Hydraulic Excavator Structure and Function

(3) Arm
① Arm operated for extension
[Pilot circuit]
When the arm 2 valve spool (306) is switched, the side bypass will be closed, thus the pressure at the
port Px (signal port for work equipment) will increase.
[Main circuit]
When the arm is extended, the pilot pressure oil will be supplied into the ports XAa1 and XAa2. When
the pilot pressure oil is applied on both sides of the ports XAa1 and XAa2, the arm 1 and arm 2 valve
spools will be switched to the left side as shown in Fig. 4-43. Thus, the hydraulic oil flowing in from P2
will be introduced into the neutral bypass (2) through the main passage (3). The neutral bypass (302) will
be disconnected through switching of the arm 1 valve spool (302). For this purpose, the hydraulic oil
flowing into the parallel passage will push away the cone valve (511) of the check valve and flow into the
peripheries of arm 1 valve spool (302) and arm 2 valve spool (306), and be supplied to the arm cylinder
piston rod side (R) from the port Aa.
On the other hand, the hydraulic oil flowing in from the port P1 will be introduced into the neutral bypass
(2) through the main passage (1). The neutral bypass (306) will be disconnected through switching of the
arm 2 valve spool (302). For this purpose, the hydraulic oil flowing in from the parallel passage will push
the logic cone valve (256-101) of the arm 2 logic valve subassembly, and the hydraulic oil flowing in from 4
the neutral bypass will push away the cone valve (511) of the check valve and flow into the arm 2 valve
spool (306) from the U-shaped passage. Then, the hydraulic oil will be converged with oil from the port
Aa through the internal passage of the arm 2 valve spool (306) and supplied to the arm cylinder piston
rod side (R).
The oil returned from the arm cylinder piston head side (H) through the port Ba will flow into the tank
circuits of arm 1 and arm 2, and return to the hydraulic tank from the tank port (R1).

Service Manual.10-2017 4-47

Structure and Function SY215CCM3K Hydraulic Excavator

Fig. 4-45

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SY215CCM3K Hydraulic Excavator Structure and Function

② Arm operated for retraction

[Pilot circuit]
When the arm 2 valve spool (306) is switched, the side bypass will be closed, thus the pressure at the
port Px (signal port for work equipment) will increase. At the same time, the pressure oil will be supplied
into the port PaL, and the release signal of the locking valve selector pair (252) will be sent.
[Main circuit]
When the arm is retracted, the pilot pressure oil will be supplied into the ports XBa1 and XBa2. When the
pilot pressure oil is applied on both sides of the ports XBa1 and XBa2, the arm 1 and arm 2 valve spools
will be switched to the left side as shown in Fig. 4-48. Thus, the hydraulic oil flowing in from P2 will be
introduced into the neutral bypass (2) through the main passage (3). The neutral bypass (302) will be
disconnected through switching of the arm 1 valve spool (302). For this purpose, the hydraulic oil flowing
into the parallel passage will push away the cone valve (511) of the check valve and flow into the arm 1
valve spool (302) from the U-shaped passage. Then, the hydraulic oil will flow to the periphery of the arm
1 valve spool (302), and will be supplied to the arm cylinder piston head side (H) from the port Ba.
On one hand, the hydraulic oil flowing in from the port P1 will be introduced into the neutral bypass (2)
through the main passage (1). The neutral bypass (306) will be disconnected through switching of the
arm 2 valve spool (302). For this purpose, the hydraulic oil flowing in from the parallel passage will push
the logic cone valve (256-101) of the arm 2 logic valve subassembly, and the hydraulic oil flowing in from
the neutral bypass will push away the cone valve (511) of the check valve and flow into the arm 2 valve 4
spool (306) from the U-shaped passage. Then, the hydraulic oil will be converged with the port Ba from
the internal passage of the arm 2 valve spool (306) and supplied to the arm cylinder piston head side
(H).
On the other hand, the oil returned from the arm cylinder piston (R) will return the hydraulic oil under
increased pressure to the port Aa by means of the dead weight of arm, etc. The hydraulic oil returned to
the port Aa will flow into the valve spool from the hole on the periphery of the arm 1 valve spool (302)
and push away the cone valve (302-317) inside the valve spool only when a low load is applied, and will
be converged with the port Ba from the hole on the valve spool, which is called the arm regeneration
function.
If the pressure on the arm cylinder piston head side and in the U-shaped passage rises, the arm
regeneration cutoff valve spool (257-211) will be switched to the left side as shown in Fig. 4-49 and
closed by means of the back pressure of the cone valve (302-317) inside it. By this means, the arm
regeneration function will be released, and the oil returned from the arm cylinder piston rod side (R) will
flow into the valve spool from the hole (a) on the periphery of the arm 1 valve spool (302) and then into
the arm regeneration cutoff valve pair (257) from the hole (c) on the periphery of the arm 1 valve spool
(302), and return to the hydraulic tank through the tank port (R1).

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Structure and Function SY215CCM3K Hydraulic Excavator

● Low load

Dead weight of arm

Fig. 4-46

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SY215CCM3K Hydraulic Excavator Structure and Function

● Arm cylinder piston head side (H) under increased pressure

Fig. 4-47

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Structure and Function SY215CCM3K Hydraulic Excavator

(4) Boom
① Boom operated for lifting
[Pilot circuit]
When the boom 1 valve spool (303) is switched, the side bypass will be closed, thus the pressure at the
port Px (signal port for work equipment) will increase.
[Main circuit]
When the boom is operated for lifting, the pilot pressure oil will be supplied to the port XAb1, and the
boom 1 valve spool (303) will move to the left side as shown in Fig. 4-50. The hydraulic oil flowing in from
the port P1 will be introduced into the neutral bypass (2) through the main passage (1). The neutral
bypass will be disconnected through switching of the boom 1 valve spool (303). For this purpose, the
hydraulic oil flowing into the parallel passage will push away the cone valve (511) of the check valve and
flow into the boom 1 valve spool (303) from the U-shaped passage. Then, the hydraulic oil will flow to the
periphery of the boom 1 valve spool (303), and will be supplied to the boom cylinder piston head cavity
(H) from the port Ah.
At the same time, the pilot pressure oil will also be supplied to the port XAb2, and the boom 2 valve spool
(307) will move to the left side as shown in Fig. 49. The hydraulic oil flowing in from the port P2 will flow
into the boom 2 valve spool (307) through switching. Then, it will push away the cone valve (511) of the
check valve, and will be converged with the port Ab and supplied to the boom cylinder piston head cavity
(H) (which is called the boom converging function).
On the other hand, the oil returned from the boom cylinder piston rod side (R) will flow to the periphery of
the boom 1 valve spool (303) from the port Bb, and return to the hydraulic tank from the tank port (R1).

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SY215CCM3K Hydraulic Excavator Structure and Function

Fig. 4-48

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Structure and Function SY215CCM3K Hydraulic Excavator

② Boom operated for lowering

[Pilot circuit]
When the boom1 valve spool (303) is switched, the side bypass will be closed, thus the pressure at the
port Px (signal port for work equipment) will increase. At the same time, the pressure oil will be supplied
into the port PbL, and the release signal of the locking valve selector pair (252) will be sent.
[Main circuit]
When the boom is lowered, the pilot pressure oil will be supplied to the port XBb1, and the boom 1 valve
spool (303) will move to the right side as shown in Fig. 4-51. The hydraulic oil flowing in from the port P1
will be introduced into the neutral bypass (2) through the main passage (1). The neutral bypass will be
disconnected through switching of the boom valve spool (303). For this purpose, the hydraulic oil flowing
into the parallel passage will push open the cone valve (511) of the check valve and flow into the boom 1
valve spool (303) from the U-shaped passage. Then, the hydraulic oil will flow to the periphery of the
boom 1 valve spool (303), and will be supplied to the boom cylinder piston rod side (R) from the port Bb.
On the other hand, the oil return from the boom cylinder piston head side (H) will passes through the
hole (a) and periphery of the boom 1 valve spool (303).
The returned oil will raise the pressure through the dead weight of the boom. To maintain sufficient
pressure, the cone valve (303-317) inside the valve spool will be pushed to the right side as shown in
Fig. 4-51 via the internal passage of the valve spool so that the oil will flow out of the valve spool. This
pressure oil will be resupplied to the boom cylinder piston rod side (R) as the hydraulic oil for boom
lowering (which is called the boom regeneration function). A part of the returned oil flowing from the hole
(a) to the internal passage of the valve spool will return to the hydraulic tank via the hole (b).

Fig. 4-49

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SY215CCM3K Hydraulic Excavator Structure and Function

(5) Bucket
① Bucket operated for digging
[Pilot circuit]
When the bucket valve spool (304) is switched, the side bypass will be closed, thus the pressure at the
port Px (signal port for work equipment) will increase. Meanwhile, the pressure oil will also be supplied to
the port XBp2.
[Main circuit]
When the bucket is operated for digging, the pilot pressure oil will be supplied to the port XAk, and the
bucket valve spool (304) will move to the right side as shown in Fig. 4-52. The hydraulic oil flowing in
from the port P1 will be introduced into the neutral bypass (2) through the passage (1). The neutral
bypass will be disconnected through switching of the bucket valve spool (304). For this purpose, the
hydraulic oil flowing into the parallel passage will push open the cone valve (511) of the check valve and
flow into the bucket valve spool (304) from the U-shaped passage. Then, the hydraulic oil will flow to the
periphery of the bucket valve spool (304), and will be supplied to the bucket cylinder piston head side (H)
from the port Ak.
On the other hand, the oil returned from the bucket cylinder piston rod side (R) will flow to the tank port
(R1) from the periphery of the valve spool via the port Bk and return to the hydraulic tank.
When the boom is lifted and the bucket is operated for digging at the same time, the pilot pressure oil will 4
be supplied to the port Pck, thus the stroke of the bucket valve spool will not only be limited to the full
stroke position but can be limited to a halfway position. By this means, the passage of the bucket
cylinder will be throttled, and the hydraulic oil will also flow into the boom 1 valve spool (303) from the
bucket valve spool (304), thus boom lifting will be preformed preferentially.

Fig. 4-50

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Structure and Function SY215CCM3K Hydraulic Excavator

② Bucket operated for dumping

[Pilot circuit]
When the bucket valve spool (304) is switched, the side bypass will be closed, thus the pressure at the
port Px (signal port for work equipment) will increase. Meanwhile, the pressure oil will also be supplied to
the port XBp2.
[Main circuit]
When the bucket is operated for digging, the pilot pressure oil will be supplied to the port XBk, and the
bucket valve spool (304) will move to the left side. The hydraulic oil flowing in from the port P1 will be
introduced into the neutral bypass (2) through the passage (1). The neutral bypass will be disconnected
through switching of the bucket valve spool (304). For this purpose, the hydraulic oil flowing into the
parallel passage will push open the cone valve (511) of the check valve and flow into the bucket valve
spool (304) from the U-shaped passage. Then, the hydraulic oil will flow to the periphery of the bucket
valve spool (304), and will be supplied to the bucket cylinder piston rod side (R) from the port Bk.
On the other hand, the oil returned from the bucket cylinder piston rod side (H) will flow to the tank port
(R1) from the periphery of the valve spool via the port Ak and return to the hydraulic tank.

Fig. 4-51
③ Bucket converging
● When the bucket is operated for digging, the pilot pressure oil will be supplied to the port XBp2, the
neutral bypass cutoff valve spool (310) will be switched. The hydraulic oil flowing in from the port P2 will
be introduced into the neutral bypass (2) through the main passage (3). The neutral bypass will be
disconnected through switching of the neutral bypass valve spool (310). For this purpose, the hydraulic
oil will push away the check valve (514), and will be converged with the bucket valve spool (304) via the
internal passage and U-shaped passage.

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SY215CCM3K Hydraulic Excavator Structure and Function

(6) Swing
① Individual swing operation
[Pilot circuit]
When the swing valve spool (305) is switched, the side bypass will be closed, thus the pressure at the
port Px (signal port for work equipment) will increase.
[Main circuit]
When the individual swing operation is performed, the pilot pressure oil will be supplied to the port XAs
(or XBs), and the swing valve spool (305) will be switched. The hydraulic oil flowing in from the port P2
will be introduced into the neutral bypass (2) through the main passage (3). The neutral bypass will be
disconnected through switching of the swing valve spool (305). For this purpose, the hydraulic oil flowing
into the parallel passage will push open the logic cone valve (2540-101) of the swing logic valve
assembly and flow into the swing valve spool (305) from the U-shaped passage. Then, the hydraulic oil
will flow to the periphery of the swing valve spool (305), and will be supplied to the swing motor from the
port As (or Bs).
On the other hand, the oil returned from the swing motor will flow to the tank port (R1) from the periphery
of the valve spool via the port Bs (or As), and return to the hydraulic tank.

Swing motor

Fig. 4-52

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Structure and Function SY215CCM3K Hydraulic Excavator

② Swing priority function

[Pilot circuit]
The pilot pressure oil will be supplied to the port Psp, and the swing priority valve (311) will be switched.
[Main circuit]
When the swing priority valve spool (311) is switched, the opening area of the swing priority valve spool
will be reduced, so the hydraulic oil from the arm 1 valve spool (302) will also flow to the swing valve
spool (305), thus the swing action will be performed preferentially.

Fig. 4-53

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SY215CCM3K Hydraulic Excavator Structure and Function

(7) Standby
The standby valve spool is used for control of various additional devices.
① Optional operation
[Pilot circuit]
When the standby valve spool (309) is switched, the side bypass will be closed, thus the pressure at the
port Px (signal port for work equipment) will increase.
[Main circuit]
When the standby operation is performed, the pilot pressure oil will be supplied to the port XAo (or XBo),
and the standby valve spool (309) will be switched. The hydraulic oil flowing in from the port P2 will be
introduced into the neutral bypass (2) through the main passage (3). The neutral bypass will be
disconnected through switching of the standby valve spool (309). For this purpose, the hydraulic oil
flowing into the parallel passage will push open the cone valve (511) of the check valve and flow into the
standby valve spool (309) from the U-shaped passage. Then, the hydraulic oil will flow to the periphery
of the standby valve spool (309), and will be supplied to the additional device from the port Ao (or Bo).
On the other hand, the oil returned from the additional device will flow to the tank port (R1) from the
periphery of the valve spool via the port Bo (or Ao) and return to the hydraulic tank.
4

Fig. 4-54
② Standby converging
For the purpose of standby converging, the pilot pressure oil will be supplied to the port XBp1, and the
bypass cutoff valve spool (310) will be switched. The hydraulic oil flowing in from the port P1 will be
introduced into the neutral bypass (2) through the main passage (1). The neutral bypass will be
disconnected through switching of the bypass cutoff valve spool (310). For this purpose, the hydraulic oil
will push away the check valve (514), and will be converged with the standby valve spool (309) via the
internal passage and U-shaped passage.

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Structure and Function SY215CCM3K Hydraulic Excavator

(8) Straight traveling

When the traveling valve spool (301) is operated simultaneously with other valve spools.
The case where the traveling valve spool (301) is operated simultaneously with the swing valve spool
(305) is considered hereinafter.
(When the ports XAtL, XAtr and XAs are supplied with the pilot pressure oil.)
[Pilot circuit]
The side bypasses of the right traveling ·left traveling valve spool (301) and the swing valve spool on the
downstream side are closed.
The pilot pressure oil from the port PG is supplied to the port PTa, and the straight traveling valve spool
(308) is switched.
[Main circuit]
When the straight traveling valve spool (308) is switched, the right traveling·left traveling valve spool
(301) will be preferentially connected to the port P2, and the parallel passage of the swing ·boom 2 ·
standby ·arm 1 oil circuit / boom 1 ·bucket ·arm 2 oil circuit will be preferentially connected to the port
P1. For this purpose, the hydraulic oil from the port P2 will mainly flow into the ports Atl and Atr, and will
be uniformly supplied to the two travel motors.
On the other hand, the hydraulic oil from the port P1 will be supplied to the swing motor from the port As.
When the pressure oil at the port P2 is less than that at the port P1, a part of the hydraulic oil from the
port P1 will be delivered to the P2 side. By this means, a rapid drop in the traveling speed can be
prevented.

Fig. 4-55

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SY215CCM3K Hydraulic Excavator Structure and Function

(9) Function of the locking valve

The locking valve selector pair (252) is mounted between the arm cylinder piston rod side (R) and the
arm 1 valve spool (302) / arm 2 valve spool (306) to reduce the internal leakage of valve spool due to the
cylinder pressure.
Similarly, the locking valve selector pair (252) is also installed between the boom cylinder piston head
side (H) and the boom 1 valve spool (303) to reduce the internal leakage of valve spool due to the
cylinder pressure.
① Valve spool in the neutral position
The condition of the boom 1 valve spool (303) is shown hereinafter. (The condition of the arm 2 valve
spool (306) is the same.)
When the boom 1 valve spool (303) is in the neutral position, the valve spool (252-511) inside the locking
valve selector pair will be held in the position shown in Fig. 4-58, i.e., on the valve seat of the valve
sleeve (252-541) inside the locking valve selector pair by the elastic force of the spring (252-321).
In this position, the hydraulic oil on the boom cylinder piston head side (H) will flow via the hole (a) to
pass through the periphery of the valve spool (252-511) of the locking valve selector pair, and will be
pressed on the valve body seat by means of the cone valve (513) in the hole (b). By this means, the
internal leakage will be reduced.
4

Fig. 4-56

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Structure and Function SY215CCM3K Hydraulic Excavator

② Boom operated for lowering

When the boom is lowered, the port PbL will be supplied with the pilot pressure oil. Because of the pilot
pressure oil, the valve spool (252-511) inside the locking valve selector pair will move to the top as
shown in the figure below. With the movement of the valve spool (252-511) inside the locking valve
selector pair, the hole (a) will be cut off, and the hydraulic oil on the boom cylinder piston head side (H)
won’t flow into the spring chamber (RH). In addition, the oil in the spring chamber (RH) cavity will flow
into the leaked oil circuit via the hole (b). By this means, the cone valve (513) will be jacked by the
pressure of the boom cylinder piston head side (H), and the function of the locking valve selector pair
(252) will be released.

Fig. 4-57
③ Boom operated for lifting
When the boom is lifted, the port XAb1 will be supplied with the pilot pressure oil. The cone valve (513)
will be opened by the oil flowing in from the the boom 1 valve spool (303), thus the hydraulic oil will flow
into the port Ab.

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(10) Function of the main relief valve

The main relief valve is mounted on the valve body A (101). Its functions are shown below.
● The hydraulic oil is filled in the cavity (a) through the holes of valve seat (541) and valve rod (512)
via the passage (P) to press the valve rod (512) against the valve seat (541) so as to form a reliable
seal.
● When the pressure in the passage (P) exceeds the elastic force of the spring (621), the cone valve
(611) will be opened. Thus the hydraulic oil will flow into the low-pressure passage (R) through the
hole of the valve sleeve (103) from the periphery of the cone valve (611).
● The pressure in the cavity (a) will drop due to the opening of the cone valve (611), and the valve rod
(512) will be opened. By this means, the hydraulic oil in the passage (P) will flow directly into the
low-pressure passage (R).
● When the pressure oil above 3 Mpa is supplied to the port Pz, it will push the piston (614) to move
leftwards and change the set load of the spring (621) so that the charge air pressure state will be
achieved.

Fig. 4-58

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Structure and Function SY215CCM3K Hydraulic Excavator

(11) Function of the port relief valve

The port relief valve is installed between the cylinder port and the low-pressure passage. Beside the
functions of an relief valve, it also has the functions of an anti-cavitation oil supplement check valve. Its
functions are shown below.
① Functions as an relief valve
● The hydraulic oil is filled in the cavity (B) through the hole (A) of the piston (301) to press the valve
rod (511) against the valve seat (541) and the valve seat (541) is pressed against the valve body
seat so as to form a reliable seal.

Fig. 4-59

Fig. 4-60

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● When the pressure in the passage (P) exceeds the elastic force of the spring (621), the cone valve
(611) will be opened. Thus the hydraulic oil will flow into the low-pressure passage (R) through the
hole (C) from the periphery of the cone valve (611).

Fig. 4-61

Fig. 4-62

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● The pressure in the cavity (B) will drop due to the opening of the cone valve (611), and the valve
rod (511) will be opened. By this means, the hydraulic oil in the passage (P) will flow directly into
the low-pressure passage (R).

Fig. 4-63

Fig. 4-64

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② Functions as an anti-cavitation oil supplement check valve

When negative pressure occurs in the passage (P), the hydraulic oil will be supplied from the passage
(R). When the pressure in the passage (R) is higher than that in the passage (P), the valve seat (541)
will move to the right. Then, the hydraulic oil will flow into the passage (P) from the passage (R) through
the periphery of the valve seat (541) so as to prevent cavitation

Fig. 4-65

Fig. 4-66

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Sectional diagram

Straight
Right traveling
traveling

Left
Swin traveling
g

Boom 1
Boom 2

Bucket
Standby

Arm 2
Arm 1

(Bypass cutoff1)
Bypass cutoff 2

Section 0-0

Fig. 4-67

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Section (A-A, N-N)

Section A-A

Section N-N

Fig. 4-68

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Section (B-B)

Fig. 4-69

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Right traveling, straight traveling section (C-C)

Right Straight
traveling traveling

Section C-C

Fig. 4-70

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Swing, left traveling section (D-D)

Swing Left
traveling

Section D-D

Fig. 4-71

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Boom 1, boom 2 section (E-E, L-L)

Boom 2 Boom 1

Swing
priority
Section E-E Section L-L

Fig. 4-72

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Standby, bucket section (F-F)

Standby Bucket

Section F-F

Fig. 4-73

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Arm 1, arm 2 section (G-G)

Section G-G

Fig. 4-74

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Structure and Function SY215CCM3K Hydraulic Excavator

Bypass cutoff 1, bypass cutoff 2 section (H-H)

Section H-H

Fig. 4-75

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Mounting Mounting
torque NO. Part name Quantity torque NO. Part name Quantity
（N·m) （N·m)
Straight traveling
101 Valve body A 1 308 1
valve spool pair
102 Valve body B 1 309 Standby valve spool 1
Bypass cutoff valve
13~17 151 Plug 3 310 2
spool
Swing priority valve
34~39 152 Plug 7 311 1
spool
220~250 153 Plug 3 320 Spring 9
69~78 154 Plug 6 321 Spring 8
7.4~9.8 156 Orifice plug 3 322 Spring 1
7.5~10 158 Plug 5 323 Spring 1
10~14 159 Plug 3 326 Spring 1
161 O-ring 3 327 Spring 1
162 O-ring 7 329 Spring 1
163 O-ring 21 331 Spring seat 4
164 O-ring 7 332 Spring seat 22
165 O-ring 14 16~18 333 Bolt with pad 2
166 O-ring 1 335 Stop block 9
168 O-ring 3 16~18 336 Bolt with pad 11
169 O-ring 2 337 Stop block 2
4
201 Spring shield 9 339 Stop block 2
202 Spring shield 2 372 Spring 2
203 Spring shield 2 373 Spring 2
204 Valve spool cover 7 511 Cone valve 8
205 Valve spool cover 1 512 Cone valve 2
206 Valve spool cover 1 513 Cone valve 2
209 Flange 2 514 Cone valve 2
210 Plate 1 521 Spring 10
211 Piston 1 522 Spring 2
49~65 251 Logic control valve 2 523 Spring 2
Locking valve selector
9.8~14 252 2 541 Steel ball 1
pair
Swing logic valve
254 1 542 Spring seat 1
subassembly
Arm 2 logic valve
256 1 543 Spring 1
subassembly
Arm regeneration
69~78 257 1 25~29 550 Plug 1
cutoff valve pair
258 Plug 1 230~260 551 Plug 11
259 Plug 1 230~260 552 Plug 2
261 O-ring 11 130~150 553 Plug 2
262 O-ring 2 561 O-ring 17
264 O-ring 9 562 O-ring 2
Hexagon socket head
25~34 273 44 69~78 601 Main relief valve 1
bolt
Hexagon socket head
98~120 274 4 69~78 602 Port relief valve 6
bolt
301 Traveling valve spool 2 120~140 604 Port relief valve 2
302 Arm 1 valve spool pair 1 69~78 612 Plug 2
Boom 1 valve spool Hexagon socket
303 1 49~65 971 8
pair head bolt
Hexagon socket
304 Bucket valve spool 1 140~180 975 10
head bolt
305 Swing valve spool 1 977 Nameplate 1
306 Arm 2 valve spool 1 978 Rivet 2
307 Boom 2 valve spool 1

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Structure and Function SY215CCM3K Hydraulic Excavator

Swing motor
Type: M5X180CHB

Fig. 4-76
A： Main oil port 1. Safety valve
Technical Specifications
B： Main oil port 2. Anti-rebound valve
M： Oil supplement port Model SY215CCM3K
PA： Pressure check port Theoretical
169.4 cm3/rev
PB: Pressure check port displacement
DR: Oil drain port Set pressure of
PG： Brake release port 25.5 MPa {260 kgf/cm2}
safety valve
SH： Brake command
Rated engine
port 2000 rpm
speed
L： Liquid level gauge
rod Brake release
3.4 MPa {34 kgf/cm2}
IP Gear oil supply port pressure

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Fig. 4-77
1. Spacer bushing 6. Check valve spring 11. Plate
2. Shell 7. Check valve 12. Piston
3. Disc 8. Port plate 13. Driving shaft
4. Brake spring 9. Cylinder barrel
5. Casing 10. Brake piston

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Swing retention brake

● The PG port is directly connected to the pilot gear pump under the pressure of 3.9 MPa;

Pump

Main
valve

Fig. 4-78
● The port SH is connected with the port PX of the main valve, therefore, if the movements except
traveling are performed on the main valve, a pressure will be created at the port PX to connect PG
with the oil cavity a under the piston 7, and the hydraulic oil will push the brake piston upward,
compress the brake spring 1 and separate the disk 5 from the plate 6, thus the brake will be
released.

Fig. 4-79
● Otherwise, no pressure will be generated at the port PX, therefore, PG will be disconnected from the
oil cavity a under the piston 7, the brake spring 1 will push the brake piston, and the disc 5 and the
plate 6 will be pushed together, thus the brake will be applied.

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Relief valve part

Structure
● The relief valve part includes relief valves (1) and (2) and check valves (3) and (4).
Function
● When the machine is in the swing retention mode, the control valve (5) will close the motor outlet oil
circuit, but the motor will continue to rotate due to the inertial force, so the motor output will
abnormally increase, which will cause motor damage.
● To prevent motor damage, the relief valve will overflow the pressure oil at an abnormally high
pressure to the oil port (M) from the motor outlet side (high-pressure side).
Operation
1. In case of start of swing (assuming the oil
port A is filled with high-pressure oil)
● When the swing control lever is operated to
the right swing position, the pressure oil from
the pump will be supplied to the port (A)
through the control valve (5).
● When the starting torque is generated inside it 4
due to the increase of pressure at the oil port
(A), the motor will start to rotate
● The pressure oil from the motor outlet will
return from the oil port (B) to the tank via the
control valve (5).

Fig. 4-80
2. In case of stop of swing
● When the swing control lever returns to the
neutral position, the supply of pressure oil
from the pump to the oil port (A) will be
interrupted.
● The pressure oil from the motor outlet will not
return to the tank because the oil circuit
between the control valve (5) and the tank is
closed, thus leading to increase in the
pressure at the port (B).
● When the swing resistance is generated on
the motor, the brake will start to work.
● When the pressure at the port (B) increases to
the set value of the relief valve (2), relief will
occur.
● The motor with a large brake torque applied
on it will stop running.
● When the relief valve (2) starts to work, the
overflown pressure oil and the pressure oil Fig. 4-81
from the oil port (M) will be supplied to the oil
port (A) via the check valve (3).
● The oil port (A) is protected against cavitation
under the above conditions.

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Damping valve
Working diagram
Swing motor

The spring chamber is under high pressure Orifice

Screw
plug
Spring A

Poppet
Anti-rebound valve Ball The chamber N is under high
Piston pressure Anti-rebound valve(B)
Spring B Chamber M

Pressure at the oil

port AM
Pres
sure

Piston Time

Pressure at the oil

port AM
With anti-rebound
valve
Pres
sure

Without anti-rebound Time

Control valve valve

Fig. 4-82
Effect illustration diagram
With anti-rebound valve

Without anti-rebound valve

Rebounding pressure

Pressure MA

Suppression pressure
Rebounding pressure
Pressure MB

First rebounding

Second rebounding
Motor speed

Start Braking Rebounding

Time

Fig. 4-83

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Overview

● The machine may shake during rotation due

to the inertia of swing body, recoil force and
rigidity of mechanical system, compressibility
of hydraulic oil, etc. The anti-swing valve can
effectively mitigate this effect. It can be
effectively used to prevent the overflow of the
load in the bucket and reduce the cycle time
when rotation stops (the good positioning
performance ensures rapid movement for the
next operation.)

Fig. 4-84

Operation
1. In case of generation of the brake pressure 4
at the oil port (B)
● The pressure chamber N is under high
pressure; the piston is held in the position
shown in the figure; the pressure oil at the end
BM cannot be transferred to the end AM, and
relief braking of relief valve is guaranteed at
this time. (Fig. 4-84)
2． After stop of the motor
● Because of pressure drop at the oil port BM,
the piston at the top shown in the figure moves Fig. 4-85
leftward under the action of spring, and the
pressure oil at the end BM enters the end AM
via the poppet and steel ball, thus further
reducing the pressure at the end BM. (Fig.
4-85)

3． When the machine is to rotate reversely

● When the machine is to rotate reversely due
to the inertia during shutdown, the pressure at
the end AM rises, the piston at the lower
portion shown in the figure moves leftward
under the action of spring, and the pressure oil
at the end AM enters the end BM via the
poppet and steel ball at the lower portion
shown in the figure, thus reducing the
pressure at the end AM and avoiding swing.
(Fig. 4-86)

Fig. 4-86

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Structure and Function SY215CCM3K Hydraulic Excavator

Central swivel joint

Fig. 4-87

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1. Swing shaft A： Independent valve BTL

2. Dust ring B： Independent valve BTR
3. O-ring C： Independent valve ATL
4. Swing body
D： Independent valve ATR
5. Rotary seal φ100x5
A1: To the left travel motor oil port (P1)
6. Gasket
B2: To the right travel motor oil port (P2)
7. Retaining ring φ90
C3: To the left travel motor oil port (P2)
8. Plug (ZG3/4)
D4: To the right travel motor oil port (P1)
9. Plug (ZG1/4)
G： To the swing motor port DB
10. Cover
G: From the oil drain port (D1, D2) of travel motor
11. Spacer bushing reducer assembly
12. Gasket F： From the port A2 of solenoid valve group
13. Gasket F1： To the high and low speed switching port (P) 4
of travel motor reducer

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Structure and Function SY215CCM3K Hydraulic Excavator

Travel motor
Model: TM40VD

Fig. 4-88

P: 2-speed pilot piping port D1: Oil drain port

P1: Pressure check port D2: Plug
P2: Pressure check port A：Main oil port
P5: External parking brake release port B：Main oil port

Working conditions
Technical Specifications
Speed 1 Speed 2
Gear ratio 49.95
Reduction gear Theoretical output torque (kgf.m) Max. 4650 4535 2767
Theoretical output speed (r.p.m) Max. 60 28 45.9
Displacement (cc/rev) Max. 174.7 162.9 99.4
2
Continuous pressure (kgf/cm ) Max. 350 350
Theoretical speed (r.p.m) Max. 2800 1400 2294
Hydraulic
Flow (l/min) 250 228
motor
2
2-speed control pressure(kgf/cm ) 20~70
Braking torque (kgf.m) Min. 50
2
Brake release pressure (kgf/cm ) 8.2
Above 365 (1-3 L/min)
Relief valve opening pressure
Below 420 (15 L/min)

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Exploded view

Fig. 4-89

1. Rear flange 16. Pipe plug 31. Retaining plate 46. Ball bearing
2. H5 type balance 17. Valve spool 32. Ball bushing 47. Spring
valve spool
18. Spring 33. Timing plate 48. Piston
3. Pipe plug
19. Steel ball 34. Parking piston 49. Stop
4. D type stop block
20. Orifice plate 35. Spring 50. Pivot
5. Non-return pipe plug
21. O-ring 36. Cylinder block 51. Piston
6. Check valve spring
22. Filter 52. Piston seal
7. Spring 37. Friction plate
23. Nameplate 53. Valve body
8. Stop spring 38. Partition
24. Rivet 54. Washer
9. O-ring 39. Oil seal
25. Plug 55. O-ring
10. O-ring 40. O-ring
26. Driving shaft 56. O-ring
11. Parallel pin 41. O-ring
27. P type swashplate 57. Adjusting shim
12. Hexagon socket 42. Parallel pin
28. Cylinder 58. Spring
head bolt
43. Washer
29. Piston 59. Piston rod
13. O-ring
44. Washer
30. Stop
14. Plug
45. Ball bearing
15. Plug

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Structure and Function SY215CCM3K Hydraulic Excavator

Travel motor
Model: MAG-170VP

Fig. 4-90

Ps： 2-speed pilot piping port P2： Main oil port

Pm1: Pressure check port A. Mounting contact surface with the sprocket
Pm2: Pressure check port B. Mounting contact surface with the carrier frame
Tin： Oil filler in the motor housing 1. Mounting hole with the sprocket
Pp： External parking brake release port 2. Mounting hole with the carrier frame

Dr： Oil drain port

P1： Main oil port

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Equivalent displacement cm3/rev 7304

Motor Large displacement q1 cm3/rev 168.9
displacement
q Small displacement q2 cm3/rev 100.3
Reduction ratio i 43.246
Travel speed Low speed to high speed Mpa Above 1.5
switching
pilot High speed to low speed Mpa Below 0.4
pressure
Parking brake torque N•m 581×i
Working flow L/min Below 270
Working pressure Mpa Below 34.3
Peak pressure Mpa Below 44.1
Number of times of action when the
pressure is greater than 34.3 Mpa but Times Below 1.2 million
less than 44.1 Mpa 4
In case of
high rpm
Motor capacity
shaft
In case of
rpm Below 2500
low capacity
Swing speed
In case of
high rpm
Reducer capacity
In case of
rpm Below 60
low capacity
Output torque KN•m Below 37.3
Normal PS
Input power Below 210 (within a continuous period
Maximum PS
of 30 s)
Oil drain Normal Mpa Below 0.2
pressure Maximum instant Mpa Below 0.5 (below 300,000 Hz)
Weight kg 250

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Structure and Function SY215CCM3K Hydraulic Excavator

Connected with the

sprocket

Fixed on the lower frame

Piston motor shaft

Fig. 4-91

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Operation instruction of basic components

Double balance valve
Function:
● It has the overspeed prevention function for controlling the motor speed to correspond to the supply
flow when the speed of the piston motor tends to increase relative to the supply flow due to the
external load (hereinafter referred to as the pump action).
● It has the brake function of gradual motor stop through application of a brake force to the swing
action of the piston motor by means of formation of a brake circuit together with the overload relief
valve.
● It has the function of a shuttle valve for high pressure selection to release the parking brake by
means of its pressure.
● The structure of a standard double balance valve is shown in Fig. 1. The working principles will be
described hereinafter using this standard double balance valve as an example.
A. Stop
● When the main valve is in the neutral state (the motor stops), the ports M1 and M2 will be closed by
the valve spool (1) and check valve (2) (the oil ports will be closed) due to the lack of pressure on
the ports P1 and P2 , and the motor won’t slew . 4

Oil circuit B

Oil circuit C2

Oil circuit C1
Orifice D3
Orifice D1

Damping chamber A2
Damping chamber A1

Orifice D4
Orifice D2
Spring chamber 2
Spring chamber 1

Fig. 4-92
Fig. 1 Structure of double balance valve (stop)

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B. Motor start
● When the hydraulic oil from the main pump flows in from the port P1 of the double balance valve,
the check valve (2-1) will push the spring (3) to move leftwards, the oil circuit C1 will be opened,
and the hydraulic oil will flow into the piston motor from the port M1 to drive the motor to rotate. At
the same time, the oil returned from the piston motor will flow back to the double balance valve
through the port M2 but will be blocked by the check valve (2-2), so the discharge pressure of the
main pump will rise. Therefore, the pressure at the port P1 will increase, and the hydraulic oil will
act on the spring chamber 1 and damping chamber A1 through the orifice (4-1) and check valve
(5-1) to generate a force in proportion to the pressure to push the spring (7-2) on the opposite side
so as to push the piston (1) to move rightwards. At this time, the oil returned from the port M2 will
pass through the oil passage B of the notch around the piston (1), flow through the port P2 while
generating a back pressure at the port M2 and then return to the tank through the main valve, thus
the motor will start to rotate.

Oil circuit B

Oil circuit C2
Oil circuit C1
Orifice D3
Orifice D1

Damping chamber A2
Damping chamber A1

Orifice D4
Orifice D2

Spring chamber 2
Spring chamber 1

Fig. 4-93
Fig. 2 Double balance valve during swing of motor
C. Balance function
● When the motor is subjected to overspeed rotation by the external load during operation, the piston
motor pump action will occur, thus causing the motor to run out of control. In this case, the port P1
will act as the suction side for the pump action, so the pressure will decrease. At the same time, the
pressure in the spring chamber 1 and damping chamber A1 will also decrease, therefore, the piston
(1) will move to the left under the action of the spring (7-2) and close the oil circuit B, oil return
circuit as well as oil circuit on the suction side. After the oil circuit B is closed, the pressure at the
port P1 will rise instantaneously due to the hydraulic oil from the main pump, thus causing the
piston (1) to move to the right again. In this way, when the external load generates a pump action,
the oil circuit B will maintain a constant opening area due to the micromotion of the piston (1).
Therefore, motor rotation can be maintained at a speed corresponding to the supply flow of the
main pump to prevent the motor from running out of control due to a vacuum in the hydraulic circuit.

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D. Motor brake
● The double balance valve and overload relief valve form a brake circuit. When the main valve
returns to the neutral position, the hydraulic oil from the main pump will be cut off, and the pressure
at P1 and P2 will the same. Therefore, the piston (1) will move to the neutral position, and the
opening area of the oil circuit B will become small. Meanwhile, the motor will still try to rotate (pump
action) due to the inertial force of the external load, so the pressure at the port M2 will rise to act as
a brake force for motor rotation. In this case, when the pressure at the port M2 reaches the set
pressure of the relief valve (8), the cone valve (8-1) of the port M1 will move to the left since its
pressure exceeds the elastic force of the spring (8-2), and the hydraulic oil will flow to the port M1
side. In this way, the impact generated by the inertial energy on port M2 side will be controlled, and
a vacuum can be avoided on the port M1 side.

Oil circuit B 4
Oil circuit C2
Oil circuit C1
Orifice D3
Orifice D1
Damping chamber A2
Damping chamber A1
Orifice D4
Orifice D2

Spring chamber 2
Spring chamber 1

Fig. 4-94
Fig. 3 Double balance valve and relief valve during motor braking

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E. Function of shuttle valve for high pressure selection

● The double balance valve has the function of shuttle valve for high pressure selection, which is
used for self-release of the parking brake. When the hydraulic oil is supplied to the port P1, the
piston (1) will move to the right as shown in Fig. 4. In this case, the motor housing oil drain passage
F will be closed, the passage D to the parking brake cylinder chamber E will be opened, and the
hydraulic oil will flow to the passage G through the orifice and finally enter the parking brake
cylinder chamber E to release the parking brake. In addition, when the motor stops, the piston (1)
will return to the neutral state as shown in Fig. 5, the passage D will be closed, the motor housing
oil drain passage F will be opened, and the hydraulic oil in the parking brake cylinder chamber E
will be guided into the motor housing oil drain passage, thus the parking brake function will work.

Oil circuit D

Oil circuit D

Orifice
Oil circuit F
Oil circuit F
Oil circuit D Oil circuit G Oil circuit G Cylinder
chamber E

Fig. 4-95
Fig. 4 High pressure selection function High pressure selection

Oil circuit D

Oil circuit D

Orifice
Oil circuit F
Oil circuit F
Oil circuit D Oil circuit G Oil circuit G Cylinder
chamber E

Fig. 4-96
Fig. 5 High pressure selection function Opening of motor housing oil drain passage

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Operation of the parking brake

1) In case of start of traveling
● When the oil starts to be supplied from the port Cylinder block
assembly
P1 and the motor is tried to drive, the hydraulic
oil will be introduced to the parking brake
Oil
cylinder chamber E through the passage D, and pressure

the brake piston (3) will push the spring (4) to

move leftwards under the pressure of hydraulic Motor casing
oil. Therefore, the force pressing the disc (1) will
be lost, the disc (1) will be in a free state, and Cylinder
the parking brake will be released. chamber

Fig. 4-97

2) In case of stop of traveling 4

● When the travel lever is in the neutral position,
the oil supplied to the port P1 will be cut off;
when the motor is tried to stop, the passage D Cylinder block
assembly
will be connected to the passage F, the
hydraulic oil in the parking brake cylinder
Spring
chamber E will be introduced to the motor force

housing oil drain passage, and thus the

pressure will drop. Therefore, the brake piston
(3) will move rightwards because of the elastic
Motor casing
force of the spring (4), the disc (1) will be locked
on the motor housing by the brake piston
because of the elastic force of the spring, the Cylinder
chamber
motor shaft will be locked, and the parking
brake will work.

Fig. 4-98

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Operation of the brake valve Traveling control

valve
● The brake valve includes a safety suction valve
(8A) and a balance valve (18) as shown in the
right figure. The functions and operation of
each part are described hereinafter.

Fig. 4-99

1) Balance valve, check valve

Traveling control
Function valve

● In the case of traveling downhill, the weight of

the hydraulic excavator will try to make the
speed of the hydraulic excavator higher than
that of the motor. Therefore, it is very
dangerous when the machine travels with the
engine running at a low speed, because the
motor will rotate without load, causing loss of
control of the machine. To prevent this, the
valve will act to keep the machine traveling as
per the engine speed (pump flow).
Operation in case of pressure oil supply
● When the travel lever is operated, the pressure
oil from the control valve will be delivered to the Fig. 4-100
port PA. The pressure oil will open the safety
suction valve (8A) and flow to the motor oil
outlet MB from the motor oil inlet MA. However,
the motor oil port will be closed by the safety
suction valve (8B) and slide valve (19), so the
pressure on the oil supply side will rise (as
shown in the right figure).

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● The pressure oil on the oil supply side will flow

Traveling control
to the cavity S1 via the orifices E1 and E2 in valve
the slide valve (19) . When the pressure in the
cavity S1 is higher than the slide valve
switching pressure, the slide valve (19) will be
pushed rightwards in the direction of the arrow.
Therefore, the oil ports MB and PB will be
connected, the motor outlet port will be
opened, and the motor will start to rotate (as
shown in the right figure).

Fig. 4-101

Operation of the machine on a downward slope Traveling control

4
valve
● If the machine runs out of control on a
downward slope, the motor will run without
load, the pressure at the motor oil inlet will
drop, and the pressure in cavity S1 will also
decrease through orifices E1 and E2. When
the pressure in the cavity S1 drops below the
slide valve switching pressure, the slide valve
(19) will return to the left in the direction of the
arrow through the spring (20), and the oil outlet
MB will throttle. Therefore, the pressure at the
oil outlet will rise, and the motor rotation
resistance will be generated to prevent the
machine from running out of control. On the
other hand, the slide valve will move to the
pressure balance position of the oil outlet MB
and oil inlet and generate a force by means of Fig. 4-102
the machine weight. It will throttle the oil outlet
circuit and control the traveling speed
according to the pump flow (as shown in the
right figure).

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2) Safety valve
Function
● When the machine stops traveling (or travels downslope), the oil circuits of motor oil inlet and outlet
will be closed by the balance valve, but the motor will still rotate under the action of inertia, so the
pressure in the motor oil outlet will be abnormally high, which will damage the motor or pipe. The
safety valve will release this abnormal pressure and transmit it to the motor oil inlet side to avoid
equipment damage.

Operation Traveling control

valve
1． In case of stop of traveling (or downslope
traveling, rightward turning)
● When the motor oil inlet pressure (pressure
PA) drops, the pressure in cavity S1 will also
decrease. When the pressure is lower than the
slide valve switching pressure, the slide valve
will return to the left through the spring (20),
and the oil outlet passage B1 will throttle. In
this case, the motor will still rotate under the
action of inertia, so the oil outlet pressure
(pressure MB) will rise (as shown in the right
figure).

Fig. 4-103

● If this pressure is higher than the set pressure

of the safety suction valve (8A), the vale spool
will be opened. The oil will flow through the
large notch A1 in the slide valve (19) of
balance valve and into the cavity MA in the
opposite oil circuit (as shown in the right
figure). Valve spool

Fig. 4-104

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2． In case of start of traveling (normal Traveling control

traveling) valve

● When the travel lever is operated, the pressure

oil from the pump will move the slide valve (19)
of balance valve to the right. In this case, the
oil passage to the safety suction valve will
become the oil circuit through the small notch
B2 in the slide valve of balance valve. As a
result, a large pressure difference will be
generated, and the pump pressure will rise to
provide a strong traction force (as shown in the
right figure).

Fig. 4-105

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3. Overload relief valve

● The structure of the relief valve is shown in the
right figure. The relief valve is an
area-difference-type direct-acting relief valve
with a damping function for mitigation of impact
at the time of machine startup or brake start.

Fig. 4-106

A. Working principle and function of the relief valve

● When the main valve works in such a way that
the motor startup or brake is initiated and the
pressure in front of the cone valve (2-9-2)
exceeds the set value, the pressure will
exceed the elastic force of the spring (2-9-5) so
that the cone valve (2-9-2) will move away
from the valve seat (2-9-3) to the right, and the
high-pressure oil in front of the cone valve
(2-9-2) will flow to the low-pressure side
through bypass. In this way, the impact
generated by the inertial energy on the
high-pressure side will be controlled, and a
vacuum can be avoided on the low-pressure Fig. 4-107
side.

B. Damping function
● When the relief valve starts to operate, the Area S2

damping piston (2-9-9) will move to the left so

that a low pressure can be maintained in the
spring chamber D. In this case, the
pressurization area S1 of the cone valve
(2-9-2) will be much larger than the normal set
value S1-S2 of the relief valve. Therefore, the
operating pressure of the relief valve shall be
maintained at approximately 1/3 of the normal Area S1 Spring chamber
set value during movement of the damping D

piston (2-9-9) to absorb the impact generated

by the inertial energy on the high-pressure oil
circuit side. After the damping piston stops Fig. 4-108
moving, the pressure in the spring chamber D
will rise, the pressure in front of and behind the
cone valve (2-9-2) will be the same, and the
relief valve will operate at the normal set
pressure. As described above, the relief valve
operates in 2 steps to mitigated the impact at
the time of motor startup and brake, thus
providing good maneuverability.

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Motor parts maintenance criteria

Position to be checked Maintenance•treatment
Applicable part Allowable limit
and measured essentials
Grind the sliding surface of
Roughness 0.8a, surface roughness, slipper, and replace the 4
1. Sliding surface of
or scratches with a depth greater than cylinder block assembly
slipper
0.02 mm. when the scratches can't be
repaired.
Roughness 1.2a, surface roughness,
1-4-2 piston 2. Outer diameter of
or scratches with a depth greater than
assembly piston
0.02 mm.
3. Outer diameter of Replace the 4 cylinder block
piston and inner assembly .
Gap 0.060.
diameter of 4-1 cylinder
block
4. Slipper ball clearance Clearance 0.4.
Grind the sliding surface of
Roughness 0.8a, surface roughness, slipper, and replace the 4
1. Valve plate and
or scratches with a depth greater than cylinder block assembly
sliding surface
0.02 mm. when the scratches can't be
repaired.
Roughness 1.6a, surface roughness, 4
2. Inner diameter of
or scratches with a depth greater than
shaft hole
0.02 mm.
1-4-1 cylinder block
3. Inner diameter of
shaft hole and outer
Gap 0.060. Replace the 4 cylinder block
diameter of 4-2 piston
assembly .
assembly
Round rod having a span of less than
4. Spline of shaft 38.749 (diameter of pin for
connection fitting part measurement Φ3.333 (V1=2.80)) or
subjected to breakage.
32 Grind the sliding surface,
Sliding surface with roughness of 0.8a
and replace the 22 valve
1-21 port plate 1. Sliding surface having scratches with a depth greater
plate when the scratches
than 0.02 mm or subjected to burning.
can't be repaired.
1-4-3 fixing plate Sliding surface with roughness of 0.8a Replace the fixing plate and
1-4-4 fixing 1. Sliding surface having scratches with a depth greater fixation retention
mechanism than 0.02 mm or subjected to burning. mechanism.
1-4-1 Grind the sliding
Sliding surface with roughness of 0.8a
surface, and replace the 22
1. Sliding surface having abnormal wear or scratches
valve plate when the
with a depth greater than 0.02 mm.
scratches can't be repaired.
1-5 swashplate Roughness 1.6a.
2. Mounting hole of steel
ball part
Replace the swashplate.
3. Mounting hole of steel
Ball depth 14.5.
ball part
Oil seal with roughness of 1.6a having
1. Outer diameter of scratches with a depth greater than
Replace the swashplate.
sliding part of oil seal 0.02 mm or surface roughness besides
sliding marks on the lip.
Round rod having a span of less than
2. Cylinder block fitting 47.380 (diameter of pin for
1-3 shaft
spline measurement Φ3.00) or subjected to
breakage.
Replace the shaft.
Round rod having a span of less than
3. Driving gear 30.498 (diameter of pin for
connection measurement Φ3.33) or subjected to
breakage.

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Position to be checked Maintenance•treatment

Applicable part Allowable limit
and measured essentials
1. Overall size Height 38.2
2. Sliding surface Roughness 2.5a
1-15 brake piston Replace the bake piston.
Scratches with a depth greater than
3. Appearance
0.02 mm, or surface roughness.
1. Overall size Thickness 3.2
1-13 disc plate Sliding surface having deep scratches
2. Appearance Replace the disc plate.
or friction material peeling-off.
1. Rolling surface Peeling-off or fracture.
1-8 Ball bearing
Abnormal rotation (abnormal Replace the ball bearing.
1-9 Ball bearing 2. Action
noise•nonuniform rotation)
Grind the sliding surface,
Roughness 1.6a, surface roughness,
1. Sliding surface of and replace the ring flange
or scratches with a depth greater than
slipper part when the scratches
0.02 mm.
can't be repaired.
Roughness 1.2a, surface roughness,
2. Outer diameter of
or scratches with a depth greater than
1-7 piston assembly piston
0.02 mm.
3. Outer diameter of
Replace the ring flange part.
piston and inner
Gap 0.040.
diameter of 1-1 ring
flange part
4. Slipper ball clearance Clearance 1.0.
Roughness 0.8a, scratches with a
1. Outer diameter of
depth greater than 0.02 mm, or surface
piston
1-2-2 piston roughness. Replace the valve plate
assembly 2. Outer diameter of subassembly.
piston and inner Clearance 0.060.
diameter of valve plate
Roughness 0.8a, scratches with a
1. Mounting hole of 2-2
depth greater than 0.02 mm, or surface
piston assembly
roughness.
2. Inner diameter of
valve plate and outer Clearance 0.060
diameter of piston
Roughness 0.8a, scratches with a
3. Mounting hole of 2-11
depth greater than 0.02 mm, or surface
1-2-1 valve plate slide valve spool Replace the valve plate
roughness.
subassembly.
4. Inner diameter of
slide valve plate and
Clearance 0.060.
outer diameter of valve
spool
5. Movable piston sliding
Scratches with a depth greater than
part and valve seat part
0.02 mm, or surface roughness.
of relief valve
Roughness 0.8a, scratches with a
1. Outer diameter of
depth greater than 0.02 mm, or surface
valve spool
roughness.
1-2-9 slide valve Replace the valve plate
2. Outer diameter of
spool assembly accessory.
slide valve spool and
Clearance 0.060.
inner diameter of valve
plate
1-2-7-9 movable 1. Valve plate sliding Scratches with a depth greater than
piston part and valve seat part 0.02 mm, or surface roughness. Replace the relief valve
1. Movable piston sliding Scratches with a depth greater than assembly.
1-2-7-1 housing
part (outer diameter) 0.02 mm, or surface roughness.
1-4-7 spring 1. Overall size Free length 61.0
Deformation and steel wire surface
2. Appearance
damage

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Position to be checked Maintenance•treatment

Applicable part Allowable limit
and measured essentials
1-18 spring 1. Overall size Free length 39.0
Deformation and steel wire surface
2. Appearance
damage
1-20 spring 1. Overall size Free length 41.5
Deformation and steel wire surface
2. Appearance
damage
1-2-4 spring 1. Overall size Free length 48.5
Deformation and steel wire surface
2. Appearance
damage
1-2-10 spring 1. Overall size Free length 28.3
Deformation and steel wire surface
2. Appearance
damage
Replace the O-rings and oil
O-rings and oil seals During removal
seals

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Control system

Fig. 4-109
Position of travel lever
1. Travel pilot valve 7. Adapter (1) Holding (8) Arm ―extension‖
2. Left travel lever 8. Hydraulic pump (2) Boom ―lifting‖ (9) Swing - rightward
3. Right travel lever 9. Main control valve (3) Boom ―lowering‖ (10) Swing - leftward
4. Right pilot valve 10. Solenoid valve (4) Bucket ―unloading‖ (11) Neutral
5. Right joystick 11. Left control lever (5) Bucket ―digging‖ (12) Traveling
―reverse‖
6. Accumulator 12. Right pilot valve (6) Holding (13) Traveling
―forward‖
(7) Arm ―retraction‖

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Pilot valve
Manual pilot valve

Fig. 4-110
P: From the pilot pump relief valve
P1: Left pilot valve: arm extension/ right pilot valve: boom lowering
P2: Left pilot valve: arm retraction/ right pilot valve: boom lifting
P3: Left pilot valve: leftward swing/right pilot valve: bucket roll-in
P4: Left pilot valve: rightward swing/right pilot valve: bucket roll-out
T: To the tank

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Structure and Function SY215CCM3K Hydraulic Excavator

Fig. 4-111

1. Valve rod 6. Nut (for control lever connection)

2. Adjusting spring 7. Connector
3. Central spring 8. Plate
4. Piston 9. Positioner
5. Disc 10. Valve body

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Operation
1. In the neutral position
● The oil ports (A) and (B) of the control valve
and the oil ports (P1) and (P2) of the pilot
valve will be connected to the discharge
cavity (D) through the flow groove (f) of the
valve rod (1).

Pilot
pump

4
Control valve

Fig. 4-112
2. Fine control (neutral → fine control)
● When the piston (4) is pushed by the disc (5), the
positioner (9) will be pushed, and the valve rod (1) will
also be pushed to move downward by the adjusting
spring (2).
● When the flow groove (f) is disconnected from the
discharge cavity (D), it will be interconnected with the
pump pressure cavity (PP) almost at the same time.
The pilot pressure of the control pump will be guided
from the oil port (P1) to the oil port (A) via the flow
groove (f). When the pressure at the oil port (P1)
becomes higher, the valve rod (1) will be pushed
back, and the flow groove (f) will be disconnected
from the pump pressure cavity (PP) and connected
with the discharge cavity (D) almost at the same time
to release the pressure at the oil port (P1). As a result,
the valve rod (1) will move upward and downward until
the force of the adjusting spring (2) is balanced with
the pressure at the oil port (P1).
● The valve rod (1) and valve body (10) flow groove (f) Pilot
will be in the middle of the discharge cavity (D) and pump
the pump pressure cavity (PP), which will remain
unchanged before the positioner (9) contacts with the
valve rod (1). The adjusting spring (2) will contract in
direct proportion to the stroke of the control lever. The
pressure at the oil port (P1) will also increase in direct Control valve
proportion to the stroke of the control lever. In this
way, the control valve rod will move to the balance
position of the cavity (A) pressure (the same as the
pressure at the oil port (P1)) and the return spring Fig. 4-113
force.

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3. Fine control (when the control lever

returns)
● When the disc (5) starts to return, the valve
rod (1) will be pushed upward by the force of
the central spring (3) and the pressure at the
oil port (P1) .
● Therefore, the hollow groove (f) will be
connected with the discharge chamber (D) to
discharge the pressure oil at the oil port (P1).
● If the pressure at the oil port (P1) drops
excessively, the valve rod (1) will be pushed
downward by the adjusting spring (2).
● The flow groove (f) will be disconnected from
the discharge cavity (D) and interconnected
with the pump pressure cavity (PP) almost at Pilot
the same time. A pressure will be provided pump
before the pressure at the oil port (P1)
returns to a level corresponding to the
position of the control lever.
● When the control valve rod returns, the oil in Control valve

the discharge cavity (D) will flow in from the

flow groove (f) in the valve on the
non-operating side. The oil will pass through Fig. 4-114
the oil port (P2) and flow into the cavity (B) to
replenish the cavity with pressure oil.

4. Full stroke
● The disc (5) will push the piston (4)
downward, and the positioner (9) will push
the valve rod (1) downward.
● The flow groove (f) will be disconnected from
the discharge cavity (D) and interconnected
with the pump pressure cavity (PP).
● Therefore, the pressure oil from the reducing
valve will pass through the flow groove (f)
and flow to the cavity (A) from the oil port
(P1) so as to push the control valve rod.
● The oil returned from the cavity (B) will flow
to the discharge cavity (D) from the oil port
(P2) through the flow groove (f).
Pilot
pump

Control valve

Fig. 4-115

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Travel pilot valve

Figure 4-116

P： From the pilot pump P4: Right travel forward

P1: Left travel backward P5: Travel signal
P2: Left travel forward P6: Travel signal
P3: Right side reverse T： To the tank

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Structure and Function SY215CCM3K Hydraulic Excavator

Fig. 4-117
1. Retaining plate
2. Valve body
3. Piston
4. Grommet
5. Central spring
6. Adjusting spring
7. Valve

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Working process
Operation
1) In the neutral position
● The oil ports (A) and (B) of the control
valve and the oil ports (P1) and (P2) of the
pilot valve will be connected to the
discharge cavity (D) through the fine
control hole (f) of the valve rod (1).

Pilot pump

Control valve

Fig. 4-118
2) Fine control (neutral → fine control)
● When the piston (4) is pushed by the disc (5), the
4
positioner (9) will be pushed, and the valve rod (1)
will also be pushed to move downward by the
adjusting spring (2).
● When the fine control hole (f) is disconnected from
the discharge cavity (D), it will be interconnected
with the pump pressure cavity (PP) almost at the
same time.
● The pilot pressure of the control pump will be
guided from the oil port (P1) to the oil port (A) via
the fine control hole (f).
● When the pressure at the oil port (P1) becomes
higher, the valve rod (1) will be pushed back, and
the fine control hole (f) will be disconnected from Pilot pump

the pump pressure cavity (PP) and connected with

the discharge cavity (D) almost at the same time to
release the pressure at the oil port (P1).
Control valve
● As a result, the valve rod (1) will move upward and
downward until the force of the adjusting valve rod
(2) is balanced with the pressure at the oil port
(P1). Fig. 4-119
● The position of valve rod (1) and valve body (10)
[the fine control hole (f) in the middle of the
discharge cavity (D) and the pump pressure cavity
(PP)] will remain unchanged before the positioner
(9) contacts with the valve rod (1).
● The adjusting spring (2) will contract in direct
proportion to the stroke of the control lever.
● The pressure at the oil port (P1) will also increase
in direct proportion to the stroke of the control
lever.
● In this way, the control valve rod will move to the
balance position of the cavity (A) pressure (the
same as the pressure at the oil port (P1)) and the
return spring force.

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3) Fine control (when the control lever

returns)
● When the disc (5) starts to return, the valve
rod (1) will be pushed upward by the force
of the central spring (3) and the pressure at
the oil port (P1) .
● Therefore, the fine control hole (f) will be
connected with the discharge cavity (D) to
release the pressure oil at the oil port (P1).
● If the pressure at the oil port (P1) drops
excessively, the valve rod (1) will be
pushed downward by the adjusting spring Pilot pump
(2).
● The fine control hole (f) will be
disconnected from the discharge cavity (D) Control valve
and interconnected with the pump pressure
cavity (PP) almost at the same time.
● A pressure will be provided before the Fig. 4-120
pressure at the oil port (P1) returns to a
level corresponding to the position of the
control lever.
● When the control valve rod returns, the oil
in the discharge cavity (D) will flow in from
the fine control hole (f) in the valve on the
non-operating side. The oil will pass
through the oil port (P2) and flow into the
cavity (B) to replenish the cavity with
pressure oil.

4) Full stroke
● The disc (5) will push the piston (4)
downward, and the positioner (9) will push
the valve rod (1) downward.
● The fine control hole (f) will be
disconnected from the discharge cavity (D)
and interconnected with the pump pressure
cavity (PP).
● Therefore, the pressure oil from the
reducing valve will pass through the fine
control hole (f) and flow to the cavity (A)
from the oil port (P1) so as to push the Pilot pump

control valve rod.

● The oil returned from the cavity (B) will flow
Control valve
to the discharge cavity (D) from the oil port
(P2) through the fine control hole (f).

Fig. 4-121

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Solenoid valve
Pilot valve lockout solenoid valve, traveling speed solenoid valve, swing priority solenoid valve

Fig. 4-122

1. High/low travel speed switching solenoid A1: To center swivel joint oil port
valve
A2: To operating valve oil port PsP
2. Swing priority solenoid valve
A3: To operating valve oil port Xbp1
3. Neutral shut-off valve 1
A4: To operating valve oil port Xbp2
4. Neutral shut-off valve 2
A5: To operating valve port PZ
5. Secondary pressurization solenoid valve
A6: To pilot valve block P
6. Pilot valve lockout solenoid valve
T： To the tank
P： Pilot pump

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Accumulator

1. Air plug
2. Hosing
3. Seat valve spool
4. Retainer
5. Bag
6. Oil port
Technical Specifications
Gas quantity: 300 cc

Fig. 4-123

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Pilot oil filter

Model
Pressur
e
Accura
cy

Fig. 4-124

1. Nameplate Technical Specifications

2. Top cap Maximum flow: 40 L/min
3. O-ring Filtering precision: 10 um
4. Seal ring Operating pressure: 20 Mpa
5. Filter Maximum operating pressure: 40 Mpa
6. Hosing Pressure loss: 0.05 Mpa
Maximum allowable differential pressure: 1 Mpa
Specification of oil inlet/outlet O-ring: 30×3.1

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Structure and Function SY215CCM3K Hydraulic Excavator

Hydraulic cylinder
Boom cylinder

Fig. 4-125
Arm cylinder

Fig. 4-126
Bucket cylinder

Fig. 4-127

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Unit: mm
S/N Inspection Item Criterion Solution
Oil Standard Tolerance Standard Clearance
cylinder size Shaft Hole clearance limit
-0.036 +0.222 0.083～
Clearance Boom 85 0.412
-0.090 +0.047 0.312 Replace
between the
1 the
piston rod and -0.036 +0.222 0.083～
Arm 95 0.412 bushing
the bushing
-0.090 +0.047 0.312
-0.030 +0.258 0.078～
Bucket 80 0.434
-0.076 +0.048 0.334
-0.030 +0.246 0.230～
Clearance Boom 80 1.0
-0.076 +0.200 0.322
between the
piston rod -0.030 +0.246 0.230～
2 Arm 80 1.0
supporting pin -0.076 +0.200 0.322 4
and the
bushing -0.030 +0.246 0.230～
Bucket 70 1.0
-0.076 +0.200 0.322 Replace
the pin or
-0.030 +0.246 0.230～ bushing
Clearance Boom 70 1.0
-0.076 +0.200 0.322
between the oil
cylinder bottom -0.030 +0.246 0.230～
3 Arm 80 1.0
supporting pin -0.076 +0.200 0.322
and the
bushing -0.030 +0.246 0.230～
Bucket 70 1.0
-0.076 +0.200 0.322

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Work equipment
Part size

Fig. 4-128

Fig. 4-129

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Unit: mm
No. Inspection Item Criterion Measures
Clearance between Standard Tolerance Standard Clearance
the pin for size Shaft Hole clearance limit
1 connecting the boom
and the turntable –0.036 +0.140 0.141 ～
90 1.0
and the bushing –0.071 +0.105 0. 211
Clearance between
the pin for –0.036 +0.174 0.140 ～
2 connecting the boom 90 1.0
and the arm and the –0.071 +0.104 0. 345
bushing
Clearance between
the pin for –0.030 +0.335 0.305 ～
3 connecting the arm 70 1.0
and the rocker and –0.060 +0.275 0. 395
the bushing
Clearance between Replacement
the pin for 4
–0.030 +0.324 0.300 ～
4 connecting the arm 80 1.0
and the bucket and –0.060 +0.270 0. 384
the bushing
Clearance between
the pin for
connecting the –0.030 +0.373 0.303 ～
5 80 1.0
linkage and the –0.060 +0.273 0. 433
bucket and the
bushing
Clearance between
the pin for –0.030 +0.335 0.305 ～
6 connecting the 70 1.0
linkages and the –0.060 +0.275 0. 395
bushing

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Arm size

Fig. 4-130

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Unit: mm

SY195、205、215C10 SY225C9
No.
Standard size Tolerance Standard size Tolerance
+0.1 +0.1
1 φ80 φ80
0 0
+0.5 +0.5
2 107 107
0 0
-0.3 -0.3
3 310 310
-0.8 -0.8
-0.036 -0.036
4 φ90 φ90
-0.071 -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
4
10 411 ±0.8 411 ±0.8
0 0
11 640 640
-0.5 -0.5
12 600 — 600 —
13 458 — 458 —
14 1,483 — 1,495 —
15 φ80 — φ80 —
16 326.5 — 326.5 —
+0.2 +0.2
17 φ80 φ80
0 0
Arm body 311 — 311 —
18 Press fit of
325 — 325 —
bushing
Minimum 1,680 — 1,680 —
19
Maximum 2,800 — 2,800 —

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Bucket size

Fig. 4-131

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Unit: mm
215C
No.
Standard size Tolerance
1 457.5 ±0.5
2 22 ±0.5
3 91.8° —
4 458 —
5 1,483 —
6 177 —
7 45° —
+0.2
8 φ80
0
+0.2
9 348.5
0
10 37 —
4
11 107 —
12 473.5 —
13 φ23.5 —
14 φ190 —
15 φ136 —
16 131 —
17 125 —
18 R180 —
19 R140 —
20 57 —
21 326.5 ±0.5

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HVAC group

Fig. 4-132

1. Hot water duct A. Outside air

2. A/C compressor (DENSO.2) B. Inside air
3. Cooling pipeline C. Hot/cold air
4. Condenser (SG447750-A040)
5. Reservoir (DENSO.4)
6. Hot water return pipe
7. Evaporator (ZF5.625×365×345D)
8. Air duct

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Layout of A/C elements

Fig. 4-133

1. Sunlight sensor 5. Compressor

2. Control panel 6. Outside air sensor
3. A/C unit 7. Recirculation temperature sensor
4. Condenser

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A/C control panel

Fig. 4-134

1. OFF switch 6. Recirculation/fresh air selector switch

2. Fan speed setting switch 7. LCD display area
3. Temperature setting switch 8. HVAC switch
4. Air vent mode setting switch 9. Sunlight sensor
5. Automatic mode setting switch

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Schematic circuit diagram

Wiring table

Fig. 4-135

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Wire Wire
Wire Wire
diameter/wire Wire color diameter/wire Wire color
size size
color symbol color symbol
05 B Black 21 GB Green + black
03 YW Yellow + white 25 BrR Brown + red
4 RW Red + white 29 LG Blue + green
5 OB Orange + black 30 GW Green + white
6 PB Pink + black 31 YR Yellow + red
7 RB Red + black 32 GR Green + red
8 LB Blue + black 40 R Red
9 BrB Brown + black 41 RG Red + green
10 VW Purple + white 42 W White
11 VR Purple + red 43 WG White + green
13 WR White + red 44 BL Black + blue
14 BR Black + red
15 PW Pink + white
16 O Orange
17 RL Red + blue
19 WB White + black
20 GrB Gray + black

Code Name Code Name Code Name

Condenser
ACM A/C controller FUACC A/C main fuse RLCH
high-speed relay
BAT Power RLCC Compressor relay Ss Sunlight sensor
Speed governing High/low voltage
BLC FUM A/C controller fuse SPHL
resistor switch
CMB Power supply relay ALT Alternator SWk Ignition key switch
Dc Diode MAM A/M servo motor THAM Outside air thermistor
D1 Diode 1 MB Fan motor THF Anti-frost thermistor
Inside/outside air servo
ECC Compressor clutch MRF THI Inside air thermistor
motor
Fu1 Fuse MV1 Vent servo motor ECU Controller
Fu2 Fuse RLBM Fan main relay THI Inside air thermistor

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Working principles of A/C

Schematic diagram of refrigeration cycle

Expansion valve
Cooling air

Low-temperature and
Evaporator low-pressure fluid (mist)

High-temperature and
Low-temperature and

high-pressure fluid
low-pressure gas

Cooling fan
Blower motor

Indoor air

Outdoor cooling
air
High-temperature and
high-pressure gas

Low-press
ure side High-pres
sure side Reservoir
4

Compressor

Hot air
Low-pressure High-pressure
part part

Fig. 4-136
Schematic diagram of heating cycle
Water valve
Radiator
switch

Water pump Warm air

Engine

Blower motor

Indoor air

Low temperature water

High temperature water

Fig. 4-137

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Compressor

Fig. 4-138

1. Stator 9. Slipper
2. Front radial bearing 10. Front cylinder block
3. Thrust bearing 11. Piston
4. Front radial bearing 12. Front cylinder head
5. Rear cylinder head 13. Shaft seal
6. Safety valve 14. Spindle
7. Rear cylinder block 15. Hub
8. Swashplate 16. Rotor

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Working principles
The 10S15C compressor is used. 5 pistons are totally provided for the compressor, one piston is
installed before and behind each piston respectively, thus 10 pistons are equipped in total (5 are
arranged before and behind the piston respectively). The rotation of the swashplate causes the piston to
reciprocate to change the low-temperature and low-pressure gaseous refrigerant sucked from the
evaporator into a high-temperature and high-pressure one.

Project 1 Project 2

Pipe on the Pipe on the Pipe on the Pipe on the

high-pressure side low-pressure side high-pressure side low-pressure side

Valve plate

Exhaust valve plate

Time

4
Spindle and Intake valve plate
swashplate

Project 6 Project 3

Pipe on the Pipe on the Pipe on the Pipe on the

high-pressure side low-pressure side high-pressure side low-pressure side

Project 5 Project 4

Pipe on the Pipe on the Pipe on the

Pipe on the
high-pressure side low-pressure side low-pressure side
high-pressure side

Fig. 4-139

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Structure and Function SY215CCM3K Hydraulic Excavator

Clutch

1. Clutch rotor
2. Stator coil
3. Snap ring
4. Ball bearing
5. Clutch stator
6. Central plate
● The electromagnetic clutch is used to transfer
torque. When the engine is running, the
compressor may not work. The electromagnetic
clutch will control the compressor to work only
when the A/C is in the refrigeration mode.
● Working principle
Fig. 4-140
When the A/C switch is turned on, the clutch
coil with electromagnet will be charged to
generate a magnetic field to stick the iron plate
so that the clutch stator and rotor will be
combined together to drive the compressor
spindle to rotate.

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Condenser

4
Fig. 4-141

1. Condenser core Function

2. Condenser bracket ● It converts the high-temperature and
high-pressure gaseous refrigerant (16 kg/cm2,
3. Bolt with pad
about 80°C) to a high-temperature and
4. Refrigerant inlet high-pressure liquid refrigerant (16 kg/cm2,
about 60°C or below).
5. Refrigerant outlet

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Expansion valve

1. Spring
Evaporator
2. Membrane
3. Temperature sensing rod
4. Needle valve
Principle
● The refrigerant from the reservoir is injected
from the orifice and rapidly expands, thus it
becomes a low-temperature and low-pressure
liquid (mist) and flows into the evaporator.

Compressor

Reservoir
Reservoir

Fig. 4-142

Evaporator

1. Expansion valve
2. Evaporator
Principle
● The evaporator and condenser with a similar
structure are a heat exchanger. The hot air in
the cab is sent to the evaporator by the blower
motor, and exchanges heat with the evaporator
surface. The heat absorbed becomes cold air,
and is sent back to the cab through each air
duct. The evaporator surface absorbs heat →
the refrigerant in the evaporator absorbs heat
→ the refrigerant evaporates. The evaporated
refrigerant (gas) is sucked away by the
compressor.
Fig. 4-143

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Dryer

1. Inlet
2. Outlet
3. Receiver/Dryer
4. Drying agent
Function
● Temporarily stores the refrigerant
● Remove water from the refrigerant
● Filter dust in the refrigerant
● Check the refrigerant quantity

Fig. 4-144

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Pressure switch

1. O-ring Pressure

2. Movable contact
3. Cover
4. Plug and fixing contact
5. Spring
6. Cavity
7. Diaphragm
Purposes:
● The pressure switch is a combination switch
(high- and low-voltage combination switch)
installed between the reservoir and the
expansion valve (high-pressure pipe).
● When the pressure is too high, the compressor
will stop.
● When the pressure is too low, the low
temperature environment will terminate.
Fig. 4-145

Action features:

Characteristic

High-pressure Above 0.02 MPa

operating
value

Low-pressure
operating
value

Medium
pressure
action value

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Refrigerant
1. General characteristics of refrigerant
● Strong heat absorptivity, easy to liquify
● Incombustible and non-explosive
● Stable chemical composition, non-deteriorated
● Non-toxic
● Non-corrosive
● No damage to clothing
2. Refrigerant circulation
● After evaporating in the evaporator, the refrigerant is changed from gas to liquid by the
compressor and condenser, thus it is circulated.
Low-pressure side of compressor (suction port):
low-temperature\low-pressure\gas
Compressor Pressure and temperature: 2kgf/cm², about 8℃ Evaporator
Suction → discharge Heat absorption → Cold air
emission
4

High-pressure side of compressor (discharge port):

high-temperature\high-pressure\gas
Pressure and temperature: 16kgf/cm², about 80℃

Condenser (outlet): low-temperature\low-pressure\mist

Pressure and temperature: 2kgf/cm², about 0~2℃

Condenser (outlet):
high-temperature\high-pressure\liquid
Pressure and temperature: 16kgf/cm², below about Expansion valve
Condenser 60℃ High pressure→Low
Through heat radiation: gaseous pressure
refrigerant → liquid refrigerant High temperature→Low
temperature
Liquid→Mist

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Structure and Function SY215CCM3K Hydraulic Excavator

● Refrigerant circulation principle (pressure-enthalpy diagram)

Complete
Refrigerant circulation curve
liquification
Start of
liquification

Throttle point
Condenser

Condensation
Liquid process

Expans
ion and Compressio
Expansion Compressor
valve throttlin n process
g
Evaporation
process

Evaporator

Gas-liquid
Complete
gasification

U - Internal energy p - Pressure V - Specific A - Heat equivalent

volume of work

Fig. 4-146

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3. Refrigerant filling
● Refrigerant filling method and quantity:
(1) Refrigerant: HFC-134a;
(2) Refrigerant filling quantity: 900±50 g
(for reference only);
(3) Refrigerant filling method: Do not add
the liquid refrigerant from the
low-pressure side. If re-operation is
required due to failure, the added
refrigerant must be discharged and
then re-added.

Fig. 4-147

● Check the flow state of the refrigerant in 4

Sight glass
the A/C circulation system through the
sight glass:
(1) Appropriate filling: Almost no bubbles
are seen when the refrigerant flows.
When the engine is gradually
accelerated from idle to 1,500 rpm,
the bubbles disappear and the Appropriate
filling
refrigerant is transparent;
(2) Excessive filling: No bubbles are
seen when the refrigerant flows;
(3) Insufficient filling: Bubbles are usually
seen when the refrigerant flows. Insufficient
filling

Fig. 4-148

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Structure and Function SY215CCM3K Hydraulic Excavator

4. Vacuumization
● Causes of vacuumization
When installing the air conditioner, make
sure there is no water inside it. The
refrigerant (R134a) used is easily soluble
in water. If any, a small amount of water in
the air conditioner will freeze in the small
hole of expansion valve, and cause
rusting of the compressor valve etc.
Therefore it is necessary to remove the
moisture from the cooling system as
much as possible before adding the
refrigerant. To minimize residual water in
the cooling system, the best way is to
remove water in the unit by gasifying it
through boiling by means of
vacuumization.
● Steps of vacuumization
(1) Connection of the manifold pressure gauge; Valve part
Low pressure
gauge
i) Close the high-pressure valve (HI) Above 750
and low-pressure valve (LO) of the Opene Opene mmHg Closed Closed
d d
manifold pressure gauge. Low pressure
gauge High pressure
ii) Connect the charging hose (red, blue) gauge

to the compressor auxiliary valve.

Red hose - High-pressure side (mark Low-pressure High-pressure
valve (opened) valve (opened)
D) Green
Blue hose - Low-pressure side (mark Red
S)
★ The side with a L-shaped bend at the Blue
front end of the charging hose should
be pressed against the compressor Compress
auxiliary valve. In case of wrong or
Vacuum pump
connection, the internal valve of the (rotating)
compressor won’t be opened. In
addition, be careful not to reverse the
high-pressure and low-pressure parts. Fig. 4-149
iii) Connect the charging hose (green) in
the middle of the manifold pressure
gauge to the vacuum pump.
(2) Vacuumization
i) Open the high-pressure valve (HI) and
low-pressure valve (LO) of the
manifold pressure gauge;
ii) Turn on the vacuum pump switch and
perform vacuumization (for about 15
min);
iii) When the negative pressure scale (i.e.
vacuum level) on the pressure gauge
reaches above 750 mmHg, disconnect
the vacuum pump switch, and close
the high-pressure valve and
low-pressure valve of the manifold
pressure gauge.

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(3) Airtightness inspection Valve part

Place them for more
i) Place the closed high- and than 5 min Low pressure gauge
low-pressure valves of the Closed Closed
The pointer returns to
Low pressure zero
manifold pressure gauge for gauge
more than 5 min, and confirm
that the pressure reading
doesn’t return to zero;
The pointer
ii) When the pointer of the returns to zero
Tighten the pipe
pressure gauge returns near 0, joint
it means there is leakage.
Therefore, the pipe joint must
be further corrected and Fig. 4-150
tightened, and then
vacuumization shall be
performed again until there is no
leakage.

(4) Air leakage inspection Valve part

4
i) Connect the charging hose Closed Closed

(green) originally connected to

the vacuum pump to the fluorine
tank;
ii) Connect the charging hose Discharge the
air by bleeder
(green) to the manifold pressure Open the fluorine
valve
tank valve
gauge, open the fluorine tank
valve, press the bleeder valve of
the pressure gauge (be careful
not to press it directly by hand
Blue
so as to prevent freezing injury Charging hose
caused by refrigerant injection), Red (green)

and discharge the air in the To the Fluorine tank

charging hose by means of the compressor
refrigerant pressure (release the
bleeder valve when hearing Fig. 4-151
sizzle);

iii) When the high-pressure valve

of the manifold pressure gauge Valve part Low pressure gauge
is opened, add the refrigerant reading 1 kg

until the low pressure gauge

reading reaches 1 kgf/cm2, and Low pressure gauge
reading 1 kg f/cm2
Closed Opene
d
Closed Closed

close the high-pressure valve

after filling;
Low-pressure
Open the
iv) For the sake of caution, check valve (closed)
high-pressure valve
the cooling system for air Fluorine tank valve
(opened)
leakage with a leak detector;
v) If there is leakage, repair the
leaky part (tighten it).
Fluorine tank
Compressor

Fig. 4-152

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5. Refrigerant filling
● After vacuumization is completed, it is necessary to add the refrigerant into the cooling system
as per the following essentials:

Refrigerant filling, kg/cm2

Finish of vacuumization

Airtightness inspection
Start of vacuumization

Air leakage inspection

Air leakage inspection

Performance test
Refrigerant filling
75cm-Hg or above
For more than 15
min Place it for 5 Normal pressure
min gauge reading

Abnormal pressure gauge

reading
Tighten the pipe joint (1) Add the refrigerant from the high-pressure side when the
compressor stops
Repair the leaky part (2) Add the refrigerant from the low-pressure side when the
compressor is in operation

● Filling from the high-pressure side: Valve part

(1) Remove the charging hose (green) of

the manifold pressure gauge from the Closed Close
d

vacuum pump and connect it to the (Note)

Discharge the refrigerant
fluorine tank; when hearing sizzle

(2) Open the fluorine tank valve, press

down the bleeder valve on the side of Release the
air
the manifold pressure gauge, and Open fluorine tank valve
discharge the air in the charging hose
Loosen flare
by means of the refrigerant pressure; nut

Release the bleeder valve when

sizzle is heard after the refrigerant is Blue
Charging hose
discharged. Do not press the bleeder Red (green)
valve directly by hand so as to
prevent freezing injury. To the Fluorine tank
compressor

Fig. 4-153
(3) When the engine isn’t in operation,
open the high-pressure valve of the
manifold pressure gauge and the Valve part
Add 1 tank (about
fluorine tank valve, and add one and 600 g)
Closed Open Closed Closed
a half tank of refrigerant (about 600 ed
(Don'ts)
g). ·Do not run the compressor
·Do not open the low-pressure
valve
In this case, do not run the
Low-pressure Open the
compressor. Once it is in operation, valve (closed) high-pressure valve
the fluorine tank and hose may be Fluorine tank valve
(opened)
damaged due to the return of the
refrigerant, which will lead to
dangers.
Do not run the compressor when
there isn't refrigerant; otherwise, the
compressor will be burnt.
Do not open the low-pressure valve Fig. 4-154
of the manifold pressure gauge (the
compressor may be damaged if liquid
compression occurs).
(4) Close the high-pressure valve of the
manifold pressure gauge and the
fluorine tank valve.

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● Filling from the low-pressure side (supplementary

filling):
High-pressure
(1) First, confirm that the high-pressure valve of Manifold valve (closed) (Opened)
the manifold pressure gauge is closed; pressure
gauge
(2) Start the engine and open all the doors;
(3) Turn on the A/C switch; set the temperature
control at "MIN";
(4) Set the engine speed to 1,300~1,500 rpm; Engine startup

(5) During refrigerant filling, open the (Note)

If the high-pressure valve is opened,
low-pressure valve of the manifold pressure the fluorine tank may crack, which will
gauge and the fluorine tank valve, and add lead to major injury.

the refrigerant until no bubbles are seen in

the reservoir; Fig. 4-155
Note:
Manifold pressure gauge reading (for reference Add the refrigerant until
only): Valve part no bubbles are seen
through the sight glass
²
High pressure 13~17 kg/cm (at ambient Low pressure
Closed Opene Opene Opene
temperature of 30℃); gauge
d d d
High pressure
Low pressure 1.5~2 kg/cm² (at ambient gauge

temperature of 30℃).
4
(6) Close the low-pressure valve of the manifold Low-pressure valve High-pressure valve
(closed) (Do not open it)
opened
pressure gauge and the fluorine tank valve
Fluorine tank valve
after refrigerant filling; (opened)
(7) Carefully check whether there is leakage
with a leak detector;

Do not open the high-pressure valve (HI) of Compress

the manifold pressure gauge. If the or is
Fluorine tank (Do not put running
high-pressure valve is opened, the it upside down)
high-pressure gas will flow reversely, and
the fluorine tank and charging hose will
crack, which may lead to a danger (or cause
major injury); Fig. 4-156

Do not put the fluorine tank upside down. Add the refrigerant until no
(The refrigerant is added when the engine is Valve part bubbles are seen through
the sight glass
started). If the fluorine tank is put upside
down, the liquid refrigerant will be directly Closed Opened Opened Opened

sucked into the compressor so that liquid

compression will occur, which will damage
the compressor valve and bushing. It is
required that the fluorine tank should be Low-pressure valve
High-pressure valve
(opened)
placed vertically and the refrigerant in the (closed)

gaseous state should be added. Fluorine tank valve

(opened)
(8) At a low ambient temperature
If refrigerant filling can’t be performed at a
low ambient temperature, it is necessary to
put the fluorine tank in warm water below Compressor is
40°C to increase the pressure of the Warm water below 40°C
running

refrigerant in the fluorine tank. (Do not heat it with hot water)

(9) At a high ambient temperature

On the contrary, if the fan is used to cool
the compressor at a high ambient
temperature, the filling operation can be
Fig. 4-157
performed smoothly.

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● Replacement of the fluorine tank:

If the refrigerant in the fluorine tank is Handwhee
used up during filling, the fluorine tank can l

be replaced as per the following

essentials.
(1) Close the high-pressure valve and Charging hose port
low-pressure valve of the manifold
pressure gauge; Needle valve
(2) Raise the pin and circular plate of the
fluorine tank valve, and remove the Liner
empty tank; Circular plate
(3) Install a new fluorine tank on the
Refrigerant
fluorine tank valve; tank
(4) Remove the air inside the charging
hose as per the following methods:
i) Tighten the fluorine tank valve,
and then loosen it slightly; Fig. 4-158
ii) Open the low-pressure valve of
the manifold pressure gauge
slightly;
iii) Press the bleeder valve while
discharging the refrigerant, and
immediately close the fluorine
tank valve and the low-pressure
valve of the manifold pressure
gauge.
★ Do not press the bleeder valve Valve part
directly by hand so as to prevent
freezing injury. Slightly
opened
Closed If the refrigerant is discharged when
sizzle is heard, close the
(5) Rotate the fluorine tank valve handle low-pressure valve immediately

to open the fluorine tank and

continue filling.

Loosen the tank valve slightly

Low-pressure
valve

Green

Blue

Red

To the Refrigerant tank

compressor

Fig. 4-159

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6. Fault detection with the manifold pressure gauge

After engine warm-up, it is necessary to read the pressure value of the manifold pressure gauge
under the following specific conditions.
1) The temperature at the air inlet is 30~35℃.
2) The engine speed is 1,500 rpm.
3) The fan speed is high.
4) The temperature control is set at MIN.
5) The "Repeated Circulation‖ is set.
● Readings of the cooling system meter in normal state:
Low-pressure end: 0.15~0.25 MPa (1.5~2.5 kgf/cm2)
High-pressure end: 1.37~1.57 MPa (14~16 kgf/cm2)

Fig. 4-160

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● Water in the refrigeration system

Condition: Intermittent refrigeration, finally no refrigeration

Fig. 4-161
Symptom of refrigeration
Possible cause Diagnosis Troubleshooting method
system
● Replace the
● Water in the cooling ● The dryer is in a
receiver/dryer.
system freezes at the supersaturation state.
● Remove water from
● When the system is expansion valve, which ● Water in the
the system by
running, vacuum or causes temporary stop refrigeration system
means of
normal pressure of the circulation. freezes at the
continuous
exists at the However, when the ice expansion valve, which
pumping.
low-pressure end. melts, the system hinders the circulation
returns to the normal ● Add a proper
of the refrigeration
state. amount of new
system.
refrigerant.

● Insufficient refrigeration
Condition: Insufficient refrigeration

Fig. 4-162
Symptom of refrigeration
Possible cause Diagnosis Troubleshooting method
system
● The pressures at the ● Check whether there is gas
high-and leakage with a leak detector, and
low-pressure ends ● There isn’t repair the leaky part if necessary.
● Gas leakage
are relatively low. enough ● Add a proper amount of
occurs in a
● Bubbles are refrigerant in the refrigerant.
certain part of
continuously seen system. ● If the pressure value
the refrigeration
through the sight ● Refrigerant approximates to 0 when the
system.
glass. leakage occurs. meter is connected, set the
● Insufficient system in vacuum state after
refrigeration inspection and repair.

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● Poor refrigerant circulation

Condition: Insufficient refrigeration

Fig. 4-163
Symptom of refrigeration
Possible cause Diagnosis Troubleshooting method
system
● The pressures at the high-
4
and low-pressure ends are
● Dirt in the reservoir
relatively low. ● The reservoir is ● Replace the
hinders the refrigerant
● Frost is formed on the pipes blocked. reservoir
flow.
from the parts to the
reservoir.

● No refrigerant circulation
Condition: No refrigeration (intermittent refrigeration in some cases)

Fig. 4-164
Symptom of refrigeration
Possible cause Diagnosis Troubleshooting method
system
● Check the expansion valve and
● Vacuum appears at EPR.
the low-pressure ● Remove dirt in the expansion
● Moisture and dirt in the
end and the valve by blowing. If this does
refrigerant hinder the
pressure at the not work, replace the
refrigerant flow. ● The
high-pressure end is expansion valve.
● Gas leakage in the refrigerant
extremely low. ● Replace the receiver.
expansion valve does not
● Frost or dew is ● Remove air by pumping and
thermo-sensitive pipe circulate.
formed on the pipes add a proper amount of
hinders the refrigerant
before and behind refrigerant. If the
flow.
the expansion valve thermo-sensitive pipe leaks
or receiver/dryer. gas, replace the expansion
valve.

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● Excessive refrigerant filling or inadequate refrigeration of the condenser

Condition: Inadequate refrigeration

Fig. 4-165
Symptom of refrigeration
Possible cause Diagnosis Troubleshooting method
system
● Excessive refrigerant in
● The pressures at the ● The excessive
the system → ● Clean the condenser.
high- and refrigerant in the
excessive refrigerant ● Check the fan motor
low-pressure ends system can’t bring
filling. operation.
are excessively high. a proper
● Inadequate ● If the above two
● Bubbles are not refrigeration effect.
refrigeration of the conditions are normal,
seen through the ● The condenser fails
condenser → blockage check the refrigerant
sight glass even to provide
of the condenser quantity. Add a proper
when the engine adequate
radiating fin or failure of amount of refrigerant.
speed drops. refrigeration.
the fan motor.
● Air in the refrigeration system
Condition: Poor refrigeration

If the refrigerant is added without vacuumization after the refrigeration system is started, the meter
reading will be as follows.

Fig. 4-166
Symptom of refrigeration
Possible cause Diagnosis Troubleshooting method
system
● The pressures at the
high- and low-pressure ● Check whether the
ends are excessively ● Air enters the compressor oil is
high. ● Air enters the refrigeration system; unclean or
● The low-pressure pipe is cooling system. ● Vacuumization is not inadequate;
hot by hand touch; sufficient. ● Pump out the air and
● Bubbles can be seen add new refrigerant.
through the sight glass.

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● Improper installation of the expansion valve/defective thermo-sensitive pipe (excessively wide

opening)
Condition: Insufficient refrigeration

Fig. 4-167
Symptom of refrigeration 4
Possible cause Diagnosis Troubleshooting method
system
● The pressures at the ● There is
high- and low-pressure excessive ● Check the installation of
ends are excessively ● The expansion valve refrigerant in the the thermo-sensitive tube;
high. is faulty or the low-pressure
thermo-sensitive pipe ● If the above condition is
● Frost or a large pipe; normal, check the
is installed
amount of dew is improperly. ● The expansion expansion valve and
formed on the valve opening is replace it if it is defective.
low-pressure pipe. too wide.

● Compressor failure
Condition: No refrigeration

Fig. 4-168
Symptom of
Possible cause Diagnosis Troubleshooting method
refrigeration system
● The pressure at the
● The compression
low-pressure end is
● There is leakage failure occurs;
excessively high; ● Repair or replace the
inside the ● The valve is leaky or
● The pressure at the compressor .
compressor.
damaged, and the
high-pressure end
parts slip off.
is excessively low;

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Structure and Function SY215CCM3K Hydraulic Excavator

Compressor oil
A certain amount of oil shall be injected into the HVAC for lubrication. The compressor oil is dissolved in
the refrigerant and circulated throughout the system. When the HVAC is shut down, the compressor oil
will remain in the parts of the system. If the system is not supplemented with a proper amount of oil when
the main parts are replaced, insufficient lubrication will be caused. The amount of oil that shall be added
when the main parts are replaced is shown in the following table:
Replaced part
Compressor Condenser Evaporator
See the following
Oil filling quantity (CC) 40 40
precautions for details
Compressor oil ND8# oil (10P, 10PA and 10S series compressors)
designation ND9# oil (TV series compressors)

CAUTION
● A new compressor shall be filled with the required amount of oil necessary for the
circulation system. When the compressor is replaced, the excess oil shall be drained.
● Filling of an improper amount of compressor oil: If excessive compressor oil is added in the
A/C system, the refrigeration capacity will decline. If too little compressor oil is injected in
the system, the compressor will be abnormal.
● When the compressor is disassembled, the pipe joints and O-rings shall be kept clean.

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Engine control

Fig. 4-169

1. Battery relay Overview

2. Power management module ● The engine is started and stopped only by the
ignition switch (6).
3. Battery
● The main controller (5) receives a signal from
4. Engine ECU
the throttle knob (7), and sends a speed
5. Main controller command to the engine ECU (4) via the CAN
bus after program operation. Then the engine
6. Ignition switch
ECU (4) controls the engine speed by
7. Throttle knob controlling the fuel injection quantity.
8. Starter motor ● After the engine ECU (4) detects a shutdown
signal when the ignition switch (6) is turned to
OFF position, the engine ECU stops fuel
injection and then the engine is shut down.

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System operation

Start the engine Starter relay

● When the ignition switch is turned to START Power management

module

position, the controller collects the starting

signal and handle pilot signal, and sends a Engine

starting command to the power management Battery relay

Throttle
Battery knob
module via the CAN bus after logical operation.
Then the power management module outputs

Adjustment signal
Main Engine

the starting signal to the starter motor which Ignition key

controller controller

rotates to start the engine. When the engine switch

Pilot switch
speed is greater than 600 rpm, the engine ECU Starting
signal

outputs a corresponding command, Power-on

signal

disconnects the starter relay and completes the

start process.
Fig. 4-170
At this time, the controller detects the signal
voltage from the throttle knob and sets the
engine speed to the value set by the throttle
knob.

Engine speed control Starter relay

● The throttle knob sends a signal voltage Power management

module

corresponding to the angle of rotation to the

controller. Engine

Then the controller sends a speed command to Battery

Battery relay
Throttle
knob

the engine ECU via the CAN bus according to

Adjustment signal

the signal voltage, and the engine ECU Main

controller
Engine
controller

controls the engine speed by controlling the Ignition key

switch

Pilot switch
fuel injection quantity. Starting
signal

Power-on
signal

Fig. 4-171

Stop the engine Starter relay

● When the ignition switch is turned to STOP Power management

module

position, the engine ECU detects a shutdown

signal and stops fuel injection, and then the Engine

engine is shut down. Battery relay

Throttle
Battery knob
Adjustment signal

Main Engine
controller controller

Ignition key
switch
Pilot switch

Starting
signal

Power-on
signal

Fig. 4-172

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System components
Fuel control knob

Position 1
Position 10

Leftmost limit Rightmost limit

position position

Yellow

Blue

Red

Fig. 4-173

1． Knob 4． Ball
2． Dial 5． Potentiometer
3． Spring 6． Plug

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Structure and Function SY215CCM3K Hydraulic Excavator

Function
● When the throttle knob is turned, the resistance
of the sliding rheostat inside the knob will
change so that the voltage signal collected by

Knob rotation angle

the controller will also change. The controller
will perform calculation according to the
collected value, drive the throttle motor through
the output signal, and control the injection
quantity of the injection pump so that the engine
can reach the ideal control speed.
Voltage (V)
● When the throttle voltage is outside the zone,
the controller will give an alarm code and the
engine will run at low idle speed. The area Fig. 4-174
composed of oblique lines in the right figure is
the abnormality inspection area.
Note: The leftmost limit position indicates 0%, and
the rightmost limit position indicates 100%.

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Controller

Fig. 4-175
Distribution of controller ports

Fig. 4-176

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Structure and Function SY215CCM3K Hydraulic Excavator

Input and output signals

A1 A1 A2
Pin Pin Pin
Signal name Input/output Signal name Input/output Signal name Input/output
No. No. No.
1 Power ground wire Rear pump High and low
53 Input
pressure sensor 82 speed switching
2 Power ground wire solenoid valve
Sensor power
3 Power ground wire 54 Input
ground Counterweight
85 Output
Power supply (24 V swing amber light
4 Input Sensor power
constant) 55 Input
ground Front pump
88
Power supply (24 V solenoid valve
5 Input Sensor power
constant) 56 Output
supply 96 Analog ground
Power-on/shutdown Terminal resistor 97 Analog ground
7 Input 58
signal CAN1-L
Swing priority
8 Horn signal Input 98
59 Shielding ground solenoid valve
11 Fuel level Input 60 CAN1-H Bucket converging
99
17 solenoid valve
Terminal resistor
61
20 LAN port TD- CAN0-H Boom priority
101
solenoid valve
21 LAN port RD- 62 CAN0-L
Arm digging
27 Oil pressure Input 65 Air filter switch Input 107
solenoid valve
Fuel filter element 66 Pilot switch Input Arm dumping
28 Input 108
level alarm Right traveling solenoid valve
67 Input
Hydraulic oil pressure sensor 114 Power ground
31 temperature sensor Input Swing pressure
signal 68 Input 115 Power ground
sensor
34 Throttle knob signal Input 116 Power ground
Bucket unloading
69 Input
Engine throttle pressure sensor 117 Power ground
35 Output
voltage Boom lifting Power supply (24 V
70 Input 118
39 LAN port TD+ pressure sensor constant)

40 LAN port RD+ Arm unloading Power supply (24 V

71 Input 119
pressure sensor constant)
45 Analog ground
Front pump Power supply (24 V
48 Oil pressure switch Input 72 Input 120
pressure sensor constant)
Left traveling Sensor power Power supply (24 V
49 Input 73 121
pressure sensor ground constant)
Bucket digging Sensor power
50 Input 74 Output
pressure sensor supply
Boom lowering Sensor power
51 Input 75 Output
pressure sensor supply
Arm digging Terminal resistor
52 Input 77
pressure sensor CAN1-H
78 CAN1-L
Terminal resistor
79
CAN0-L
80 Shield ground
81 CAN0-H

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Electrical control system

Control functions

Engine - pump combination control function

Pump control function

Valve control function

Traveling dual-speed control

Electrical control system Engine warm-up/overheating alarm 4

Excessively low oil pressure alarm

Automatic idle speed/acceleration control

Self-diagnosis function

★ For detailed description of the self-diagnosis function, see ―Fault diagnosis‖.

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Machine control system diagram

Starter relay

Wiper
Power management
module
Sprinkler

Engine
Horn

Work light
lamp
Cab ceiling lamp/tail

A/C controller

Operation
panel
Throttle
Battery relay knob EGR
Battery Display controller
Adjustment
signal

Engine
Main
controller
controller
Ignition key switch
Pilot switch

Starting
signal
Main pump
Power-on 1. Boom lifting pilot pressure
signal 2. Boom lowering pilot pressure
Front pump displacement solenoid valve

3. Arm digging pilot pressure Rear pump displacement solenoid valve

Bucket converging solenoid valve

Swing priority solenoid valve

solenoid valve
High/low travel speed switching
Boom priority solenoid valve

4. Arm dumping pilot pressure Front pump main pressure

Pilot lever 5. Bucket digging pilot pressure Rear pump main pressure

6. Bucket dumping pilot

pressure
7. Swing pilot pressure
8. Left traveling pilot pressure
9. Right traveling pilot pressure

Main valve
PPC valve

Pilot solenoid valve

Figure 4-177

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Engine - pump combination control function

Pilot valve Cab

Monitor panel
Traveling Traveling

Boom lifting or lowering

Arm extension or
Bucket digging or
retraction
unloading
Swing

Throttle knob

MC controller input
Cancel the function
of automatic idling
Switch travel speed Pressure
Alarm output sensor

Mode switch
knob

Pilot oil pressure

4
Main control valve

Engine
compartment
Pressure sensor
Controller

Pum
p Engine fuel
delivery control

CAN bus Pump proportional

reducing solenoid
valve

Control of inclination
angle of rear pump
Fuel, coolant
temperature and others Control of inclination
angle of front pump

Engine speed

Engine

Fig. 4-178

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Structure and Function SY215CCM3K Hydraulic Excavator

Function

● This function allows the operator to select the

system working mode to change the engine
power output according to different work of the

Engine torque T
machine. To select the working mode, it is
necessary to use the working mode selection
button on the display.
● The master controller controls the pump so
that it can absorb all torques at the engine
output point. These torques depend on the
pump absorption torque specification, fuel
control knob setting and actual engine speed Engine speed N
in each mode.

Fig. 4-179

● Technical parameters
Mode S
Speed (rpm) ~1600 1600~1800 2000 Engine power KW

Power (kW) 70.4 87 94.5

Mode E/L/B
Speed
~1600 1600~1850
(rpm)
Power (kW) 81.7 92.4
Engine speed N

Fig. 4-180

Engine speed setting

Position 1 2 3 4 5 6 7 8 9 10 11
Mode B 1100 1200 1300 1400 1500 1550 1580 1600 1650 1750 1800
Mode
1100 1200 1300 1400 1500 1550 1580 1600 1650 1750 1850
L/B
Mode S 1100 1200 1300 1400 1500 1550 1580 1600 1700 1800 1900

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Pump control function

Pressure Pressure sensor

sensor
Main pump

Engine

Speed Servo
Servo
sensor

Engine controller Proportional

valve
Proportional
valve
4
(Control signal)

(Control signal)
Fuel control knob

CAN bus Monitor panel

Controller

CAN bus
Boom lowering signal
Bucket digging signal

Arm unloading signal

Right traveling signal

Left traveling signal
Arm digging signal

Boom lifting signal

Bucket unloading
Swing signal

signal

Fig. 4-181

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Electrical positive flow control

Pump 1
displace
ment

Boom lifting pilot pressure

Pump 1
displace
ment

Arm digging pilot pressure

Pump 1
displace
ment

Arm unloading pilot pressure

Pump 1
displace Pilot corresponding
ment displacement output

Bucket digging pilot pressure

Pump 1
displace
ment

Bucket unloading pilot pressure

Pump 1
displace
ment

swing pilot pressure

Pump 1
displace
ment

Left traveling pilot pressure

Fig. 4-182

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Pump 2
displace
ment

Boom lifting pilot pressure

Pump 2
displace
ment

Arm digging pilot pressure

Pump 2
displace
ment

Arm unloading pilot pressure

Pump 2
displace Pilot corresponding
ment displacement
output
4
Bucket digging pilot pressure
Pump 2
displace
ment

Bucket unloading pilot pressure

Pump 2
displace
ment

Pump 2 Boom drop pilot pressure

displace
ment

Right traveling pilot pressure

Fig. 4-183

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Structure and Function SY215CCM3K Hydraulic Excavator

Function
● It directly uses the handle pilot pressure signal as the hydraulic pump displacement control signal.
The pilot pressure acts on the valve stem on one hand and is collected by the controller on the other
hand. The controller maintains the hydraulic pump displacement at the determined value under the
corresponding pilot pressure based on the function of the given hydraulic pump displacement and
the pilot pressure. When a combination action is performed, the given displacement of each action
shall be increased.
Operation
● When the work equipment acts, the controller will collect the pilot pressure sensor signal and give
the control displacement of pumps 1 and 2 according to the pilot pressure signal.

Constant power control

Function
Flow
● It mainly calculates theoretical maximum Pump P-Q curve
diagram
displacement of the pump. The system adopts
constant power control. The two regulators
are hydraulically linked so that the two
actuators having the same specifications and
acting at the same time can be synchronized.
The pump flow change is mainly determined
by the sum P∑ of working pressures of the two Pressure
hydraulic pumps. As long as 2P0≤P∑≤2PMax is
satisfied, the sum of power of the two
hydraulic pumps will always remain constant Fig. 4-184
and will not exceed the diesel engine power.

Operation
● When the work equipment acts, the controller will collect the main pressure sensor signal of pumps
1 and 2 and realize constant pump power control according to the main pressure signal.
ESS control
Function
● It controls the pump power based on the engine speed variation due to the load change, thus the
engine output is used more effectively. (Engine stalling can be avoided when the machine operates
under plateau and other harsh conditions).
Operation
The target operating speed of the engine is controlled by the engine control dial.
● The controller collects the actual speed signal of the speed sensor and performs closed loop control
of the target speed. Then, the controller involves the output under closed loop control in the solenoid
valve control signal calculation and sends the final regulating current signal to the pump proportional
solenoid valve.
● The solenoid valve supplies pilot pressure oil to the pump regulator to control the pump flow based
on the signal from the controller.

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Valve control function

Arm 2 dumping

Arm 2 digging

Neutral shut-off Main valve

2

Neutral shut-off
1 Pressure sensor Pressure sensor
Engine
Main pump
Swing priority

Nozzle

Speed
sensor
Engine speed signal Servo Servo

Engine

Proportional Proportional
valve valve

Fuel control knob Mode switch knob

(Control signal)

(Control signal)
Throttle position feedback

Engine speed signal

signal

Monitor panel

Controller

CAN bus
Bucket unloading signal

Bucket digging signal

Arm unloading signal

Boom lowering signal

Right traveling signal

Left traveling signal
Arm digging signal

Boom lifting signal

Swing signal

Fig. 4-185
Valve control function
● Neutral shut-off valve 1
● Neutral shut-off valve 2
● Swing priority
● Arm 2 digging
● Arm 2 dumping

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Structure and Function SY215CCM3K Hydraulic Excavator

1) Bucket flow control

Function Swashplate
angle
● It controls the pump swashplate angle
according to the bucket handle opening.
Operation
● When the bucket handle acts, the controller will
collect the signals of the bucket unloading
pressure sensor and bucket digging pressure
sensor to control the bucket converging Bucket handle
pilot pressure
proportional valve.

Fig. 4-186

Bucket converging
proportional valve
current

Bucket handle
pilot pressure

Fig. 4-187

2) Swing priority control

Function
● The pressure oil of pump 1 passes over the arm 1 valve spool and flows to the swing motor valve
spool for priority swing operation.
Operation
● The controller will activate the solenoid valve when the signals from the pump 1 oil delivery pressure
sensor, arm pressure sensor and swing pressure sensor are under the following conditions. The
solenoid valve delivers the pilot pressure oil to the arm flow controller so that the parallel oil circuit of
the arm 1 valve spool is limited. The swing valve spool guarantees the swing motor power
preferentially to avoid the impact of the upper swing platform rotation at the time of arm retraction on
the positioning precision.
Operational conditions
● Swing pressure sensor: With the output signal;
● Arm pressure sensor: With the output signal.

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Traveling dual-speed control

Travel motor

Regulator Regulator
Left traveling pressure

pressure sensor
Right traveling
sensor

Traveling speed
Main valve solenoid valve

Main pump
Engine
4

Servo Servo

Fuel control knob

Engine
controller
Control

Control
signal

signal
CAN bus

Monitor panel

Controller

CAN bus

Fig. 4-188
Function
● It controls the traveling mode.
Operation
● When the slow traveling mode is set, the maximum travel motor swashplate angle will be achieved,
and the machine will travel at a low speed.
● When receiving the signal sent by the traveling pressure sensor under the following conditions, the
controller will activate the solenoid valve. Then, the solenoid valve will deliver the pilot pressure oil
to the travel motor swashplate angle control valve to minimize the swashplate angle so as to
increase the traveling speed.

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Operational conditions
● The fast traveling function on the display is enabled.
Note:
When the track on one side is lifted above the ground and rotated with the work equipment, the pressure
of the pump on one side will increase to achieve fast rotation of the lifted track. When the machine
travels in the fast traveling mode, this traveling mode will be kept unchanged even if the work equipment
is operated (the work equipment pressure sensor is turned to ON).

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Automatic idle speed/acceleration control

Right work equipment

control lever
Boom Bucket

Unloading
Digging
Lower

Lift
Left work equipment
Swing control lever Arm
Engine

Unloading
Retraction
Right

Left
Fuel control Engine
knob controller
Left Travel lever Right
traveling traveling

Reverse

Reverse
Forward

Forward
CAN bus

Throttle signal

4
Controller

CAN bus

Travel lever
signal

Fig. 4-189
Function
● It decreases the engine speed to reduce the Speed (rpm)

fuel consumption and noise when all travel

levers are put in the neutral position. Set speed
Reduction by 100
rpm
● If any control lever is operated, the engine
Deceleration
speed will immediately return to the value set
by the fuel control knob.
<1s
Operation <1s
● When the travel lever is returned to the neutral
position for 3 s, the diesel engine will Time (s)

immediately decelerate to the first gear speed With action Without action With action

which is 100 rpm lower than the set speed. If Control lever
the engine automatically operates at a low
speed (1,400 rpm) after 3 s, the hydraulic Fig. 4-190
system air flow loss and diesel engine wear
can be reduced, thus achieving energy
conservation and noise reduction. When the
travel lever is operated again, the diesel
engine will automatically return to its original
speed. When the pilot switch is locked (pilot
rod in vertical direction), the engine speed will
drop to 800 rpm.
● If any control lever is operated when the
engine decelerates, the engine speed will
immediately rise to the level set by the fuel
control knob.

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Structure and Function SY215CCM3K Hydraulic Excavator

System parts
Pump pressure sensor

Connector Main body Pressure joint

Connection diagram

Terminal Signal name

No.

Power supply (+5 V)

GND

Output

Fig. 4-191

Operation
● The relationship between the pressure (P)
applied to the sensor and the output voltage
(E) is shown in the figure below.
Sensor output voltage
(E)

Oil pressure (P)

Fig. 4-192

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Pilot pressure sensor

Connector Main body Pressure joint

Connection diagram

Terminal Signal name

No.

Power supply (+5 V)

GND

Output
4

Fig. 4-193

Operation
● The relationship between the pressure (P)
applied to the sensor and the output voltage
(E) is shown in the figure below.
Sensor output voltage
(E)

Oil pressure (P)

Fig. 4-194

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Structure and Function SY215CCM3K Hydraulic Excavator

Engine speed sensor

View A

Fig. 4-195

Function
● The engine speed sensor is installed at the CAUTION
ring gear of the engine flywheel to calculate ● If the tightening torque of engine speed
the number of teeth of the gear in front of the sensor is insufficient, the sensor may
sensor and send the calculated result to the have no output signal. Tighten the
controller. engine speed sensor to the specified
Operation torque.
● During operation, measure the resistance
between the terminal 1 and terminal 2.
Standard value (at
860 ± 86 kΩ
20°C)
● If the measured value exceeds the standard
value, replace the sensor.

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Coolant temperature sensor

Fig. 4-196
1. Sensor
2. Connector 4
Function
● The output resistance of the engine coolant
temperature sensor varies with the
temperature, and the controller acquires and
processes the signal and calculates the
coolant temperature.
Technical Specifications

50℃ 80Ω (reference)

60℃ 56.3Ω

Standard 80℃ 29.5±10Ω

value 100℃ 16.5Ω
106℃ 14.3±0.5Ω
120℃ 10Ω (reference)

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Structure and Function SY215CCM3K Hydraulic Excavator

Fuel level sensor

Fig. 4-197

[1] Float [3] Hosing

[2] Lever [4] Connector

Conversion table of resistance and physical value

of fuel sensor
Sensor
Ω 87 8.7
resistance
Fuel position % 0 100

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Oil pressure switch

Load

Pressure

Fig. 4-198
4
1. O-ring
2. Sensor
3. Connection
Function
● The oil pressure switch is primarily installed on
the outlet pipe of the oil filter to mainly detect
the oil pressure and generate and send an
alarm signal to the controller.
Technical Specifications
● Contact type: Normally closed contact
● Operating pressure: 1.9 kg

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Structure and Function SY215CCM3K Hydraulic Excavator

Display system
Display

A/C controller

Controller

CAN signal

supply
voltage
Power
management
module

Each sensor

Power

Battery

Fig. 4-199

● The machine condition is monitored by ● The display panel also has various mode
sensors installed on various parts of the selection switches and function keys to
machine and processed by the controller, and operate the machine control system.
the obtained information is immediately shown
on the display panel to inform the operator of
the machine condition.
● The content on the display panel is generally
divided into the following two parts.
1. Alarm information when a fault occurs on the
machine.
2. Machine condition (coolant temperature,
hydraulic oil temperature, fuel level, etc.).

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Display

Fig. 4-200

Overview IMPORTANT
● The display has the function of displaying
● When the LCD display panel has less
monitoring information and selecting the
than 10 dark dots (dots not lighted) or
working mode.
bright dots (dots always lighted), it
● The display is configured with a CPU (central conforms to the technical standard.
processing unit) for information processing,
● When the display works continuously,
display and output.
blue bright dots may be displayed on
● The display is a LCD (liquid crystal) display. the interface on a black background,
which is normal.
Input and output signals of connector
● When the display starts, there will be
Pin No. Signal name Remarks flashing stripes, which is normal.
Pin No. Signal name Input/output
1 Digital input A Input
3 CAN high
4 CAN low
7 Digital input B
Trigger power
8
supply (24 V)
Power supply
9
(24V)
10 GND
11 Digital input C
12 GND

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Display overview
Function overview

The display panel has the functions of monitoring

display, working mode display and switching of
electrical components.
Display appearance
This display mainly consists of 3 parts:
A： Alarm and signal indicator area
B： Main image display area
C： Key area

Fig. 4-201

Alarm and signal indicator area

Fault alarm indicator lamp

The fault alarm indicator will turn on to remind the Alarm indicator
user of troubleshooting when the excavator is faulty.

Fig. 4-202

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Main image display area

The LCD is a main interface display area, which
displays different page names, page item content,
parameters, time, function icons, etc. according to
the selected item. The user can switch options and
adjust the set data and parameter by operating the
keys. Main information of the main interface is
displayed as shown in the right figure.
1. Working mode
2. Coolant thermometer
3. Fuel level gauge
4. DTC
5. Machine working time
6. Function icon
7. Current time
4
8. Current date Fig. 4-203
9. GPS signal indication
10. Engine position indication

● Coolant thermometer: The range has 13

divisions (yellow) indicating the temperature of
0~120℃.
A: It is displayed when the engine is just
started.
B: It is displayed at the temperature of
0~110°C.
C: It is displayed when the temperature is
higher than 110°C. At this time, the last
division will turn red and the alarm
indicator will be on.
When the temperature returns below 110℃,
the alarm indicator lamp will go out
automatically.

Fig. 4-204

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● Fuel level gauge: The range has 13 divisions

(yellow) indicating the fuel level of 0~100%.
A: When the fuel level is below 8%, the
division will be blank and the alarm
indicator lamp will turn on.
B: When the fuel level returns to above 8%,
the alarm indicator will go out
automatically.
C: It is displayed when the fuel is full.

Fig. 4-205

Key area

The key area includes function keys and operational

keys.
1: Function key
2: Operational key

Fig. 4-206

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Function key
Function keys are F1, F2, F3, F4, and F5 with purposes corresponding to the function icons displayed on
the main interface display area above them.
● When different function icons are displayed, each key will have a different purpose.
● When no corresponding function icon is displayed in the main image display area, this function
button will be invalid.
The corresponding relationship between common function display icons and keys is shown in the table
below.
Display
Function key Function Display range
icon
Full speed/ auto idle speed
F2 Full speed/ auto idle speed
switching
High/low traveling speed
F3 High/low speed
switching
F4 Enter the selected/set item The same as the operational key Enter

Select information query -- 4

F5 Return to the previous
The same as the operational key Esc
interface
Operational key
Operational key Function
Enter the selected/set item

Return to the previous interface

Select the upper item (select the lowermost item after selection of the
uppermost item)
Increase the value at the cursor position by increment
Select the lower item (select the uppermost item after selection of the
lowermost item)
Decrease the value at the cursor position by decrement
Select the left item (select the rightmost item after selection of the leftmost
item)
Move the cursor leftwards
Select the right item (select the leftmost item after selection of the rightmost
item)
Move the cursor rightwards

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Operation method of each page of the display

Operation methods
1. Working mode
Switching among working modes S, E, L and B
can be achieved by rotating the mode switch
knob.
S mode - standard working mode
E mode - economic working mode
L mode - level working mode
B mode - breaker working mode
Note: The default working mode is ―S‖ mode
each time the machine is powered on.
2. Automatic idle speed selection
Use to cancel and start the automatic idle
speed function.
When the symbol is displayed above ,
press down this key to cancel the automatic
idle speed function; when the symbol is
displayed above the key, press down this key Fig. 4-207
to start the automatic idle speed function.
Note: The default mode of the automatic idle speed
is the "Start" mode when the machine is
powered on each time.
● By default, the automatic idle speed switch is
turned on. When all travel levers are put in the
neutral position for 0.2 s, the engine will
decelerate by 100 rpm immediately and then
enter the idle state automatically after 3 s (the
controller will automatically adjust the speed to
the idle speed) to save fuel and reduce noise.
● If the controller detects an action or position
change in the idle state, the engine will
automatically return to the speed corresponding
to the position.
3. High/low traveling speed selection
Use to realize switching between ―High
Traveling Speed‖ and ―Low Traveling Speed‖.
When the symbol is displayed above the
key , press down this key to select high
traveling speed; when the symbol is
displayed above the key, press down this key
to select low traveling speed.
Note: The default traveling speed is the low speed
when the machine is powered on each time.
4. Fault information query
When the alarm indicator light lights up on the
display, a DTC will appear at the bottom of the
display. At this time, the red symbol will
appear above . Press down this key to enter
the fault information query page.

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5. System information query

Press to enter the system information
query page.
Note: Input the password before entering the system
information page. Please contact the local
dealers authorized by Sany Heavy Machinery
Co., Ltd.
Information query - password entry
Press on the ―Home Page‖ to enter the
―Information Query - Password Entry‖ page.
Input the correct password before entering the
[Information Query] page.
Key operation
● Press or and to achieve
progressive increase or decrease of the number
in the password digit indicated by the cursor.
● Press or and to move the cursor
leftwards or rightwards.
Fig. 4-208 4
● Press to enter the ―System Unlocking‖
page.
● Press to enter the ―Backlight Adjustment‖
page.
● Press or to return to the [Home Page].
● Press to confirm the correctness of the
password. If it is correct, switch to the
[Information List].

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Information List
Enter the correct password on the ―Password Entry‖
page and press to enter the [Information List]
page.
This page is used to display the system function list.
Different pages can be entered through selection of
different entries in the list.
Key operation
● Press or and to select different
entries in the system function list, move the
cursor from top to bottom, and return to the
topmost position when the cursor reaches the
bottom.
● Press or to enter the page
corresponding to the entry selected by the
cursor.
● Press to switch to the [System Setting] Fig. 4-209
page.
● Press or to return to the [Home
Page].

Engine and throttle signal

Select [Operation Information Query] on the
[Information List] page, and then press or
to enter the [Engine and Throttle Signal] page.
This page is used to display the operation
parameters of engine and throttle signals.
Key operation
● Press to switch to [Pilot Pressure Signal]
page.
● Press or to return to the [Information
List] page.

Fig. 4-210

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Pilot pressure signal

Press on the [Engine and Throttle Signal] page
to enter the [Pilot Pressure Signal] page. This page
is used to display the pilot pressure signal.
Key operation
● Press to switch to the [Main Pump and
Main Valve Signal] page.
● Press or to return to the [Information
List] page.
● Main valve signal
● Function
● Display of main valve signal
● Page switching
● Press F1 to switch to the [Engine Signal] page.
● Press F5 to return to the [Information List] 4
Fig. 4-211
page.

Main pump and main valve signal

Press on the [Pilot Pressure Signal] page to
enter the [Main Pump and Main Valve Signal] page.
This page is used to display the main pump and
main valve signal.
Key operation
● Press to switch to the [Engine and Throttle
Signal] page.
● Press or to return to the [Information
List] page.

Fig. 4-212

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DTC query
Select [DTC Query] on the [Information List] page,
and then press to enter this page.
This page is used to display the DTC and
information.
Key operation
● Press to switch to the DTC on the next
page.
● Press or to return to the [Information
List] page.

Fig. 4-213

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System Language Selection

Select [System Language Selection] on the
[Information List] page, and then press to enter
this page.
This page is used to select the system language.
Key operation
● Press to select the Chinese systems.
● Press to select the English systems.
● Press or to return to the [Information
List] page.
Press and to move the cursor upward or
downward to select different entries in the list.

4
Fig. 4-214

System Clock Calibration

Select [System Time Setting] on the [Information
List] page, and then press to enter this page.
This page is used to set the system clock.
Key operation
● Press and to achieve progressive
increase or decrease of the number at the
cursor position.
● Press and to move the cursor
leftwards or rightwards.
● Press or to confirm the calibration
result. The prompt of ―Calibration is OK. Power
off and restart the machine!‖ is displayed on the
page.
● Press or to return to the [Information
List] page.
Fig. 4-215
Note: Once the system time is powered on, it can
only be calibrated once. After the power on,
press or , after which the interface will
always display the calibration result!

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GPS monitoring information

Select [GPS Monitoring Information] on the
[Information List] page, and then press to enter
this page.
This page is used to display the GPS monitoring
information.
Key operation
● Press or to return to the [Information
List] page.
Note:
1. In longitude, ―E‖ indicates east longitude, and
―W‖ indicates west longitude;
2. In latitude, ―N‖ indicates north latitude, and ―S‖
indicates south latitude;
3. In altitude, ―P‖ indicates altitude above sea
level, and ―N‖ indicates altitude below sea level; Fig. 4-216
4. The lateral fill bar range of the SNR is [0,99],
and the value on the right indicates the actual
signal-to-noise ratio;
5. If the indicated altitude is not zero and no
latitude and longitude are indicated, it indicates
that GPS data is being received, but the
position is not precisely determined at this time;
6. When the communication indication is 1023,
the GPRS communication is normal; when it is
615, the GPRS communication is abnormal;
7. When the communication indication changes
from 7 to 0, the SIM card or the antenna is
connected abnormally;
8. When the communication indication changes
from 15 to 0, the GPRS service is not activated,
or the SIM card is due, or the GPRS network is
abnormal;
9. When the communication indication changes
from 31 to 0, the monitoring center is turned off;
10. For this page, the functions of remote locking,
remote unlocking and remote downloading
should be tested.

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System setting list

Press on the [Information List] page to enter the
[System Setting] page. This page is used to set the
machine configuration.
Note: Input the password before entering the
―System Setting‖ page. For the password entry
method, see [Information Query - Password]
page.
Key operation
● Press or and to select different
entries in the system function list, move the
cursor from top to bottom, and return to the
topmost position when the cursor reaches the
bottom.
● Press or to enter the page
corresponding to the entry selected by the
cursor. 4
Fig. 4-217
● Press or to return to the [Information
List] page.

Machine configuration
Select [Machine Configuration Query] on the
[System Setting] page, and then press or
to enter this page. This page is used to query the
machine configuration.
Note: Input the password before entering the
[Machine Configuration] page. For the
password entry method, see [Information
Query - Password] page.
Key operation
● Press or to return to the [System
Setting] page.
Note: The ―V217‖ following the machine model
represents the software version number.

Fig. 4-218

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Working time calibration

Select [Working Time Setting] on the [System
Setting] page, and then press or to enter
this page. This page is used to set the working time.
Note: Input the password before entering the
[Machine Configuration] page. For the
password entry method, see [Information
Query - Password] page.
Key operation
● After calibration, press or to confirm
the calibration result. The prompt of ―Calibration
is OK. Power off and restart the machine!‖ is
displayed on the page.
● Press or to return to the [System
Setting] page.

Fig. 4-219
Machine configuration calibration
Select [Machine Configuration Calibration] on the [System
Setting] page, and then press or to enter this
page. This page is used to calibrate the machine
configuration after the display is installed.
Note: Input the password before entering the [Machine
Configuration] page. For the password entry method,
see [Information Query - Password] page.
Key operation
● When the "215" following the machine model flashes,
press once to increase the number by 10; when
the "32" following "\Gps" flashes, press once to
increase the number by 10.
● Press to change the engine on the corresponding
page once.
● Press to change the hydraulic system on the
corresponding page once.
● Press to change the controller on the
corresponding page once.
● Press to confirm the calibrated content, after which
the prompt of ―Calibration is OK. Power off and restart Fig. 4-220
the machine‖ will be displayed.
● Press or to achieve progressive increase or
decrease of the selected machine ID, with a magnitude
of (100).
● Press or to achieve progressive increase or
decrease of the selected machine ID, with a magnitude
of (1) through short-time press and a capability of rapid
decrease or increase through long-time press.
● Press to return to the [System Setting] page.
● Every time the key is pressed, the number behind
the machine ID or model will flash, and then the
corresponding value can be changed by pressing the
key.

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Hydraulic oil temperature

Select [Hydraulic Oil Temperature Query] on the
[System Setting] page, and then press or
to enter this page. This page is used to display the
hydraulic oil temperature.
Key operation
● Press or to return to the [System
Setting] page.

4
Fig. 4-221

Display brightness adjustment

Press on the [Information Query] page to enter
this page. This page is used to adjust the backlight
brightness of the display.
Key operation
● Press to decrease the brightness of
backlight.
● Press to increase the brightness of the
backlight.
● Press to save the backlight adjustment.
● Press to return to the [Information Query]
page.

Fig. 4-222

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Level I locking interface

The appearance of this page on the display
indicates that the excavator is set in the Level I
locking state.
Key operation
● Press to enter the unlocking page.
Note: The corresponding state is displayed based
on the command after 5 s: ―Level I Locking‖,
―Level II Locking‖ or ―No Locking‖. (The
purpose of waiting for 5 s is to achieve filtering.)

Fig. 4-223

Level II locking interface

The appearance of this page on the display
indicates that the excavator is set in the Level II
locking state.
Key operation
● Press to enter the unlocking page. Note:
The corresponding state is displayed based on
the command after 5 s: ―Level I Locking‖, ―Level
II Locking‖ or ―No Locking‖. (The purpose of
waiting for 5 s is to achieve filtering.)

Fig. 4-224

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Standard Values of Components

Contents
Table of Standard Values of Engine Related Components .................................................................... 5-2
Table of Standard Values of Body Related Components ....................................................................... 5-3

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Standard Values of Components SY215CCM3K Hydraulic Excavator
Table of Standard Values of Engine Related Components
Applicable model SY215CCM3K
Engine Mitsubishi 4M50
Standard values for Limit values for
Item Measurement conditions Unit
new machine maintenance
High idle speed rpm 2,060 ± 70 2,060 ± 70
Engine speed Low idle speed rpm 1,050 ± 50 1,050 ± 50
Rated speed rpm 2,000 2,000
Intake pressure ● Outlet of air cleaner
kPa Min. 133 Min. 133
(negative ● Arm retracted and overflow + max.
{mmH2O} {Min. 1,000} {Min. 1,000}
pressure) speed

Exhaust smoke Abrupt acceleration Bosch Max. 25 35

color High idle speed Index — —

Valve Intake valve mm 0.25 0.152 – 0.381

clearance Exhaust valve mm 0.51 0.381 – 0.762
● oil temperature:
Compression 40~60℃ Compression Mpa Min. 2.41 1.69
pressure ● Engine speed: 250 pressure {kg/cm2} {Min. 24.6} {17.2}
rpm
● Coolant temperature: within the
Blow-by operating range kPa Max. 0.98 1.96
pressure ● Arm retracted and overflow + max. {mmH2O} {Max. 100} {200}
speed
MPa Min. 0.29 0.25
High idle speed
{kg/cm2} {Min. 3.0} {2.5}
Oil pressure
MPa Min. 0.10 0.07
Low idle speed
{kg/cm2} {Min. 1.0} {0.7}
Oil temperature ● Full speed range (inside the oil pan) ℃ 80 – 110 120
● Between the fan pulley and the
Fan belt alternator pulley
mm 8 Min. 6, Max. 10
tension ● Sag when being pressed by finger
with force about 58.8 N {6 kg}
● Between the fan pulley and the
A/C compressor pulley
compressor mm 5–8 5–8
belt tension ● Sag when being pressed by finger
with force about 58.8 N {6 kg}

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SY215CCM3K Hydraulic Excavator Standard Values of Components

Table of Standard Values of Body Related Components

Applicable model SY215CCM3K
Standard values
Category Item Measurement conditions Unit Allowable value
for new machine
● Engine coolant
temperature: within the
operating range
● Hydraulic oil temperature:
within the operating range
When No. 2 pump
• The engine runs at a high rpm 1900±30 1900±30
overflows
idle speed
Engine speed

● Heavy-duty working mode

(S)
● Arm is retracted and
overflows
• The engine runs at a high
idle speed
During automatic ● The automatic idling
rpm 1,400±50 1,400±100
deceleration switch is on
● All the control levers are in
the neutral position
Lift mm 11.5±0.5 11.5±0.5
Boom control valve ● The
engine is Lower mm 9.5±0.5 9.5±0.5
shut down Retraction mm 11.5±0.5 11.5±0.5
Spool valve travel

Arm control valve ● As for the Extension mm 9.5±0.5 9.5±0.5

key points
Bucket control for Digging and
mm 9.5±0.5 9.5±0.5
valve measurem dumping
ent, see Travel to left
Swing control valve the mm 9.5±0.5 9.5±0.5
and right
Section
Traveling control ―Control Go forward
Valve‖ and mm 9.5±0.5 9.5±0.5
valve
backward
Boom control lever mm 85±10 85±10
● The engine is shut down
Arm control lever ● Center of control lever mm 85±10 85±10 5
Bucket control ● Take the maximum value mm 85±10 85±10
lever at the end of the travel
Swing control lever (minus the lever play in the mm 85±10 85±10
neutral position)
Travel lever mm 115±12 115±12
● The Work
Control lever travel

mm Max. 15 Max. 20
engine is equipment
shut down
● Slightly
push the
control
lever by
hand until
Control lever play
obvious
resistance Travel mm Max. 20 Max. 25
is felt
● Take the
maximum
value at
the end of
the travel

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Standard Values of Components SY215CCM3K Hydraulic Excavator

Applicable model SY215CCM3K

Standard values
Category Item Measurement conditions Unit Allowable value
for new machine
Boom Max. 19.6 Max. 24.5
Operating force of control lever and the

control lever {Max. 2.0} {Max. 2.5}

Arm control ● Hydraulic oil temperature: within Max. 19.6 Max. 24.5
lever the operating range
{Max. 2.0} {Max. 2.5}
• The engine runs at a high idle
Bucket speed Max. 15.6 Max. 21.6
control lever
pedal

● The control lever is at neutral N {Max. 1.6} {Max. 2.2}

Swing position {kg} Max. 15.6 Max. 21.6
control lever ● The pedal is at the topmost {Max. 1.6} {Max. 2.2}
position
Max. 30.4 Max. 39.2
Travel lever ● Max. reading at the end of the
travel {Max. 3.1} {Max. 4.0}
Travel Max. 93.1 Max. 107.6
control pedal {Max. 9.5} {Max. 11}
● Hydraulic oil temperature: within
the operating range
• The engine runs at a high idle
Standby speed 0~1.0 0 ~2.0
pressure ● Working mode: S Mode {0 ~10} {0 ~20}
● Output pressure of the hydraulic
pump when all control levers are
in the neutral position
Boom ● Hydraulic oil temperature: within 34.3 ± 1.0 33.3 – 35.3
overflow the operating range {350 ± 10} {340 – 360}
● After running the engine at a high
Arm 34.8 ± 1.0 33.3 – 36.8
idle speed, operate the
overflow corresponding control lever {355 ± 10} {340 – 375}
● Working mode: S Mode
Hydraulic pressure

Bucket ● Output pressure of the hydraulic 34.8 ± 1.0 33.3 – 36.8

overflow pump when all measured {355 ± 10} {340 – 375}
hydraulic lines overflow MPa
● Hydraulic oil temperature: within {kg/cm2} 25.5 ± 1.0 24.5 － 27.5
Swing
overflow the operating range {261 ± 10} {250 －280}
● After running the engine at a high
idle speed, operate the
corresponding control lever
Traveling ● Working mode: S Mode 33.4 ± 1.0 32.4 – 34.4
overflow ● Output pressure of the hydraulic {342±10} {330 – 351}
pump when all measured
hydraulic lines overflow
● Hydraulic oil temperature: within
the operating range
• The engine runs at a high idle
Control oil 3.9±0.2 3.7 – 4.1
speed
line source
pressure ● Output pressure of the {40±2} {37 – 41}
self-operated pressure reducing
valve when all control levers are
in the neutral position

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SY215CCM3K Hydraulic Excavator Standard Values of Components

Applicable model SY215CCM3K

Standard
Allowable
Category Item Measurement conditions Unit values for new
value
machine
● Hydraulic oil temperature: within the
operating range
• The engine runs at a high idle speed
Angle of swing ● Working mode: S Mode degree Max. 100 Max. 130
brake ● Angular misalignment of the swing bearing （mm） （—） （—）
after swing for a turn
● As for detail about measurement posture,
see "Rotation 1" in Page 5-9
● Hydraulic oil temperature: within 90° second 3.1 ± 0.3 Max. 3.7
the operating range
• The engine runs at a high idle
speed
Swing start ● Working mode: S Mode
time ● Time required for rotating 90°or 180° second 4.4 ± 0.4 Max. 5.5
180°from the start point
● As for detail about measurement
posture, see "Rotation 1" in
Page 5-9
● Hydraulic oil temperature: within the
operating range
Swing

• The engine runs at a high idle speed

● Working mode: S Mode
Swing time second 27 ± 3.5 Max. 30
● Measure the time required for swing for 5
turns after initial swing for 1 turn
● As for detail about measurement posture,
see "Rotation 1" in Page 5-9
● Hydraulic oil temperature: within the
operating range
● The engine is shut down
● Keep the superstructure of the machine
Hydraulic drift 5
horizontal in a 15° slope; for details, see mm 0 0
during swing
"Swing 2" in Page 5-9
● Make match marks on the inner and outer
races of the swing bearing
● Displacement of the match marks in 5 min
● Hydraulic oil temperature: within the
operating range
Leakage of • The engine runs at a high idle speed
ml/min Max. 5 Max. 10
swing motor ● Swing lockout switch: ON
● Measure leakage in 1 min during swing
overflow
● Hydraulic oil temperature: within Lo
51.3 ± 5.1 46.2 - 60.4
the operating range position
• The engine runs at a high idle
speed
Traveling

Traveling ● Working mode: S Mode

speed ● Measure the time required for second
(under no load) Hi
swing of the track shoe for 5 28.0 ± 1.4 26.6 - 31.4
position
turns after initial swing for 1 turn
● As for detail about measurement
posture, see "Traveling 1" in
Page 5-9

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Standard Values of Components SY215CCM3K Hydraulic Excavator

Applicable model SY215CCM3K

Standard
Allowable
Category Item Measurement conditions Unit values for new
value
machine
● Hydraulic oil temperature: within 19.5～
Low 22±2.5
the operating range 24.5
● The engine runs at a high idle
speed
Traveling ● Working mode: S Mode
speed ● Flat ground second
(actual) ● Time required for traveling for 10 12.5～
High 14±2.5
m after 10 m trial operation 16.5
● As for detail about measurement
posture, see "Traveling 2" in Page
5-9
● Hydraulic oil temperature: within the
operating range
● The engine runs at a high idle speed
● Working mode: S Mode
Traveling ● Traveling speed: low
mm Max. 800 Max. 900
Traveling

deviation ● Solid and flat ground

● Deviation (x) of traveling for further 20 m
after 10 m initial trial operation
● As for detail about measurement posture,
see "Traveling 2 and 3" in Page 5-9
● Hydraulic oil temperature: within the
operating range
● The engine is shut down
Hydraulic drift
● The machine is parked on a 12°slope, with
during mm 0 0
the sprocket downward
traveling
● Measure the sliding distance after 5 min
● As for detail about measurement posture,
see "Traveling 4" in Page 5-10
● Hydraulic oil temperature: within the
operating range
Leakage of ● The engine runs at a high idle speed
mm 13.6 27.2
travel motor ● Traveling when sprocket is locked
● Measure the oil leakage in 1 min after
traveling in overflow condition
Tip of ● Hydraulic oil temperature: within the
buc operating range
ket ● Flat and horizontal ground mm Max. 600 Max. 900
tee ● Bucket is filled with soil or under rated load
Hydraulic drift of work equipment

th (0.8m3: 1,440 kg)

Boom ● Boom is horizontal, arm is fully retracted and
mm Max. 20 Max. 27
cylinder arm cylinder is fully extended
Work equipment

Arm ● The engine is shut down

● The control lever of the work equipment is in mm Max. 20 Max. 20
cylinder
the neutral position
● Measure the lowering distance once every 5
min and the total lowering distance in 15 min
after initial setting
● Lowering distance of tip of bucket teeth
Bucket ● Boom cylinder: retracting distance of cylinder mm Max. 45 Max. 45
cylinder ● Arm cylinder: extending distance of cylinder
● Bucket cylinder: retracting distance of
cylinder
● As for measurement posture, see "Work
equipment 1" in Page 5-10

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SY215CCM3K Hydraulic Excavator Standard Values of Components

Applicable model SY215CCM3K

Standard values Allowable
Category Item Measurement conditions Unit
for new machine value
● Hydraulic oil temperature:
within the operating range
● The engine runs at a high idle
speed
● Working mode: S Mode
Boom ● Time required for lifting the Lift second 3.4 ± 0.4 Max. 4.8
bucket from the ground to the
end of lifting height
● As for detail about
measurement posture, see
"Work equipment 2" in Page
5-10
● Hydraulic oil temperature: Retraction second 2.8 ± 0.4 Max. 4.5
within the operating range
Speed of work equipment

● The engine runs at a high idle

Work equipment

speed
● Working mode: S Mode
Arm ● The required operation time
from the end of dumping height Extension second 2.3± 0.3 Max. 3.5
to the end of digging height
● As for detail about
measurement posture, see
"Work equipment 3" in Page
5-10
● Hydraulic oil temperature: Digging second 2.3 ± 0.4 Max. 3.4
within the operating range
● The engine runs at a high idle
speed
● Working mode: S Mode
Bucket ● The required operation time
from the end of dumping height Unloading second 1.6 ± 0.3 Max. 2.3
to the end of digging height
● As for detail about
5
measurement posture, see
"Work equipment 4" in Page
5-10

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Standard Values of Components SY215CCM3K Hydraulic Excavator

Applicable model SY215CCM3K

Standard values Judgment
Category Item Measurement conditions Unit
for new machine Standard
● Hydraulic oil temperature: within the
operating range
● The engine runs at a low idle speed
● Working mode: S Mode
● The required time of operating the
Boom joystick to make bucket touch the second Max. 1.0 Max. 1.2
ground, then pushing upward the
machine within 50mm away from the
ground
● As for measurement posture, see
"Work equipment 5" in Page 5-10
● Hydraulic oil temperature: within the
operating range
● The engine runs at a low idle speed
● Working mode: S Mode
●
Delay

Measure the average operation time

Arm second Max. 2.0 Max. 2.8
Work equipment

for inclining the control lever forward

and backward until the arm slightly
moves and reverses
● As for detail about measurement
posture, see "Work equipment 6" in
Page 5-11
● Hydraulic oil temperature: within the
operating range
● The engine runs at a low idle speed
● Working mode: S Mode
● Measure the average operation time
Bucket for inclining the control lever forward second Max. 1.0 Max. 3.6
and backward until the arm slightly
moves and reverses
● As for detail about measurement
posture, see "Work equipment 7" in
Page 5-11
Oil ● Hydraulic oil temperature: within the
5 20
cylinder operating range
leakage
Internal

Central ● The engine runs at a high idle speed ml/min

swivel ● Leakage of cylinder measured within 10 50
joint 1 min during overflow or traveling
● Hydraulic oil temperature: within the
operating range
Combined operation

The deviation ● The engine runs at a high idle speed

●
performance

value when Working mode: S Mode

operating work ● Traveling speed: low
equipment and ● Travel about 10 m in the flat and mm Max. 200 Max. 220
traveling are hard ground, measure the deviation
done at the value of further 20 m traveling
same time
● As for detail about measurement
posture, see "Traveling 2 and 3" in
Page 5-9

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SY215CCM3K Hydraulic Excavator Standard Values of Components
Applicable to all models (the machine posture for performance measurement)

Control valve: slide valve travel Traveling 1: traveling speed (under no load)

Fig. 5-1 Fig. 5-2

Swing 1: angle of swing brake, swing start time, Traveling 2: traveling speed (actual), traveling
swing time deviation

Fig. 5-3 Fig. 5-4 5

Swing 2: hydraulic drift during swing Traveling 3: traveling deviation

Sprocket

Fig. 5-5 Fig. 5-6

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Standard Values of Components SY215CCM3K Hydraulic Excavator

Traveling 4: hydraulic drift during traveling Work equipment 3: arm speed

Fig. 5-7 Fig. 5-8

Work equipment 1: hydraulic drift of work Work equipment 4: bucket speed

equipment

Fig. 5-10
Fig. 5-9

Work equipment 2: boom speed Work equipment 5: boom delay

Fig. 5-11 Fig. 5-12

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SY215CCM3K Hydraulic Excavator Standard Values of Components

Work equipment 6: arm delay

Fig. 5-13

Work equipment 7: bucket delay

Fig. 5-14
5

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Standard Values of Components SY215CCM3K Hydraulic Excavator

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SY215CCM3K Hydraulic Excavator Test and Adjustment

Test and adjustment

Contents
Exhaust smoke measurement................................................................................................................. 6-2
Valve clearance adjustment .................................................................................................................... 6-3
Compression pressure measurement ..................................................................................................... 6-5
Oil pressure measurement ...................................................................................................................... 6-7
Inspection and adjustment of A/C compressor belt tensioner ................................................................ 6-9
Measurement of swing bearing clearance ............................................................................................ 6-10
Inspection and adjustment of track tensioner ....................................................................................... 6-11
Inspection and adjustment of hydraulic oil in the work equipment, swing and travel hydraulic lines ... 6-12
Inspection and adjustment of oil pressure in control oil line ................................................................. 6-15
Measuring the output pressure of solenoid valve ................................................................................. 6-16
Measuring the output pressure of pilot valve ........................................................................................ 6-17
Adjustment of work equipment and swing pilot valve ........................................................................... 6-18
Inspection of the drift of hydraulic cylinder for work equipment ............................................................ 6-19
Release of residual pressure from hydraulic lines ................................................................................ 6-21
Leakage measurement.......................................................................................................................... 6-22
Bleeding air from each system .............................................................................................................. 6-25
Check items list ..................................................................................................................................... 6-27
Adjustment service ................................................................................................................................ 6-28 6

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Test and Adjustment SY215CCM3K Hydraulic Excavator

Exhaust smoke measurement 2. Measurement with a opacity smokemeter

★ Measurement tools for exhaust smoke 1) Mount the opacity smokemeter on the
exhaust pipe, and clamp it at the outlet.
Mark Model Part name
Filter type
1 YDJ-2006
smokemeter
2 SV-2TY Opacity smokemeter

When installing or removing the measuring tool,

avoid touching any hot part.
1. Measurement with a filter type smokemeter
1) Install a filter paper into the smokemeter.
2) Insert the inlet pipe of the smokemeter
into the exhaust pipe.
3) Start the engine and run it continuously till Fig. 6-16
the engine coolant temperature is within
the operating range. 2) Switch on and warm up the opacity
smokemeter for about 15 min.
4) When the engine accelerates suddenly or
is at high idling, operate the smokemeter 3) Start the engine and run it continuously
to allow the exhaust flow to pass through until the engine coolant temperature is
the filter paper. within the operating range.
5) Remove the filter, and obtain the
measuring value by using a support
apparatus.
6) Remove the measuring tool from the
machine after measurement, and ensure
that the machine is back to normal.

Fig. 6-17
4) When the engine accelerates suddenly or
is at high idle speed, use the opacity
smokemeter to measure the smoke.
5) Remove the measuring tool from the
machine after measurement, and ensure
Fig. 6-15 that the machine is back to normal.

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SY215CCM3K Hydraulic Excavator Test and Adjustment

Valve clearance adjustment

★ Repair standard (in mm)
Calibration
Position Item Standard value Limit value:
method
Intake valve clearance (when the engine
— 0.4 — Adjustment
is cold)
Exhaust valve clearance (when the engine
0.5 — Adjustment
is cold)

★ Special tool
Symbol Tool name and shape Part No. Purpose
Slotted screwdriver

Adjustment of valve clearance (for use in

MH060008
vehicles)

The valve clearance shall be checked and

adjusted in the cold state as follows:
Inspection
1. Remove the rocker cover.
2. Turn the No. 1 or No. 4 piston to the TDC of
the compression stroke as follows.
Pointer
● Turn the engine until the ―1 4‖ mark on the
flywheel is aligned with the pointer on the
flywheel housing inspection window.
● Turn the No. 1 or No. 4 piston to the TDC
of the compression stroke.
Note:
Bring the No. 1 or No. 4 cylinder piston to the end 6
position of the compression stroke. When the
rockers on both the intake and exhaust sides can
be pressed by the valve clearance with a hand, it
can be judged that the cylinder piston has reached
the end position of the compression stroke. Rotate
the engine by one turn to switch the end position of
the compression stroke of No. 1 and No. 4 cylinder Fig. 6-18
pistons.

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Test and Adjustment SY215CCM3K Hydraulic Excavator

3. When the No. 1 piston is at the TDC, adjust 2. After adjustment, stop the adjustment screw
the valve clearance in the order of marks (○) with a screwdriver and tighten the lock nut for
listed in the table below. fixing.
Cylinder
No.
1 2 3 4 Lock nut: 20.6 N·m {2.1 kgf·m}
Inta
Ex
Int
Ex
Int
Ex
Inta
Ex 3. Proceed to the next step until all valve
ke ake ake ke
valv
ha
val
ha
val
ha
val
ha clearances marked with (○) are adjusted.
ust ust ust ust
e ve ve ve 4. Check the valve clearance again with the
No. 1
piston at ○ ○ ○ - - ○ - - thickness gauge, and adjust again if it
TDC deviates from the standard value.
No. 4
piston at - - - ○ ○ - ○ ○
TDC
1) When a thickness gauge is used for
measuring, some resistance shall be felt when
moving the gauge in the clearance.
2) If the thickness gauge can move easily in the
clearance, accurate measurement values
cannot be obtained.
Valve clearance

Thickness gauge

Fig. 6-19
4. If the measured values are outside the
specified range, adjust it as follows.
Adjustment
1. When adjusting the valve clearance, loosen
the lock nut first and then rotate the adjusting
screw till the thickness gauge for the standard
clearance can be pulled out with slight
resistance.
Adjusting screw
Thickness gauge

Tighten the lock nut

Valve clearance

Fig. 6-20

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SY215CCM3K Hydraulic Excavator Test and Adjustment

Compression pressure measurement

★ Repair standard
Calibration
Position Item Standard value Limit value:
method
All cylinders (at 200
2550kPa {26kgf/cm2} 1960 kPa {20kgf/cm2} Inspection
Compression rpm)
—
pressure Pressure difference 2
— 390 kPa {below 4 kgf/cm } Inspection
between cylinders

★ Special tool
Symbol Tool name and shape Part No. Purpose

Compression
pressure gauge
connector
Measure the compression
A:M14×1.5 MH063853
pressure
B：58
C：φ7.2

1. The reduction in compression pressure can be

used as a guide for determining engine
overhaul intervals.

2. You should regularly check and pay attention

to the changes in compression pressure, and Cotton rag Injector mounting hole
understand that these changes are helpful for
fault diagnosis. In addition, when it is in a new
vehicle or when some parts are renewed,
because the piston ring, valve seat, etc. are in
the running-in state, the pressure will increase
and will become normal due to the wear of the
parts in the future.
3. Before checking, first check that the engine
oil, starter motor and battery are in a normal
6
state.
4. The vehicle is set as follows.
1) Warm up the engine until the engine
Fig. 6-21
coolant temperature reaches 75~85°C.
2) Turn off all lights and auxiliary equipment.
3) Turn the throttle knob to the low speed
position.
5. Remove all injectors.
6. Cover the injector mounting hole with a rag,
etc.
7. After starting the starter motor and cranking
the engine, check for foreign matters on the
rag.

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Test and Adjustment SY215CCM3K Hydraulic Excavator

8. Depending on the attachments (engine oil, CAUTION

coolant) on the rag, you can determine the
When there are engine oil and coolant on the
following causes.
rag, if you crank the engine, the engine oil
1) When there is engine oil on the rag, and coolant may be sprayed out of the
consider poor seal caused by the piston injector mounting hole under high
ring and check the piston ring. temperature, which is very dangerous. When
the engine is running, never touch or look at
2) When there are engine oil and coolant on
the injector mounting hole.
the rag, consider cracks in the cylinder
part and replace the crankcase.
9. Install the gasket and compression pressure
gauge connector to the injector mounting hole,
fix them with the top cap of the fuel injector Fuel injector
nozzle, and install the compression pressure nozzle gasket

gauge. Injector mounting

hole
10. Crank the engine, measure the compression
pressure in all cylinders, and then calculate
the pressure difference between the cylinders.
11. When the compression pressure and the
pressure difference between the cylinders
deviate from the limit values, inject a small
amount of engine oil from the injector
mounting hole, and then measure the
compression pressure. Fig. 6-22

● If the compression pressure increases,

the piston ring or the inner surface of the
cylinder may be worn or damaged.
● If the compression pressure does not
increase, the valve may be stuck or
seated poorly, or the cylinder head gasket
may not be installed properly.

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SY215CCM3K Hydraulic Excavator Test and Adjustment

Oil pressure measurement

★ Repair standard
Position Item Standard value Limit value:
Oil pressure (oil
— At min. idle speed 195 KPa 98 KPa
temperature at
— At max. idle speed 295 KPa~490 KPa 195 KPa
70~90℃)

★ Tightening torque (unit: N·m)

Symbol Tightened part Tightening torque Remarks
Sealant and engine in cold
— Oil pressure switch 7.8~12
state

★ Lubricant/sealant
Symbol Application Part No. Qty.
— Threads of oil pressure switch A420300000032 As needed

1. Remove the engine oil pressure switch.

Fig. 6-23

2. Install the transition fitting to the mounting

position of the oil pressure switch, and then
install the oil pressure gauge onto the 6
transition fitting.

Transition ring

Fig. 6-24

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Test and Adjustment SY215CCM3K Hydraulic Excavator

3. Warm up the engine until the oil temperature CAUTION

reaches 70~90°C.
Always install the oil pressure switch while
4 Measure the oil pressure at the min. idle the engine is cold.
speed and the max. idle speed respectively.
5. If the measured value is below the specified
standard value, check the lubrication system
thoroughly.
6. After the measurement, apply the sealant onto
the threads of the oil pressure switch and then
tighten it to the specified torque.

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SY215CCM3K Hydraulic Excavator Test and Adjustment

Inspection and adjustment of A/C compressor belt tensioner

Inspection
Apply a force of about 58.8 N (6 kgf) with your
fingers to the midpoint of the belt between the Compressor
drive pulley and the compressor pulley, and check pulley
the deflection (A), which shall be within 5~8 mm
(0.20in~0.31 in).

Drive pulley

Fig. 6-25
Adjustment
★ If the deflection is not appropriate, follow the
steps below to make an adjustment.
1. Loosen the bolts (1) and (2).
2. Move the compressor (3) and the bracket (4)
together to adjust the belt tension.
3. Position the compressor (3). And then tighten
the bolts (1) and (2).
4. Check the belt tensioner again after
adjustment.
Recommendation
You can also use a tension meter to check the
tension within the compressor belt.
New belt Used belt Fig. 6-26
637±108 N 441±88.2 N
{65±11 kgf} {45±9 kgf}
Note:
● Check whether each pulley is damaged, and 6
check whether the V groove and V belt are
worn. In particular, ensure that the V belt
does not contact the bottom of the V groove.
● If any of the following occurs, please contact
the dealer authorized by SANY in your region
to replace your belt.
● The fan belt is already extended, with
little margin for adjustment.
● Any cutting or crack is found on the belt.
● Abnormal slipping occurs or a squeaking
sound is heard.
● After installing a new belt, be sure to readjust
it after one hour of operation.

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Test and Adjustment SY215CCM3K Hydraulic Excavator

Measurement of swing bearing clearance

★ Measuring tool for swing bearing clearance 4. Make the arm almost perpendicular to the
ground and lower the boom until the front
Symbol Part Number Part Name track shoe tilts.
H 60033930 Dial gauge
★ At this moment, the front of the superstructure
● Measure the clearance of the swing bearing rises and the rear lowers.
mounted on the machine as follows. 5. Read the value indicated by the dial gauge H.

Park the machine on level ground, and lower ★ This value represents the bearing clearance.
the work equipment to the ground. ★ For details of the standard values, see ―Swing
oil line‖ of the section Structure, Function and
Do not put your hand or foot under the carrier. Maintenance Standard.
1. Fix the dial gauge H to the track frame, with
the indicator pointing the lower end surface of
the outer ring.

Fig. 6-29
6. Operate the machine to the condition of step
2, and check if the pointer of the dial gauge is
Fig. 6-27 back to zero.
2. Extend the work equipment to give maximum ★ If not, repeat steps 3-5.
reach, with the bucket tip and the bottom of
the upper structure on the same level.
★ At this moment, the front of the superstructure
lowers and the rear rises.
3. Reset the dial gauge to zero.

Fig. 6-28

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SY215CCM3K Hydraulic Excavator Test and Adjustment

Inspection and adjustment of track tensioner

Inspection
1. Drive the machine forward for a distance
which is equal to the length of the track
contacting the ground, keep the engine
running at low idle speed, and slowly stop the
machine.
2. Place a rod on the track above the idler (1)
and the first carrier roller (2).
★ It is recommended to use an angle bar,
which is resistant to bending. Besides,
L-shaped beam also has similar property.
3. Measure the maximum clearance a between
the upper surface of the track and the bottom
Fig. 6-30
of the rod.
● Standard maximum clearance a: 10～30
mm（0.4～1.2 in）
Adjustment
★ If the track tension is inappropriate, follow the
steps below to make an adjustment.
1. To decrease tension
1) Loosen the valve (1), drain the grease and
tighten the valve.

Do not loosen the valve for more than

one turn. Note that if the valve is too
loose, the high-pressure grease inside will
push the valve out.
2) After adjustment, check the track tension
again according to the method described
above.
2. To increase tension
1) Add grease through the grease fitting (2) with
a grease gun.
Fig. 6-31 6
2) After adjustment, check the track tension
again according to the method described
above.
★ Add grease till the distance (b) between the
idler plate and the track frame end equals 0
mm. If the tension is still low, it indicates that
the pin and bushing are excessively worn. The
pin and bushing are needed to be replaced, or
a piece of track shoe removed.

Fig. 6-32

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Test and Adjustment SY215CCM3K Hydraulic Excavator

Inspection and adjustment of hydraulic oil in the work equipment, swing

and travel hydraulic lines
★ Tools required for inspection and adjustment 2) Install test couplings to the filler line and
of hydraulic oil pressure in the work connect them to the hydraulic pressure tester.
equipment, swing and travel hydraulic lines
★ Use the oil pressure gauge with a capacity of
Symbol Part No. Part name 40 MPa {408 kgf/cm2}.

60038932
Hydraulic pressure 3) Start and run the engine until the hydraulic oil
— tester pressure rises within the operation range.
B210770000084 Test couplings
2. Unloading pressure measurement
★ The hydraulic oil pressure in the work 1） Start the engine.
equipment, swing and travel hydraulic lines
(output pressure of hydraulic pump) could also 2） Measure the hydraulic oil pressure with the
be monitored through the display screen. engine at high idling and all control levers
being placed in the middle.
Measurement
★ Indicate the hydraulic oil pressure when the
1. Preparation
unloading valve works.

Lower the work equipment to the ground and 3. Measurement of work equipment relief
shut down the engine. After the engine stops, pressure
operate the control lever several times to release 1） Start the engine and operate the control lever
the residual pressure in the pipelines; loosen the
related to the measured cylinder to the full
butterfly nut on the breather valve, and press
stroke.
down the release button to release pressure
from the hydraulic tank. 2） Measure the hydraulic oil pressure with the
1) Remove the pressure measuring plug (1) and engine at high idling and the cylinder in relief
(2). pressure.

● Plug (1): for the oil lines of rear hydraulic ★ Indicate the hydraulic oil pressure when the
pump. main relief valve opens.
● Plug (2): for the oil lines of front hydraulic 4. Measurement of swing relief pressure
pump. 1) Start the engine, and extend the work
equipment forward as much as possible with
the bucket supporting against the ground to
limit swing.
2） Measure the hydraulic oil pressure with the
engine at high idling and the swing oil line in
relief pressure.
★ Indicate the hydraulic oil pressure when the
swing motor relief valve opens.
★ The swing motor relief pressure is lower than
the main relief pressure.
5. Measurement of travel relief pressure
1） Start the engine and lock the travel
Fig. 6-33 mechanism.

Place the pin ① between the sprocket and the

track frame to lock the travel mechanism.

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SY215CCM3K Hydraulic Excavator Test and Adjustment

1） Disconnect the pilot hose.

2) Loosen the lock nut (4), and turn the adjusting
bolt (5) to adjust the pressure.
★ To increase pressure, turn the retainer
clockwise. To decrease pressure, turn the
retainer counterclockwise.
★ Each turn of the retainer varies the
pressure by:
About 12.5 MPa {about 128 kgf/cm2}
Tighten the lock nut:
53.5±4.9N·m{5.5±0.5 kgf·m}

Fig. 6-34
2） Measure the hydraulic oil pressure with the
engine at high idling and the travel oil line in
relief pressure.
★ The hydraulic oil pressure is displayed
when the main relief valve opens. The
relief pressure in the travel oil line is
always the high relief pressure.
Adjustment
★ The boom relief valve shall not be adjusted
1. Adjustment of main relief pressure (high Fig. 6-36
pressure setting) 3） Recheck the pressure after adjustment with
★ When the high relief pressure in the work the same procedures used for measurement.
equipment and travel oil lines is ★ Before measuring pressure, connect the
abnormal, follow the procedures below to
pilot hose first.
adjust the high relief pressure setting of
the main relief valve (3). ★ If the high pressure setting is adjusted,
the low pressure setting shall also be
adjusted.
2. Adjustment of swing relief pressure
★ If the swing relief pressure measured is 6
abnormal, adjust the swing motor relief
valve (6) according to the procedures
below.

Fig. 6-35

Fig. 6-37

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Test and Adjustment SY215CCM3K Hydraulic Excavator

1) Loosen the lock nut (7), and turn the adjusting

screw (8) to adjust the pressure.
★ To increase pressure, turn the retainer
clockwise.
To decrease pressure, turn the retainer
counterclockwise.
★ Each turn of the adjusting screw varies
the pressure by:
About 6.71 MPa {about 68.4 kgf/cm2}
Tighten the lock nut:
78-103N·m{8.0-10.5 kgf·m}

Fig. 6-38
2） Recheck the pressure after adjustment with
the same procedures used for measurement.

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SY215CCM3K Hydraulic Excavator Test and Adjustment

Inspection and adjustment of oil pressure in control oil line

★ Tools required for inspection and adjustment Adjustment
of oil pressure in control oil line 1. If the pressure measured is lower than 3.5
Symbol Part No. Part name MPa {36 kgf/cm2}, loosen the lock nut (2),
screw in the adjusting stud (3) till the pressure
Hydraulic pressure
21008760
tester
indicated by the pressure gauge is within the
—
specified range, and then tighten the lock nut
B210770000084 Test couplings (2).
Measurement

Lower the work equipment to the ground and

shut down the engine. After the engine stops,
operate the control lever several times to release
the residual pressure in the pipelines; loosen the
butterfly nut on the breather valve, and press
down the release button to release pressure
from the hydraulic tank.
1. Remove the pressure measuring plug (1).

Fig. 6-40
2. Remove all measuring tools from the machine
after measurement, and ensure that the
machine is back to normal.

6
Fig. 6-39
2. Install a test coupling and connect it to the
hydraulic pressure tester.
★ Use the oil pressure gauge with a
capacity of 6 MPa {61 kgf/cm²}.
3. Start the engine and allow it to run until the
temperature of hydraulic oil rises within the
operation range.
4. Measure the oil pressure with the engine at
high idling and all control levers in neutral
position.

Service Manual.12-2017 6-15

Test and Adjustment SY215CCM3K Hydraulic Excavator

Measuring the output pressure of solenoid valve

★ Measuring tool for output pressure of solenoid 3. Install a test coupling to the tee, and connect
valve the coupling to the hydraulic pressure tester.

Symbol Part No. Part name ★ Use the hydraulic pressure tester with a
Hydraulic pressure
capacity of 6 MPa {61 kgf/cm2}.
21008760
— tester 4. Start and run the engine until the temperature
B210770000084 Test couplings of hydraulic oil rises within the operation
range.
★ Before measuring the output pressure of the
solenoid valve, make sure the initial pressure 5. Run the engine at full throttle, operate the
of the control oil line is normal. control levers to open or close each solenoid
vale, and measure the pressure.
Lower the work equipment to the ground and ★ The function of each solenoid valve can
shut down the engine. After the engine stops, be monitored by the monitor panel.
operate the control lever several times to release (Special function of the machine monitor).
the residual pressure in the pipelines; loosen the
butterfly nut on the breather valve, and press ★ If each output pressure measured
down the release button to release pressure complies with the corresponding value
from the hydraulic tank. listed below, it is deemed as normal.
1. Disconnect the hose from the solenoid valve Table 1: High travel speed
and measure the pressure at the outlet.
Solenoid valve Output pressure
No. Solenoid valves to be measured OFF
0{0}
1 High/low travel speed switching solenoid valve (demagnetization)

2 Swing priority solenoid valve ON (excitation) 3.9~4.1MPa{39~41kgf/cm2}

3 Neutral shut-off valve 2 Table 2: Swing priority

4 Neutral shut-off valve 1
Solenoid valve Output pressure
5 Secondary pressurization
OFF
6 Pilot lockout solenoid valve 0{0}
(demagnetization)
7 Arm 2 digging ON (excitation) 3.0~3.9MPa{30~39kgf/cm2}
8 Arm 2 unloading
6. Remove all measuring tools from the machine
after measurement, and ensure that the
machine is back to normal.
Status and Function Table - Pilot lockout
solenoid valve
Functional status Function

Safety lock control Locked OFF

lever Released ON

Fig. 6-41
2. Install a tee at position A of the solenoid valve,
and connect the hose.

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SY215CCM3K Hydraulic Excavator Test and Adjustment

Measuring the output pressure of pilot valve

★ Measuring tool for output pressure of pilot valve 2. Install a test coupling and connect it to the
hydraulic pressure tester.
Symbol Part No. Part name
★ Use the oil pressure gauge with a
Hydraulic pressure
21008760 capacity of 6 MPa {61 kgf/cm²}.
— tester
B210770000084 Test couplings 3. Start and run the engine until the
temperature of hydraulic oil rises within the
★ Before measuring the output pressure of the operation range.
pilot valve, make sure the initial pressure of the
control oil line is normal. 4. Measure the pressure with the engine at high
idling and the control lever related to the
1. Remove the pilot oil pressure switch. measured oil line in the neutral position or at
full stroke position.
Oil line to be Oil line to be
No. No.
measured measured ★ If the output pressure measured
1 Boom lowering 7 Arm digging complies with the corresponding value
2 Bucket dumping 8 Arm dumping listed below, it is deemed as normal.
3 Bucket digging 9 Swing Control lever Hydraulic pressure
4 Boom lifting Neutral 0{0}
5 Right traveling Approaches the average
6 Left traveling initial control pressure
Full stroke
(See the Table of Standard
Values)

5. Remove all measuring tools from the

machine after measurement, and ensure that
the machine is back to normal.

Fig. 6-42
6

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Test and Adjustment SY215CCM3K Hydraulic Excavator

Adjustment of work equipment and swing pilot valve

★ If the free play of the work equipment or swing
control lever is too large, follow the
procedures below to make an adjustment.
1. Remove the work equipment and swing pilot
valve assembly.
2. Remove the rubber cover (1).
3. Loosen the lock nut (2), and turn the disc (3)
clockwise till it touches four heads of the
piston (4).
★ Do not move the piston in this case.
4. Fix the disc (3), and tighten the lock nut (2) to
specified torque.
Tighten the lock nut: 98~127 N·m Fig. 6-43
{10~13 kgf·m}
5. Install the rubber cover (1).
6. Install the work equipment and swing pilot
valve assembly.

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SY215CCM3K Hydraulic Excavator Test and Adjustment

Inspection of the drift of hydraulic cylinder for work equipment

★ If the work equipment (hydraulic cylinder) drift
occurs, follow the inspection procedures
below to determine the cause of the fault,
either due to faulty cylinder seal or defective
control valve.
1. Inspection of boom and bucket cylinder
1） Position the machine the same as shown
in the figure on the right, and stop the
engine.
★ Fill the bucket with soil or apply the rated
load on the bucket.

Fig. 6-44
2） Operate the control lever to raise the
boom and then tilt the bucket inward.
● If the lowering speed increases, it
indicates the cylinder oil seal is faulty.
● If the lowering speed is normal, it
indicates the control valve is defective.
★ Operate the control lever with the starting
switch at the ON position.
★ If the pressure in the accumulator
decreases, run the engine for about 10 s
to pressurize the accumulator again.
2. Inspection of arm cylinder
1) Position the machine as shown in the
figure on the right, operate the control
lever to locate the arm cylinder at 100 mm
to the end of the digging stroke, and stop
the engine.
2） Operate the control lever to locate the
arm at the digging position.
● If the lowering speed increases, it 6
indicates the cylinder oil seal is faulty.
● If the lowering speed is normal, it
indicates the control valve is defective.
★ Operate the control lever with the starting Fig. 6-45
switch at the ON position.
★ If the pressure in the accumulator
decreases, run the engine for about 10 s
to pressurize the accumulator again.
(Reference) If the cylinder drift is caused by faulty
seal and when the operations described
above are performed, the lowering speed
would increase due to:

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Test and Adjustment SY215CCM3K Hydraulic Excavator

3） If the work equipment is positioned as the

above (load being applied to the large
chamber), the oil escapes from the large
chamber to the small chamber, and the inside
pressure of the small chamber increases.
4） As the pressure in the small chamber
increases, the inside pressure of the large
chamber needs to rise to achieve equilibrium.
The cycle repeats until a balance is reached at
a certain pressure (according to the leakage
amount).
5） As an equilibrium is achieved, the lowering
speed becomes slow. If the above operation is
performed, the small chamber opens to the
bypass (the large chamber is closed by the
check valve), the oil in the small chamber
flows to the bypass, and the lowering
accelerates.
3. Inspection of pilot valve
When the accumulator is pressurized,
measure the drift of the work equipment
cylinder with the safety lock control lever in the
locked position and the unlocked position
respectively.
★ Operate the control lever with the starting
switch at the ON position.
★ If the pressure in the accumulator
decreases, run the engine for about 10 s
to pressurize the accumulator again.
★ If the drift of the work equipment cylinder
differs when the safety lock control lever
is in the locked position and in the
unlocked position, it indicates the pilot
valve is defective (internal).

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SY215CCM3K Hydraulic Excavator Test and Adjustment

Release of residual pressure from hydraulic lines

Before the pipes between cylinders or between

the hydraulic motor and the control valve are
disconnected, follow the procedures below to
release the residual pressure.
★ Even if there is no residual pressure inside,
the oil lines of the swing motor and the travel
motor will still be affected by the pressure in
the hydraulic tank. Therefore, be sure to open
the breather valve for pressure relief before
performing the following:
1. Stop the engine, loosen the butterfly nut of the
breather valve, and press down the release
button to release the residual pressure in the
oil tank.
2. Turn the ignition switch to ON, and operate
the control levers several times.
★ Be sure to electrify the pilot locking valve,
and operate the control lever when the
starting switch is at the ON position.
★ Operate the control lever 2-3 times, and
release the pressure stored in the
accumulator.
3. Start the engine, allow it to run at low idling to
pressurize the accumulator, and then stop the
engine.
4. Repeat the Step 2 and Step 3 for several
times.

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Test and Adjustment SY215CCM3K Hydraulic Excavator

Leakage measurement
1. Measurement of boom cylinder leakage
1） Start the engine and allow it to run until
the temperature of hydraulic oil rises
within the operation range. Extend the
boom cylinder to the end of its stroke.

Release the residual pressure from the

pipelines. Refer to the previous section
―Release of residual pressure from
hydraulic lines‖.
2) Disconnect the hose (1) from the small
chamber, and install a blind plug to the
hose end.

Do not disconnect the hose from the Fig. 6-46

large chamber.
3) Start the engine, allow it to run at high idle
speed, and apply relief pressure to the
large chamber.
4) Measure the leakage amount within 1 min
after 30 s under such condition.
5） After measurement, ensure that the
machine is back to normal.

2. Measurement of arm cylinder leakage

1） Start the engine and allow it to run until
the temperature of hydraulic oil rises
within the operation range. Extend the
arm cylinder to the end of its stroke.

Release the residual pressure from the

pipelines. Refer to the previous section
―Release of residual pressure from
hydraulic lines‖.
2） Disconnect the hose (2) from the small
chamber, and install a blind plug to the
hose end. Fig. 6-47

Do not disconnect the hose from the

large chamber.
3) Start the engine, allow it to run at high idle
speed, and apply relief pressure to the
large chamber.
4) Measure the leakage amount within 1 min
after 30 s under such condition.
5） After measurement, ensure that the
machine is back to normal.

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SY215CCM3K Hydraulic Excavator Test and Adjustment

3. Measurement of bucket cylinder leakage

1） Start the engine and allow it to run until
the temperature of hydraulic oil rises
within the operation range. Extend the
bucket cylinder to the end of its stroke.

Release the residual pressure from the

pipelines. Refer to the previous section
―Release of residual pressure from
hydraulic lines‖.
2) Disconnect the hose (3) from the small
chamber, and install a blind plug to the
hose end.

Do not disconnect the hose from the

large chamber.
3) Start the engine, allow it to run at high idle
speed, and apply relief pressure to the
large chamber. Fig. 6-48
4) Measure the leakage amount within 1 min
after 30 s under such condition.
5） After measurement, ensure that the
machine is back to normal.

4. Measurement of swing motor leakage

1) Fully extend the work equipment with the
bucket on the ground, slightly lift the
bucket, and stop the engine.
2) Disconnect the drain hoses (4) and (5),
and install a blind plug at each hose end.
3） Start the engine.Allow it to run at high
idling, and apply swing relief pressure to 6
measure the leakage.
★ Measure the leakage amount within 1 min
after 30 s under the condition described in
Step 3).
★ After the first measurement, rotate the
superstructure by 180°, and conduct the
second measurement using the same
method.
4） After measurement, ensure that the
machine is back to normal.
Fig. 6-49

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Test and Adjustment SY215CCM3K Hydraulic Excavator
5. Measurement of travel motor leakage

1） Remove the travel motor cover.

2） Start the engine and lock the travel
mechanism.

Place the pin ① between the sprocket

and the track frame to lock the Travel
mechanism.

Fig. 6-50

3) Disconnect the drain hose (6) from the

travel motor, and install a blind plug at the
hose end.
4) Start the engine, allow it to run at high idle
speed, and apply travel relief pressure to
measure the leakage.

During measurement, incorrect

operation of the control lever may lead
to serious accidents, so ensure all
signals are correct.
★ Measure the leakage amount within 1 min
after 30 s under the condition described in
Step 4).
Fig. 6-51
★ Slightly rotate the motor to switch the
positions of the port plate and the
cylinder, and the positions of the cylinder
and the piston. Repeat the measurement
several times.
5） After measurement, ensure that the machine
is back to normal.

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SY215CCM3K Hydraulic Excavator Test and Adjustment

Bleeding air from each system

Procedures for bleeding air

Item 1 2 3 4 5 6
Bleeding Bleeding
Bleeding Engine Bleeding
Operation air from air from Starting
air from air from
Starting swing travel tasks
pumps cylinders
motor motor
• Changing hydraulic oil
• Cleaning filter
(Note) (Note)
• Return filter element replacement
• Hydraulic pumps repair or replacement
• Removal of suction pipe
• Control valve repair or replacement
• Cylinder replacement
• Removal of cylinder pipeline
• Swing motor replacement
• Removal of pipes from swing motor

• Travel motor replacement

• Removal of pipes from travel motor

Note: Drain the oil from the housing, and bleed air from the swing motor and travel motor.
1. Bleeding air from the hydraulic pump.

1） Loosen the bleed screw (1) and confirm

that oil comes out from the screw.
2） When oil comes out from the bleed screw,
tighten the bleed screw (1).
Bleed screw: 7.8~9.8 N·m{0.8~1.0
kgf·m}
★ Precaution for starting the engine
After performing the above air bleeding 6
operation, start the engine and allow it to
run at low idling for 10min.

Fig. 6-52

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Test and Adjustment SY215CCM3K Hydraulic Excavator
2. Bleeding air from the hydraulic oil cylinders

1） Start the engine and allow it to run at low

idling for 5min.
2) Lift and lower the boom for 4~5 times with
the engine running at low idle speed.
★ Be careful not to apply relief pressure.
Stop the piston rod approximately 100
mm before the end of the stroke.
3) Allow the engine to run at high idling, and
repeat procedure (2).
4) Return the engine to low idling, extend
the piston rod to the end of its stroke, and
apply relief pressure.
5) Repeat the operation (from procedures 2)
to 4)) for the arm cylinder and bucket
cylinder.
★ When replacing a cylinder, it is
recommended to bleed air from the new
cylinder before installing it onto the work
equipment. Especially for the boom
cylinder, once a new boom cylinder
without air bleeding is installed to the
work equipment, the piston rod may not
extend to the stroke end. Therefore, be
sure to bleed air from the cylinder before
installing it to the work equipment.
3. Bleeding air from the swing motor
1） Start the engine and allow it to run at low
idling.
2) Slowly rotate the upper structure to bleed
air from the motor.

4. Bleeding air from the travel motor

1） Start the engine and allow it to run at low
idling.
2) Loosen the bleed screw (2) and confirm
that oil comes out from the screw.
3） When oil comes out from the bleed screw,
tighten the bleed screw (2).
Bleed screw: 27.5～35.3 N·m {2.8～3.6
kgf·m}

Fig. 6-53

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SY215CCM3K Hydraulic Excavator Test and Adjustment

Check items list

Check items Unit Remarks
Selection of controller mode Graph
Selection of high/low speed travel mode Graph
Selection of automatic idle speed Graph
Engine speed r / min
Front pump pressure Kg
Rear pump pressure Kg
Front pump solenoid proportional valve current mA
Rear pump solenoid proportional valve current mA
Boom lifting pilot pressure Kg
Boom drop pilot pressure Kg
Arm digging pilot pressure Kg
Arm unloading pilot pressure Kg
Bucket digging pilot pressure Kg
Bucket unloading pilot pressure Kg
swing pilot pressure Kg
Left traveling pilot pressure Kg
Right traveling pilot pressure Kg
Bucket converging ON / OFF
Solenoid valve
Swing priority ON / OFF
1
High and low traveling speed switching ON / OFF
Throttle knob voltage V
Engine water temperature ℃ Dial display
Hydraulic oil temperature ℃
Fuel level L Dial display
Oil pressure KPa

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Test and Adjustment SY215CCM3K Hydraulic Excavator

Adjustment service
Model Serial Number Hour meter reading
□SY215C10 (ACE) □ h

User name Carried out Inspected

/ /

Technical Specifications
Work equipment Accessory Track shoe width
Boom □ Standard □( ) □ Breaker □600mm
Arm □ Standard □( ) □（ ） □700mm
Bucket □ Standard □( ) □（ ）

Oil and coolant level check

When necessary
□ Radiator coolant □ Hydraulic oil □ Final drive case oil
□ Engine oil □ Swing gearbox oil □（ ）

Highest range of engine

Fuel level range Environmental temperature
coolant temperature
℃
Altitude

m
ZX225-1104002 ZX225-1104003
Operator’s opinion

Visual inspection result

DTC record
Electrical system Mechanical system
h Frequency
Too high engine coolant
Content:
temperature
h Too low oil pressure
Content: Too low oil level
h Overheating of hydraulic oil
Too low coolant level of
Content:
radiator
h Clogging of air filter
Content: Too low charging voltage
Abnormal automatic
h
lubrication system
Content:

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 Engine speed - oil pressure
Engine (SY215CAM3K)
Hydraulic system

Engine speed Oil pressure Lower drain pressure

SY215CCM3K Hydraulic Excavator

Part name Quantity

Vinyl hose (4 m)
Vinyl hose (1m)
Suction cup
joint
Oil filler
Dipper stick

Service Manual.12-2017
① Front pump pressure (600 K) ③ Pilot pump pressure (60 K)
② Rear pump pressure (600 K)
Lower drain hose

joint

Nozzle

Fig. 6-54
Test and Adjustment

6-29
6
Test and Adjustment SY215CCM3K Hydraulic Excavator

Model Serial Number Hour meter reading User name Carried out: Inspection:

1. Engine (SY215CAM3K)
Setting conditions Standard value
Measurement
S/N Working Automatic Operation of work Unit Measured value Judgment
Fuel control knob items New machine Fault diagnosis
mode deceleration equipment
1 Operate the travel Engine speed rpm 2,080-2,220 — OK/NG
lever (the
Full speed
2 machine does not Oil pressure Mpa｛kgf/cm2｝ 0.39-0.64｛4.0-6.5｝ 0.25｛2.6｝ OK/NG
travel)
3 OFF Engine speed rpm 980-1,080 — OK/NG
S All control levers are in
Low speed
4 the neutral position. Oil pressure Mpa｛kgf/cm2｝ Min. 0.15 {Min. 1.5} 0.09｛0.9｝ OK/NG
Arm cylinder (for
5 Engine speed rpm 1,800-2,000 — OK/NG
Full speed unloading) overflows
7 ON Engine speed Engine speed rpm 1,300-1,500 — OK/NG

2 Speed of work equipment (SY215CAM3K) Measurement conditions: hydraulic oil temperature (45-55°C)
Setting conditions Standard value
Measured
S/N Working Measurement items Unit SY195，SY205，SY215 Judgment
Fuel control knob Work equipment state value
mode New model
1 Unloaded, fully extended Boom lifting 3.0-3.8 OK/NG
2 Arm dumping 2.6-3.2
Boom remains horizontal
3 Arm digging 3.2-4.0 OK/NG
Boom and arm remain
6 Bucket digging 2.4-3.4
horizontal
Position 11 S Front second OK/NG
7 Extended fully Swing (5 turns) 21.5-27.5
Back OK/NG
Front OK/NG
Lo 17.5-22.5
Travel for 20 Back OK/NG
8 Forward/backward
m Front OK/NG
Hi 11.5-15.5
Back OK/NG

3 Hydraulic drift of work equipment (SY215CAM3K) Measurement conditions: hydraulic oil temperature (45-55°C)
Serial Setting conditions Standard value
number Measurement items Unit SY195,SY205，SY215 Measured value Judgment
Fuel control knob Working mode Work equipment state
New model Fault diagnosis
Boom and arm remain Hydraulic drift of
1 The engine is shut down horizontal, and bucket bucket teeth tip (15 mm 600 Max. 900 OK/NG
keeps digging min)

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SY215CCM3K Hydraulic Excavator Test and Adjustment

4 Inspection of hydraulic oil line (SY215CAM3K)

① ② ③
Setting conditions 600kgf/cm2 600kgf/cm2 60kgf/cm2

S/N Part to be checked Fuel Remarks

Working Automatic R main
control Operation of work equipment F main pump F pump LS
mode deceleration pump
knob
Pilot pump relief Oil line pressure
1
valve 3.9-4.1 MPa
2 Main relief valve Arm cylinder for unloading overflows
(When increasing 34.5MPa
3
power)
Overflow on
Full speed S OFF Turn swing lock right side
5 Swing relief valve 26.5MPa {270kgf/cm2}
switch to ON Overflow on left
side
Forward right

Main relief valve, Backward right

6 Load the track shoe 34.3MPa {350kgf/cm2}
travel relief valve Forward left
Backward left

6-31
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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

Fault Diagnosis and Troubleshooting

Precautions during fault diagnosis .......................................................................................................... 7-5
Work procedures during fault diagnosis .................................................................................................. 7-6
Inspection before fault diagnosis............................................................................................................. 7-7
Fault diagnosis category and steps......................................................................................................... 7-8
Fault diagnosis category .................................................................................................................. 7-8
Fault diagnosis steps ....................................................................................................................... 7-8
Connector ................................................................................................................................................ 7-9
Connector List .................................................................................................................................. 7-9
SWP connector .............................................................................................................................. 7-13
A/AMP connector ........................................................................................................................... 7-14
DT connector .................................................................................................................................. 7-15
Connector Position Diagram .......................................................................................................... 7-16
Fault diagnosis when the current DTC is displayed.............................................................................. 7-20
Information of the fault diagnosis table .......................................................................................... 7-20
DTC 11 (controller storage fault (FROM))...................................................................................... 7-21
DTC 16 (controller internal temperature abnormal) ....................................................................... 7-22
DTC 17 (sensor 5 V power output abnormal) ................................................................................ 7-23
DTC 18 (abnormal communication between the controller and display) ...................................... 7-24
DTC 20 (front pump output pressure abnormal)............................................................................ 7-25
DTC 21 (rear pump output pressure abnormal) ............................................................................ 7-26
DTC 22 (arm digging pilot pressure abnormal) ............................................................................. 7-27 7
DTC 23 (arm unloading pilot pressure abnormal) ......................................................................... 7-28
DTC 24 (boom lifting pilot pressure abnormal) .............................................................................. 7-29
DTC 25 (boom lowering pilot pressure abnormal) ......................................................................... 7-30
DTC 26 (bucket digging pilot pressure abnormal) ......................................................................... 7-31
DTC 27 (bucket dumping pilot pressure abnormal) ....................................................................... 7-32
DTC 28 (swing pilot pressure abnormal) ....................................................................................... 7-33
DTC 29 (left travel pilot pressure abnormal) .................................................................................. 7-34

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 30 (right travel pilot pressure abnormal) ............................................................................... 7-35
DTC 31 (fuel control knob setting voltage abnormal) .................................................................... 7-36
DTC 37 (hydraulic oil temperature abnormal) ............................................................................... 7-37
DTC 41 (abnormal engine speed) ................................................................................................. 7-38
DTC 50 (front pump proportional solenoid coil current abnormal A) ............................................. 7-39
DTC 50 (front pump proportional solenoid coil current abnormal B) ............................................. 7-40
DTC 51 (rear pump proportional solenoid coil current abnormal A) .............................................. 7-41
DTC 51 (rear pump proportional solenoid coil current abnormal B).............................................. 7-42
DTC 52 (swing priority proportional solenoid coil current abnormal A) ......................................... 7-43
DTC 52 (swing priority proportional solenoid coil current abnormal B) ......................................... 7-44
DTC 53 (bucket connection proportional solenoid coil current abnormal A) ................................. 7-45
DTC 53 (bucket connection proportional solenoid coil current abnormal B) ................................. 7-46
DTC 55 (boom priority 2 proportional solenoid coil current abnormal A) ...................................... 7-47
DTC 55 (boom priority 2 proportional solenoid coil current abnormal B) ...................................... 7-48
DTC 60 (high/low travel speed solenoid valve abnormal) ............................................................. 7-49
Fault diagnosis of electrical system (E category) ................................................................................. 7-50
Information of the fault diagnosis table .......................................................................................... 7-50
E-1 The engine cannot be started.................................................................................................. 7-51
E-2 Irregular fluctuation of engine speed ....................................................................................... 7-53
E-3 The complete vehicle can't be powered off ............................................................................. 7-54
E-4 It runs idly automatically and doesn’t work ............................................................................. 7-56
E-5 Principle and diagnosis of preheating function ....................................................................... 7-57
Warm-up function ........................................................................................................................... 7-57
Engine DTC and troubleshooting list ............................................................................................. 7-58
Check based on DTC ..................................................................................................................... 7-58
DTC list........................................................................................................................................... 7-58
DTC trigger conditions and check items ........................................................................................ 7-59
Maintenance data of multi-purpose tester ..................................................................................... 7-71
Actuator tests performed using multi-purpose tester ..................................................................... 7-73
Inspections performed at ECU connectors .................................................................................... 7-74
ECU connector terminal layout ...................................................................................................... 7-74
Inspection instructions ................................................................................................................... 7-75
E-6 No equipment works................................................................................................................ 7-78
E-7 The boom lifting is slow and powerless................................................................................... 7-79
E-8 The arm movement is slow and powerless ............................................................................. 7-80
E-9 The bucket movement is slow and powerless ........................................................................ 7-81
E-10 The traveling is slow and powerless ..................................................................................... 7-83
E-11 The display is blank ............................................................................................................... 7-84
E-12 The display has no display .................................................................................................... 7-85
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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
E-13 The high/low traveling speed is disabled .............................................................................. 7-86
E-15 The display of fuel level is inaccurate ................................................................................... 7-87
E-16 The wiper doesn’t work ......................................................................................................... 7-88
E-17 The display of arm digging pilot pressure is inaccurate ........................................................ 7-89
E-18 The display of arm unloading pilot pressure is inaccurate .................................................... 7-90
E-19 The display of boom lifting pilot pressure is inaccurate ........................................................ 7-91
E-20 The display of boom drop pilot pressure is inaccurate ......................................................... 7-92
E-21 The display of bucket digging pilot pressure is inaccurate ................................................... 7-93
E-22 The display of bucket unloading pilot pressure is inaccurate ............................................... 7-94
E-23 The display of swing pilot pressure is inaccurate.................................................................. 7-95
E-24 The display of left traveling pilot pressure is inaccurate ....................................................... 7-96
E-25 The display of right traveling pilot pressure is inaccurate ..................................................... 7-97
Fault diagnosis of hydraulic and mechanical system (H fault category)............................................... 7-98
Table of Hydraulic and Mechanical System ................................................................................... 7-98
Information of the fault diagnosis table ........................................................................................ 7-100
H-1 The work equipment moves slowly, or it has low traveling and rotation speed .................... 7-101
H-2 The engine speed significantly drops or engine stalls .......................................................... 7-102
H-3 The work equipment has no movement, and traveling or swing function is disabled .......... 7-102
H-4 The hydraulic pump has unusual noise ................................................................................ 7-103
H-5 It runs idly automatically and doesn’t work ........................................................................... 7-104
H-6 The boom moves slowly ........................................................................................................ 7-105
H-7 The arm moves slowly .......................................................................................................... 7-106
H-8 The bucket moves slowly ...................................................................................................... 7-107
H-9 The single cylinder of the work equipment has no movement ............................................. 7-108
H-10 The cylinder drift of the work equipment is too large .......................................................... 7-109
H-11 The work equipment moves slowly ......................................................................................7-111
H-12 Other work equipment moves when a single oil line has an overflow .................................7-111
H-13 The traveling speed drops obviously during rotation+traveling .......................................... 7-112
H-14 The machine has off-tracking during traveling .................................................................... 7-113
H-15 The machine travels at low speed ...................................................................................... 7-114 7
H-16 The machine is hard to turn or powerless........................................................................... 7-115
H-17 The traveling speed cannot be shifted ................................................................................ 7-116
H-18 It cannot travel (only on one side) ....................................................................................... 7-117

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
H-19 The machine cannot swing ................................................................................................. 7-118
H-20 It has low swing acceleration performance or low swing speed ......................................... 7-119
H-21 The overrun is too large when swing stops ........................................................................ 7-120
H-22 The impact is too large when swing stops .......................................................................... 7-121
H-23 The unusual noise is too loud when swing stops................................................................ 7-121
H-24 The natural drift during swing is too large ........................................................................... 7-122

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
Precautions during fault diagnosis

Park the machine on the horizontal ground, and confirm the function of safety pin, cushion block and parking brake.

During the collaborative operation, signals shall be strictly unified and no irrelevant personnel is allowed to be close
to site.

If the radiator cap is removed when the engine is hot, hot water will be sprayed and cause burning, so maintenance
shall be carried out after the engine is cooled down.

Be careful not to touch any hot parts or hold any rotating parts.

Always dismantle the negative terminal [-] first.

When removing the internal oil pressure, water pressure or air pressure plug or cap, release the internal pressure
first. When installing the measuring equipment, ensure that the connection is correct.
The fault diagnosis is intended to determine the root cause of the fault accurately, repair it quickly and
prevent it from reoccurrence.
During fault diagnosis, it is important to understand the structure and function.
However, in order to effectively diagnose the fault, it is also a shortcut to know the situation from the
operator so as to preliminarily understand the possible cause of the fault.
1. Do not disassemble parts immediately during fault 4. Confirm the fault
diagnosis. If parts are disassembled immediately, it ● Confirm the fault, and determine whether it is a
may cause: true fault, whether there are problems in use and
● The parts that are disassembled are irrelevant to operation, etc.
the fault, or the parts have been disassembled ★ When the machine is operated and the fault
unnecessarily. phenomenon reoccurs, no inspection or
● The fault cause cannot be found out. measurement which will make the problem
This will waste labor, parts, or oil and grease, while more serious shall be carried out.
losing the user or operator’s trust in the product. 5. Fault diagnosis
Therefore, during fault diagnosis, it is necessary to ● According to the inspection and test results of 2-4
check in advance and make fault diagnosis according items, narrow the scope of fault causes, and then
to the specified procedures. determine the fault position according to the fault
2. Issues to be asked from users or operators: diagnosis flow chart.
1) Are there any other unreported problems? ★ The basic procedure of fault diagnosis is as
2) Was there any abnormality before the fault follows:
appeared? 1) Start with the easy problem
3) Did the fault come up suddenly or following some 2) Start with the possible problem
signs? 3) Check other relevant content.
4) Under which circumstance the fault occurs? 6. Method of eliminating root cause of fault
5) Was the machine repaired before the fault ● Even if the troubleshooting is done but the root
occurred? When was the machine repaired?
7
cause is not eliminated, the same fault will occur
6) Did this fault once appear? again.
3. Check other inspection items. Therefore, it is necessary to find out the cause of
1) Check the engine oil level. the fault and eliminate the root cause.
2) Check for oil leakage from pipelines or hydraulic
devices.
3) Check the lever travel.
4) Check the spool travel of the control valve.
5) Other daily maintenance items can be inspected
from the appearance, so only those deemed
necessary can be checked.

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

Work procedures during fault diagnosis

Office Work site

Step 1
Inspection and determination of symptoms
1) When receiving customer’s service demands, first ask the followings:

● Customer name
● Machine model & serial number
● Details about work site, etc.

2) Know the main problem by asking the followings:

● Fault symptom
● Working conditions at the time of the fault Step 8
● Working environment
● History service, maintenance, etc.
Repair on work site The fault occurs!

Step 2
Determine the possible location of the fault
cause
1) Refer to the fault diagnosis section in the maintenance
manual to find out the possible location of the fault cause.
Step 7

● Determine the location of the fault (for the purpose of fault

diagnosis)
● Determine the repair plan

Step 8
1) Before the fault diagnosis, determine the location of simple
Repair in the workshop faults and conduct repair.
● Check items before starting
● Other check items

Mechanical
manual 2) Refer to the fault diagnosis section in the maintenance manual to select the fault diagnosis
process according to the machine symptoms, and then perform inspection and repair.

Maintenance Manual

Step 3
Prepare the fault diagnosis tools
Step 6
Fault recurrence
1) Refer to the table of fault diagnosis tools in the
Maintenance Manual and prepare the necessary tools. ● Start and operate the machine, confirm the symptoms of the machine and determine if
● Tee
the machine is really faulty.
● Hydraulic instrument and others

2) Refer to the parts catalog and prepare the necessary replacement parts.

Step 5
Learn from the operator about the detailed fault symptoms
Step 4
● Was there any abnormality before the fault appeared?
● Does the fault happen suddenly?
Go to the work site ● Was there any repair before the fault appeared?

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
Inspection before fault diagnosis
Judgment
Item Measures
Standard
1. Confirm fuel level and type — Refuel
2. Check the fuel for foreign matters — Clean and drain
Lubricating oil, coolant

3) Check the hydraulic oil level — Refuel

4) Check the hydraulic oil filter screen — Clean and drain
5. Check oil level of upper structure — Refuel
6. Check the engine oil level (oil pan oil level) — Refuel
7. Check the coolant level — Add coolant
8. Check the dust indicator for clogging — Clean or replace
9. Check the hydraulic oil filter element — Replacement
10. Check the level of final drive oil — Refuel
1. Check the looseness and corrosion of battery terminals and wires — Tighten or replace
equipment
Electric

2. Check the looseness and corrosion of alternator terminals and

— Tighten or replace
wires
3. Check the looseness and corrosion of starter motor terminals and
— Tighten or replace
wires
1. Check for abnormal noises and odors — Repair it
Hydrauli
devices

2. Check for oil leakage — Repair it

c

3. Exhaust air inside — Exhaust

1. Check the battery voltage (with engine shut down) 20-30V Replacement
2. Check the battery electrolyte level — Refill or replace it
Electricity and electric equipment

3. Check for discolored, burnt or peeled wires — Replacement

4. Check for falling clamps or hanging wires — Repair it
Remove the
5. Check whether the wire is wet (check connectors or terminals
— connector and
carefully)
blow it dry
6. Check whether the fuse is fused or corroded — Replacement
7. Check the alternator voltage (with the engine running under the After running for
Replacement
condition over half throttle) a few minutes:
27.5~ 29.5V
8. Check the working noise of battery relay (turn the switch between
— Replacement
ON/OFF)

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

Fault diagnosis category and steps

Fault diagnosis category
Mode Content
Carry out troubleshooting when the service code (electrical system) and DTC (mechanical
Code display
system) are displayed.
E fault category Fault diagnosis of electrical system
H fault category Fault diagnosis of hydraulic and mechanical system

Fault diagnosis steps

If machine has some suspected fault phenomena, determine relevant fault diagnosis number and
explain the diagnosis.
You can diagnose and analyze the fault with the following six basic steps, so as to find out the cause of
the fault and formulate corresponding treatment methods:
1. Please refer to relevant technical manual carefully to 4. Operate the machine personally (trial run)
understand relevant system and its working principle, When you confirm that there is no abnormality in item
the structure, functions and technical specifications of 3 above, you can start the equipment with the normal
system parts. operation method to confirm the cause of fault. If the
2. Ask the driver fault cannot be confirmed, the engine shall be stopped
and further details shall be obtained from the driver.
Prior to the inspection, know details of the fault from
relevant personnel (namely the driver). 5. Carry out fault diagnosis
Detailed analysis and confirmation shall be carried out
a) Current operation status of the machine (is the
according to the phenomena of the mechanical
machine operation correct)?
equipment and the information obtained from the
b) When the fault was found out, what kind of display.
operation was the machine doing?
Note:
c) How about the development of the fault. Is the
● It is not allowed to remove harnesses or hydraulic
fault becoming more serious or is it happening
pipes while the engine is running, otherwise, the high
suddenly for the first time?
pressure and high temperature oil and water may
d) What other fault have the machine had before? spray and cause personal injury. The engine shall be
For example: What parts have been repaired or stopped before the harnesses or hydraulic pipes are
replaced? removed.
e) What has been done after this fault? How about ● The displayed DTC doesn’t necessarily indicate a
the performance? machine fault. As the controller temporarily stores
f) Can the fault be repeated? Are there any rules? electric faults, such as drop of battery output voltage
3. Carry out inspection before start or open circuit of switch and sensor. Therefore,
Before starting the fault diagnosis, please check in the ―repeated tests‖ shall be carried out to erase the
running records and operation and maintenance accumulated DTCs from the controller’s memory and
records in the driver’s manual, know if relevant confirm whether the DTC is displayed after ―repeated
personnel has made illegal operation or maintenance, tests‖. This means that the fault can be ―reproduced‖.
and check whether there are incorrect operation and 6. Find out possible reasons
maintenance. Before making a conclusion, recheck for the most
Check whether there is any abnormality in each part probable cause and try to determine the true cause of
of the mechanical equipment; such as oil and water the fault. According to your conclusion, formulate the
insufficiency and leakage, pipeline looseness and appropriate repair plan.
disconnection, abnormal crack and fracture.
In addition, check the electrical system such as
battery voltage, and check whether the power line
connecting terminal post is loose and damaged,
whether the fuse is burnt out, etc. The multimeter shall
be used to confirm whether the fuse is burnt out.

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

Connector
Connector List
Connector No. Model Number of Pins Equipment Name
CN-1#-J1 TYCO 1-1670901-1 14 Power management module
CN-1#-J2 TYCO 2-1670901-1 14 Power management module
CN-1#-J3 TYCO 3-1670901-1 14 Power management module
CN-1-001M 282080-1 2 Radio speaker
CN-1-002M 282080-1 2 Radio speaker
CN-1-003M DT06-2S 2 Ceiling lamp
CN-1-004M DT06-2S 2 Ceiling lamp
CN-1-005 3011-4-21 1 Compartment lamp
CN-101F X01FGY-M/C 1 Fuel level sensor
CN-102M DT06-2S 2 Platform lamp
CN-105F 282080-1 Intermediate connector
CN-110M DT04-8P 8 Intermediate connector
CN-110F DT06-8S 8 Intermediate connector
CN-113F 174 352-2 2 Front pump proportional solenoid valve
CN-113M DT06-12S 12 Intermediate connector
CN-114F 174 352-2 2 Rear pump proportional solenoid valve
CN-115M 6189-6907 3 Front pump pressure sensor
CN-116M 6189-6907 3 Rear pump pressure sensor
CN-117F DT06-12S 12 Intermediate connector
CN-117M DT04-6P 12 Intermediate connector
CN-118F 282080-1 2 Diode
CN-118M DT04-6P 6 Intermediate connector
CN-119F YAZAKI 7329-3023 1 Air filter blocking sensor
CN-1-206M DT04-8P 8 Intermediate connector
CN-120F 6189-6907 3 Right traveling pressure sensor
CN-121F 6189-6907 3 Left traveling pressure sensor
CN-122F 6189-6907 3 Arm unloading pressure sensor
CN-123F 6189-6907 3 Swing pressure sensor
CN-124F 6189-6907 3 Bucket digging pressure sensor
CN-125F 6189-6907 3 Boom lifting pressure sensor
CN-126F 6189-6907 3 Boom lifting pressure sensor
7
CN-127F 6189-6907 3 Bucket unloading pressure sensor
CN-128F 6189-6907 3 Arm digging pressure sensor

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

Connector No. Model Number of Pins Equipment Name

CN-129F DT06-4S 4 Tail lamp
CN-130F DT06-4S 4 Counterweight tail lamp
CN-132F 174 352-2 2 Standby valve
CN-131F 174 352-2 2 High/low speed traveling solenoid valve
CN-133F 174 352-2 2 Swing priority solenoid valve
CN-134F 174 352-2 2 Bucket converging solenoid valve
CN-135F 174 352-2 2 Boom priority solenoid valve
CN-136F 174 352-2 2 Pilot solenoid valve
CN-141F MU802601 2 Fuel filter element heating
CN-142F MH058966 2 Fuel level alarm
CN-144M 282080-1 2 Hydraulic oil temperature sensor
CN-150F 282080-1 2 Diode
CN-151F 282080-1 2 Diode
CN-153F 282080-1 2 Diode
CN-160F 282080-1 2 Diode
CN-161F 282080-1 2 Diode
CN-162M 7223-6224-40 2 Alternator L/R terminal
CN-187F AMP 1473252 40 KC-MB controller
CN-188F AMP 1473244 81 KC-MB controller
CN-201F Yazaki 7283-1100 10 A/C
CN-202F DJ7072-3-21 7 Radio
CN-203F DT04-12P 12 Intermediate connector
CN-203M DT06-12S 12 Intermediate connector
CN-204F DT04-12P 12 Intermediate connector
CN-204M DT06-12S 12 Intermediate connector
CN-205M 282104-1 2 Pilot switch
CN-206F DT06-8S 8 Intermediate connector
CN-209F DT04-8p 8 Intermediate connector
CN-209M DT06-8S 8 Intermediate connector
CN-210F DT06-3S 3 Intermediate connector
CN-210M DT04-3p 3 Intermediate connector
CN-211M 282080-1 2 Cigar lighter
CN-211F 7123-2228 2 Wiper motor
CN-212M 282080-1 2 Diode
CN-213M 282080-1 2 Diode

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

Connector No. Model Number of Pins Equipment Name

CN-232F Sumitomo 6098-0514 4 A/C
CN-233F Sumitomo 6189-0094 2 Refrigerant switch
CN-234F 7283-7028-30 090 2 Outside air sensor
CN-301M Yazaki 7123-7464-30 6 Ignition key switch
CN-302F SAIL-M12G-5-0.5U 1 Camera
CN-302M 282105-1 3 Knob switch
CN-303M H8JA713631 8 Fault elimination switch
CN-305M H8JA713631 8 Fault display switch
CN-308M 282080-1 2 Horn
CN-501F BOSCH 58P 58 ECU
CN-502F BOSCH 96P 96 ECU
CN-504M 7323-7564-40 16 EDU
CN-511 DT06-3S 3 Terminal resistor
CN-511F DT06-3S 3 Terminal resistor
CN-512M 7323-1558 5 ECU power supply relay
CN-513M 7323-1558 5 Starter relay
CN-514M 7323-1558 5 Preheating relay
CN-701F 926500Q/SY1149 34 Display screen
CN-702M 282080-1 2 Display reset
CN-703 Yazaki 7283-7623 2 Sunlight sensor
CN-704 DT06-3S 3 Terminal resistor
CN-706M DT06-4S 4 Operation panel
CN-ECU AMP-172498-1 13 Wiper controller
CN-MOTO 174262-2 6 Wiper motor
F-103 735075 1 Horn
F-104 735075 1 Horn
F-164 PB625-01021 1 Oil bypass alarm
F-165 PB625-01021 1 Oil pressure switch
F-314 735075-0 1 Indicator
F-315 735075-0 1 Indicator
F-316 735075-0 1 Indicator
F-317 735075-0 1 Indicator 7
F-318 735075-0 1 Indicator
F-319 735075-0 1 Indicator
T-101 Y4-2.5 1 Battery relay

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

Connector No. Model Number of Pins Equipment Name

T102 Y10-10 1 GND
T-102 Y4-2.5 1 Battery relay
T-103 Y10-8 1 Battery relay
T-104 Y10-8 1 Battery relay
T-105 Y10-10 1 GND
T-106 Y10-10 1 GND
T-107 Y10-10 1 GND
T-112 1300-4393 1 A/C compressor clutch
T-115 Y10-12 1 GND
T-161 Y10-10 1 Generator B terminal
T-163 Y10-6 1 E terminal of alternator
T-201 Y10-6 1 GND
T-203 UT1-3 1 Access lamp
T-204 UT1-3 1 Access lamp

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

SWP connector
Convex (plug) Concave (socket)

(number of pins is 1)

(number of pins is 2)

(number of pins is 6)

(number of pins is 8)
7

(number of pins is 16)

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
A/AMP connector
Convex (plug) Concave (socket)

Part No.: 282104-1 Part No.: 282080-1 (number of pins is 2)

(number of pins is 3)

(number of pins is 2)

(number of pins is 40)

(number of pins is 81)

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DT connector
Housing (plug) Housing (socket)

(number of pins is 3)

(number of pins is 6)

(number of pins is 8)

(number of pins is 12)

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
Connector Position Diagram

Fig. 7-58

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

Fig. 7-59

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

Fig. 7-60

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

Fig. 7-61

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
Fault diagnosis when the current DTC is displayed
Information of the fault diagnosis table
Displayed code Service code
It is displayed on the display Fault Name of the fault in the fault history record
——
panel
Alarm triggering conditions Existing fault in the fault history record
When a fault is detected, the controller has taken a series of actions to protect the affected
Controller response
system or equipment
Phenomenon of the The phenomenon of the machine caused by the protective measures taken by the
machine controller

Standard value under normal conditions and fault diagnosis

Reason
reference value
1 <Content included>
2 • Standard values under normal conditions, which can be
used to determine if the assumption is true.
Predicted
cause 3 • Reference value, which can be used to pass the above
and the judgment.
standard Hypothetical cause of fault to be <Wire harness fault>
4 discussed
value • Open circuit
under (Serial numbers are only for the
Poor contact with connector or open circuit of wire harness.
normal convenience of writing, instead of
conditions representing the priority) • Ground wire fault
A wire that shall not be connected to a ground wire circuit is in
5 contact with this circuit.
• Short circuit
A wire that shall not be connected to a 24 V circuit is in contact
with this circuit.

Relevant circuit diagram

This is part of the circuit diagram. It mainly shows the defective part
● Connector number: It indicates the connector
● Arrow: It indicates the approximate installation position of the machine

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

DTC 11 (controller storage fault (FROM))

Service
Displayed code
code Fault The controller memory has fault, and the system movement is slow
11 E111
When it is powered on, abnormality is discovered by verifying with the sum of FROM and
Alarm triggering conditions
verifying and detecting with RAM verify
Controller response Stop the motor and electromagnetic coil drive
Phenomenon of the
The engine cannot be accelerated, and the machine movement is very slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
1 Internal
The fault diagnosis cannot be carried out because it is an internal fault. (If this fault
fault of
occurs, the controller shall be deemed to be defective and shall be replaced)
controller
Predicted
cause 2
and the
standard
value 3
under
normal
conditions 4

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

DTC 16 (controller internal temperature abnormal)

Displayed code Service code The engine internal temperature is abnormal, it cannot be
Fault
16 E116 accelerated, and the movement is slow

Alarm triggering When it is powered on, the controller internal temperature is higher than 80℃ or keeps at
conditions -30℃ for consecutive 10 s.
Controller response Stop the motor and electromagnetic coil drive
Phenomenon of the
The engine cannot be accelerated, and the machine movement is very slow
machine

Predicted Reason Standard value under normal conditions and fault diagnosis reference value
cause
and the
standard
value Internal fault of The fault diagnosis cannot be carried out because it is an internal fault. (If this fault
1
under controller occurs, the controller shall be deemed to be defective and shall be replaced)
normal
conditions

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

DTC 17 (sensor 5 V power output abnormal)

Displayed code Service code
Fault Sensor power output abnormality
17 E017
Alarm triggering When it is powered on, the controller detects that the sensor power output is overcurrent or
conditions short circuited
Controller response There is only alarm output
Phenomenon of the
——
machine

Reason Standard value under normal conditions and fault diagnosis reference value
Predicted
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
Harness OFF position for fault diagnosis.
and the
1 short circuit
standard Measure the part between 56, 75 and 74 pins of the Resistance
(grounding) Above 2 MΩ
value KC-MB and ground value
under
normal Internal
The fault diagnosis cannot be carried out because it is an internal fault. (If the above cause
conditions 2 fault of
is eliminated, the controller shall be deemed to be defective and shall be replaced)
controller

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

DTC 18 (abnormal communication between the controller and display)

Displayed code Service code Abnormal communication terminal between the controller and
Fault
18 E118 display

Alarm triggering When it is powered on, the display responds to communication and stops after consecutive 5
conditions times
Controller response There is only alarm output
Phenomenon of the
——
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the OFF
CAN position for fault diagnosis.
1 resistance
fault Resistance
Predicted Between ① and ② of CN-7-709 60 Ω
value
cause
and the ★Turn the engine starting switch to the OFF position for preparation, and keep it in the OFF
standard position for fault diagnosis.
value Harness Remove the controller connector, and measure the part
under 2 open Below 1 Ω
normal between the 60 pin and ③ of CN-7-705 Resistance
circuit
conditions Remove the controller connector, and measure the part value
Below 1 Ω
between the 78 pin and ④ of CN-7-705
Internal
The fault diagnosis cannot be carried out because it is an internal fault. (If the above cause
3 fault of
is eliminated, the controller shall be deemed to be defective and shall be replaced)
controller

120 Ω resistor

Controller

Displa
y
screen

Power Power

Cab Body harness

Fig. 7-62

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DTC 20 (front pump output pressure abnormal)
Displayed code Service code The front pump pressure display is abnormal, and there is only
Fault
20 E320 alarm output

Alarm triggering When it is powered on, the voltage beyond the pressure feedback voltage of 0.25~4.75 V lasts
conditions over 200 msec.
Controller response There is only alarm output
Phenomenon of the
——
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1
supply fault Voltage
Between A and B of CN-115M About 5V
value

Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause OFF position for fault diagnosis.
Signal wire
and the 2
open circuit Between C of CN-115M and controller 72 pin Resistance Below 1 Ω
standard
Between B of CN-115M and ground value Below 1 Ω
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal wire OFF position for fault diagnosis.
conditions 3 short circuit
(grounding) Resistance
Between C of CN-115M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between C of CN-115M and ground 0.5±0.2V
value

Controller Front pump pressure sensor

Front pump pressure Signal

signal acquisition port

Ground wire Ground wire

5V power supply

Body harness
7

Fig. 7-63

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 21 (rear pump output pressure abnormal)
Displayed code Service code The rear pump pressure display is abnormal, and there is only
Fault
21 E321 alarm output

Alarm triggering When it is powered on, the voltage beyond the pressure feedback voltage of 0.25~4.75 V lasts
conditions over 200 msec.
Controller response There is only alarm output
Phenomenon of the
——
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1
supply fault Voltage
Between A and B of CN-116M About 5V
value

Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause OFF position for fault diagnosis.
Signal wire
and the 2
open circuit Between C of CN-116M and controller 53 pin Resistance Below 1 Ω
standard
Between B of CN-116M and ground value Below 1 Ω
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal wire OFF position for fault diagnosis.
conditions 3 short circuit
(grounding) Resistance
Between C of CN-116M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between C of CN-116M and ground 0.5±0.2V
value
Controller
Rear pump pressure sensor

Rear pump pressure Signal

signal acquisition port

Ground wire Ground wire

5V power supply

Body harness

Fig. 7-64

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DTC 22 (arm digging pilot pressure abnormal)
Displayed code Service code The arm digging pilot pressure display is abnormal, and there is
Fault
22 E322 only alarm output

Alarm triggering When it is powered on, the voltage beyond the pressure feedback voltage of 0.25~4.75 V lasts
conditions over 200 msec.
Controller response There is only alarm output
Phenomenon of the
The arm digging is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1
supply fault Voltage
Between A and B of CN-128M About 5V
value

Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause OFF position for fault diagnosis.
Signal wire
and the 2
open circuit Between C of CN-128M and controller 71 pin Resistance Below 1 Ω
standard
Between B of CN-128M and ground value Below 1 Ω
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal wire OFF position for fault diagnosis.
conditions 3 short circuit
(grounding) Resistance
Between C of CN-128M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between C of CN-128M and ground 0.5±0.2V
value

Controller
Arm digging pilot pressure
sensor

Arm digging pilot pressure Signal

Signal acquisition port

Ground wire Ground wire

5V power supply

Body harness

Fig. 7-65

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 23 (arm unloading pilot pressure abnormal)
Displayed code Service code The arm unloading pilot pressure display is abnormal, and there
Fault
23 E323 is only alarm output

Alarm triggering When it is powered on, the voltage beyond the pressure feedback voltage of 0.25~4.75 V lasts
conditions over 200 msec.
Controller response There is only alarm output
Phenomenon of the
The arm unloading is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1
supply fault Voltage
Between A and B of CN-122M About 5V
value

Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause OFF position for fault diagnosis.
Signal wire
and the 2
open circuit Between C of CN-122M and controller 52 pin Resistance Below 1 Ω
standard
Between B of CN-122M and ground value Below 1 Ω
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal wire OFF position for fault diagnosis.
conditions 3 short circuit
(grounding) Resistance
Between C of CN-122M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between C of CN-122M and ground 0.5±0.2V
value

Controller
Arm unloading pilot pressure
sensor

Arm unloading pilot pressure Signal

Signal acquisition port

Ground wire Ground wire

5V power supply

Body harness

Fig. 7-66

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DTC 24 (boom lifting pilot pressure abnormal)
Displayed code Service code The boom lifting pilot pressure display is abnormal, and there is
Fault
24 E324 only alarm output

Alarm triggering When it is powered on, the voltage beyond the pressure feedback voltage of 0.25~4.75 V lasts
conditions over 200 msec.
Controller response There is only alarm output
Phenomenon of the
The boom lifting is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1
supply fault Voltage
Between A and B of CN-126M About 5V
value

Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause OFF position for fault diagnosis.
Signal wire
and the 2
open circuit Between C of CN-126M and controller 70 pin Resistance Below 1 Ω
standard
Between B of CN-126M and ground value Below 1 Ω
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal wire OFF position for fault diagnosis.
conditions 3 short circuit
(grounding) Resistance
Between C of CN-126M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between C of CN-126M and ground 0.5±0.2V
value

Controller
Boom lifting pilot pressure
sensor

Boom lifting pilot pressure Signal

Signal acquisition port

Ground wire Ground wire

5V power supply

Body harness

Fig. 7-67

Service Manual.12-2017 7-29

Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 25 (boom lowering pilot pressure abnormal)
Displayed code Service code The boom drop pilot pressure display is abnormal, and there is
Fault
25 E325 only alarm output

Alarm triggering When it is powered on, the voltage beyond the pressure feedback voltage of 0.25~4.75 V lasts
conditions over 200 msec.
Controller response There is only alarm output
Phenomenon of the
The boom drop is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1
supply fault Voltage
Between A and B of CN-125M About 5V
value

Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause OFF position for fault diagnosis.
Signal wire
and the 2
open circuit Between C of CN-125M and controller 51 pin Resistance Below 1 Ω
standard
Between B of CN-125M and ground value Below 1 Ω
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal wire OFF position for fault diagnosis.
conditions 3 short circuit
(grounding) Resistance
Between C of CN-125M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between C of CN-125M and ground 0.5±0.2V
value

Controller
Boom drop pilot pressure
sensor

Boom drop pilot pressure Signal

Signal acquisition port

Ground wire Ground wire

5V power supply

Body harness

Fig. 7-68

7-30 Service Manual.12-2017

SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DTC 26 (bucket digging pilot pressure abnormal)
Displayed code Service code The bucket digging pilot pressure display is abnormal, and there
Fault
26 E326 is only alarm output

Alarm triggering When it is powered on, the voltage beyond the pressure feedback voltage of 0.25~4.75 V lasts
conditions over 200 msec.
Controller response There is only alarm output
Phenomenon of the
The bucket digging is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1
supply fault Voltage
Between A and B of CN-124M About 5V
value

Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause OFF position for fault diagnosis.
Signal wire
and the 2
open circuit Between C of CN-124M and controller 69 pin Resistance Below 1 Ω
standard
Between B of CN-124M and ground value Below 1 Ω
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal wire OFF position for fault diagnosis.
conditions 3 short circuit
(grounding) Resistance
Between C of CN-124M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between C of CN-124M and ground 0.5±0.2V
value

Controller
Bucket digging pilot pressure
sensor

Bucket digging pilot pressure Signal

Signal acquisition port

Ground wire Ground wire

5V power supply

Body harness
7

Fig. 7-69

Service Manual.12-2017 7-31

Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 27 (bucket dumping pilot pressure abnormal)
Displayed code Service code The bucket unloading pilot pressure display is abnormal, and
Fault
27 E327 there is only alarm output

Alarm triggering When it is powered on, the voltage beyond the pressure feedback voltage of 0.25~4.75 V lasts
conditions over 200 msec.
Controller response There is only alarm output
Phenomenon of the
The bucket unloading is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1
supply fault Voltage
Between A and B of CN-128M About 5V
value

Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause OFF position for fault diagnosis.
Signal wire
and the 2
open circuit Between C of CN-128M and controller 50 pin Resistance Below 1 Ω
standard
Between B of CN-128M and ground value Below 1 Ω
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal wire OFF position for fault diagnosis.
conditions 3 short circuit
(grounding) Resistance
Between C of CN-128M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between C of CN-128M and ground 0.5±0.2V
value

Controller
Bucket unloading pilot
pressure sensor

Bucket unloading pilot Signal

pressure
Signal acquisition port
Ground wire Ground wire

5V power supply

Body harness

Fig. 7-70

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DTC 28 (swing pilot pressure abnormal)
Displayed code Service code The bucket pilot pressure display is abnormal, and there is only
Fault
28 E328 alarm output

Alarm triggering When it is powered on, the voltage beyond the pressure feedback voltage of 0.25~4.75 V lasts
conditions over 200 msec.
Controller response There is only alarm output
Phenomenon of the
The swing is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1
supply fault Voltage
Between A and B of CN-123M About 5V
value

Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause OFF position for fault diagnosis.
Signal wire
and the 2
open circuit Between C of CN-123M and controller 68 pin Resistance Below 1 Ω
standard
Between B of CN-123M and ground value Below 1 Ω
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal wire OFF position for fault diagnosis.
conditions 3 short circuit
(grounding) Resistance
Between C of CN-123M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between C of CN-123M and ground 0.5±0.2V
value

Controller
swing pilot pressure sensor

swing pilot pressure Signal

Signal acquisition port

Ground wire Ground wire

5V power supply

Body harness
7

Fig. 7-71

Service Manual.12-2017 7-33

Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 29 (left travel pilot pressure abnormal)
Displayed code Service code The left traveling pilot pressure display is abnormal, and there is
Fault
29 E329 only alarm output

Alarm triggering When it is powered on, the voltage beyond the pressure feedback voltage of 0.25~4.75 V lasts
conditions over 200 msec.
Controller response There is only alarm output
Phenomenon of the
The left traveling is slow and has off-tracking
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1
supply fault Voltage
Between A and B of CN-120M About 5V
value

Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause OFF position for fault diagnosis.
Signal wire
and the 2
open circuit Between C of CN-120M and controller 49 pin Resistance Below 1 Ω
standard
Between B of CN-120M and ground value Below 1 Ω
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal wire OFF position for fault diagnosis.
conditions 3 short circuit
(grounding) Resistance
Between C of CN-120M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between C of CN-120M and ground 0.5±0.2V
value

Controller
Left traveling pilot pressure
sensor

Left traveling pilot pressure Signal

Signal acquisition port

Ground wire Ground wire

5V power supply

Body harness

Fig. 7-72

7-34 Service Manual.12-2017

SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DTC 30 (right travel pilot pressure abnormal)
Displayed code Service code The right traveling pilot pressure display is abnormal, and there
Fault
30 E330 is only alarm output

Alarm triggering When it is powered on, the voltage beyond the pressure feedback voltage of 0.25~4.75 V lasts
conditions over 200 msec.
Controller response There is only alarm output
Phenomenon of the
The right traveling is slow and has off-tracking
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1
supply fault Voltage
Between A and B of CN-121M About 5V
value

Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause OFF position for fault diagnosis.
Signal wire
and the 2
open circuit Between C of CN-121M and controller 67 pin Resistance Below 1 Ω
standard
Between B of CN-121M and ground value Below 1 Ω
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal wire OFF position for fault diagnosis.
conditions 3 short circuit
(grounding) Resistance
Between C of CN-121M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between C of CN-121M and ground 0.5±0.2V
value

Controller
Right traveling pilot pressure
sensor

Right traveling pilot pressure Signal

Signal acquisition port

Ground wire Ground wire

5V power supply

Body harness

Fig. 7-73

Service Manual.12-2017 7-35

Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 31 (fuel control knob setting voltage abnormal)
Displayed code Service code The throttle knob setting voltage is abnormal, and the engine
Fault
31 E231 returns to automatic idle speed

Alarm triggering When it is powered on, the voltage beyond the throttle knob voltage of 0.25~4.75 V lasts over
conditions 200 msec.
Controller response Control the throttle to the idle speed position
Phenomenon of the
The engine returns to automatic idle speed
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1
supply fault Voltage
Between ① and ③ of CN-302F About 5V
value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
Signal wire OFF position for fault diagnosis.
2
open circuit Resistance
Predicted Between ② of CN-302F and controller 34 pin Below 1 Ω
cause value
and the ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
standard Signal wire OFF position for fault diagnosis.
value 3 short circuit
under (grounding) Resistance
Between ② of CN-302F and ground Above 2 MΩ
normal value
conditions Signal wire ★Turn the engine starting switch to the OFF position for preparation, and it in the ON
short circuit position for fault diagnosis.
4 (contact
with power Voltage
Between ② of CN-302F and ground Below 5V
supply) value

★Turn the engine starting switch to the OFF position for preparation, and keep it in the
OFF position for fault diagnosis.
5 Knob fault
Remove the connector CN-302F, and measure the part Resistance
5K±15% Ω
between ① and ③ of knob value

Yellow

Sensor 5 V Blue Throttle

control knob
Red
Ground wire

Throttle control
voltage setting
voltage

Cab

Fig. 7-74

7-36 Service Manual.12-2017

SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DTC 37 (hydraulic oil temperature abnormal)
Displayed code Service code The hydraulic oil temperature is abnormal, and there is only
Fault
37 E237 alarm output

Alarm triggering The hydraulic oil temperature which is converted to the voltage beyond the voltage of
conditions 0.25~4.75 V and detected by the controller lasts over 200 msec.
Controller response There is only alarm output, and the alarm automatically recovers under normal conditions
Phenomenon of the
——
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
1
fault Voltage
Between ① of CN-113M and ground 0.2～4.75V
value
Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause Wire OFF position for fault diagnosis.
and the 2 harness
open circuit Resistance
standard Between ① of CN-113M and controller 31 Below 1 Ω
value
value
under Wire ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal harness OFF position for fault diagnosis.
conditions 3
short circuit Resistance
(grounding) Between ① of CN-113M and ground Above 1 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
24V power ON position for fault diagnosis.
4
supply fault Voltage
Between ② of CN-113M and ground About 24V
value

Controller

Hydraulic oil
temperature sensor

Hydraulic oil
temperature sensor Signal

24 V power
24 V power supply
supply

Cab Body harness

7

Fig. 7-75

Service Manual.12-2017 7-37

Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 41 (abnormal engine speed)
Displayed code Service code
Fault The engine speed is abnormal, and there is only alarm output
41 E541
Alarm triggering The CPU detects that the engine speed is above the threshold (2600 rpm) for a set time
conditions (above 1 s)
Controller response There is only alarm output, and the alarm automatically recovers under normal conditions
Phenomenon of the
——
machine

Predicted Reason Standard value under normal conditions and fault diagnosis reference value
cause Normal ★ There is no DTC 41 when the machine is powered on or in the process of starting
and the 1
situation up
standard
value
under Abnormal CAN
★ Power off (disconnect the battery terminal) and on the vehicle, and reset the CAN
normal 2 bus
bus
conditions communication

7-38 Service Manual.12-2017

SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

DTC 50 (front pump proportional solenoid coil current abnormal A)

Displayed code Service code The front pump proportional solenoid coil current is abnormal,
Fault
50 E450 and the system movement is slow

Alarm triggering It detects that the load wire of the proportional solenoid coil is abnormal. The current above 1.8
conditions A lasts for 1 s. The deviation current occurs on the drive protection circuit.
When stopping the drive of the solenoid coil at the detected time point, it shall be powered on
Controller response
again.
Phenomenon of the
The system movement is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
OFF position for fault diagnosis.
Wire harness
1
open circuit Between ① of CN-113F and controller 88 pin Resistance Below 1 Ω
Between ② of CN-113F and ground value Below 1
Predicted
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
and the Wire harness OFF position for fault diagnosis.
standard 2 short circuit
value (grounding) Resistance
Between ① of CN-113F and 0# wire Above 1 MΩ
under value
normal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
conditions Proportioning OFF position for fault diagnosis.
3 valve coil
fault Remove the connector CN-113F, and measure the Resistance
17.5 Ω
part between ① and ② of solenoid valve value
The fault diagnosis cannot be carried out because it is an internal fault. (If the above
Controller
4 cause is eliminated, the controller shall be deemed to be defective and shall be
fault
replaced)

Controller
Front pump proportional
solenoid valve

Front pump proportional Signal

solenoid valve signal output
port

Ground wire Ground wire

Body harness

Fig. 7-76

Service Manual.12-2017 7-39

Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 50 (front pump proportional solenoid coil current abnormal B)
Displayed code Service code The front pump proportional solenoid coil current is abnormal,
Fault
50 E450 and the system movement is slow

Alarm triggering It detects that the load wire of the proportional solenoid coil is abnormal. The deviation current
conditions above 0.1 A lasts fr 1 s. The deviation current occurs on the drive protection circuit.
When stopping the drive of the solenoid coil at the detected time point, it shall be powered on
Controller response
again.
Phenomenon of the
The system movement is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
OFF position for fault diagnosis.
Wire harness
1
open circuit Between ① of CN-113F and controller 88 pin Resistance Below 1 Ω
Between ② of CN-113F and ground value Below 1 Ω
Predicted
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
and the Wire harness OFF position for fault diagnosis.
standard 2 short circuit
value (grounding) Resistance
Between ① of CN-113F and 0# wire Above 1 MΩ
under value
normal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
conditions Proportioning OFF position for fault diagnosis.
3 valve coil
fault Remove the connector CN-113F, and measure the Resistance
17.5 Ω
part between ① and ② of solenoid valve value
The fault diagnosis cannot be carried out because it is an internal fault. (If the above
Controller
4 cause is eliminated, the controller shall be deemed to be defective and shall be
fault
replaced)

Controller
Front pump proportional
solenoid valve

Front pump proportional Signal

solenoid valve signal output
port

Ground wire Ground wire

Body harness

Fig. 7-77

7-40 Service Manual.12-2017

SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DTC 51 (rear pump proportional solenoid coil current abnormal A)
Displayed code Service code The rear pump proportional solenoid coil current is abnormal,
Fault
51 E451 and the system movement is slow

Alarm triggering It detects that the load wire of the proportional solenoid coil is abnormal. The current above 1.8
conditions A lasts for 1 s. The deviation current occurs on the drive protection circuit.
When stopping the drive of the solenoid coil at the detected time point, it shall be powered on
Controller response
again.
Phenomenon of the
The system movement is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
OFF position for fault diagnosis.
Wire harness
1
open circuit Between ① of CN-114F and controller 89 pin Resistance Below 1 Ω
Between ② of CN-114F and ground value Below 1 Ω
Predicted
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
and the Wire harness OFF position for fault diagnosis.
standard 2 short circuit
value (grounding) Resistance
Between ① of CN-114F and 0# wire Above 1 MΩ
under value
normal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
conditions Proportioning OFF position for fault diagnosis.
3 valve coil
fault Remove the connector CN-114F, and measure the part Resistance
17.5 Ω
between ① and ② of solenoid valve value
The fault diagnosis cannot be carried out because it is an internal fault. (If the above
Controller
4 cause is eliminated, the controller shall be deemed to be defective and shall be
fault
replaced)

Controller
Rear pump proportional
solenoid valve

Rear pump proportional Signal

solenoid valve signal output
port

Ground wire Ground wire

Body harness

Fig. 7-78

Service Manual.12-2017 7-41

Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 51 (rear pump proportional solenoid coil current abnormal B)
Displayed code Service code The rear pump proportional solenoid coil current is abnormal,
Fault
51 E451 and the system movement is slow

Alarm triggering It detects that the load wire of the proportional solenoid coil is abnormal. The deviation current
conditions above 0.1 A lasts fr 1 s. The deviation current occurs on the drive protection circuit.
When stopping the drive of the solenoid coil at the detected time point, it shall be powered on
Controller response
again.
Phenomenon of the
The system movement is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
OFF position for fault diagnosis.
Wire harness
1
open circuit Between ① of CN-114F and controller 89 pin Resistance Below 1 Ω
Between ② of CN-114F and ground value Below 1 Ω
Predicted
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
and the Wire harness OFF position for fault diagnosis.
standard 2 short circuit
value (grounding) Resistance
Between ① of CN-114F and 0# wire Above 1 MΩ
under value
normal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
conditions Proportioning OFF position for fault diagnosis.
3 valve coil
fault Remove the connector CN-114F, and measure the Resistance
17.5 Ω
part between ① and ② of solenoid valve value
The fault diagnosis cannot be carried out because it is an internal fault. (If the above
Controller
4 cause is eliminated, the controller shall be deemed to be defective and shall be
fault
replaced)

Controller

Rear pump proportional

solenoid valve

Rear pump proportional

solenoid valve signal output Signal
port

Ground wire
Ground wire

Body harness

Fig. 7-79

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DTC 52 (swing priority proportional solenoid coil current abnormal A)
Displayed code Service code
Fault The swing priority proportional solenoid coil current is abnormal
52 E452
Alarm triggering It detects that the load wire of the proportional solenoid coil is abnormal. The current above 1.8
conditions A lasts for 1 s. The deviation current occurs on the drive protection circuit.
When stopping the drive of the solenoid coil at the detected time point, it shall be powered on
Controller response
again.
Phenomenon of the
——
machine

Predicted Reason Standard value under normal conditions and fault diagnosis reference value
cause
and the ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
standard OFF position for fault diagnosis.
Wire harness
value 1
open circuit Between ① of CN-133F and controller 98 pin Resistance Below 1 Ω
under
Between ② of CN-133F and ground value Below 1 Ω
normal
conditions
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
Wire harness OFF position for fault diagnosis.
2 short circuit
(grounding) Resistance
Between ① of CN-133F and 0# wire Above 1 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
Proportioning OFF position for fault diagnosis.
3 valve coil
fault Remove the connector CN-133F, and measure the part Resistance
17.5 Ω
between ① and ② of solenoid valve value
The fault diagnosis cannot be carried out because it is an internal fault. (If the above
Controller
4 cause is eliminated, the controller shall be deemed to be defective and shall be
fault
replaced)
Controller
Swing priority proportional
solenoid valve

Signal output of swing

Signal
priority proportional
solenoid valve

Ground wire
Ground wire

Body harness

Fig. 7-80

Service Manual.12-2017 7-43

Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 52 (swing priority proportional solenoid coil current abnormal B)
Displayed code Service code
Fault The swing priority proportional solenoid coil current is abnormal
52 E452
Alarm triggering It detects that the load wire of the proportional solenoid coil is abnormal. The deviation current
conditions above 0.1 A lasts fr 1 s. The deviation current occurs on the drive protection circuit.
When stopping the drive of the solenoid coil at the detected time point, it shall be powered on
Controller response
again.
Phenomenon of the
——
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
OFF position for fault diagnosis.
Wire harness
1
open circuit Between ① of CN-133F and controller 98 pin Resistance Below 1 Ω
Between ② of CN-133F and ground value Below 1 Ω
Predicted
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
and the Wire harness OFF position for fault diagnosis.
standard 2 short circuit
value (grounding) Resistance
Between ① of CN-133F and 0# wire Above MΩ
under value
normal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
conditions Proportioning OFF position for fault diagnosis.
3 valve coil
fault Remove the connector CN-133F, and measure the part Resistance
17.5 Ω
between ① and ② of solenoid valve value
The fault diagnosis cannot be carried out because it is an internal fault. (If the above
Controller
4 cause is eliminated, the controller shall be deemed to be defective and shall be
fault
replaced)
Controller
Swing priority proportional
solenoid valve

Signal output of swing

Signal
priority proportional
solenoid valve

Ground wire
Ground wire

Body harness

Fig. 7-81

7-44 Service Manual.12-2017

SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DTC 53 (bucket connection proportional solenoid coil current abnormal A)
Displayed code Service code The bucket connection proportional solenoid coil current is
Fault
53 E453 abnormal, and the bucket movement is slow

Alarm triggering It detects that the load wire of the proportional solenoid coil is abnormal. The current above 1.8
conditions A lasts for 1 s. The deviation current occurs on the drive protection circuit.
When stopping the drive of the solenoid coil at the detected time point, it shall be powered on
Controller response
again.
Phenomenon of the
The bucket movement is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
OFF position for fault diagnosis.
Wire harness
1
open circuit Between ① of CN-134F and controller 99 pin Resistance Below 1 Ω
Between ② of CN-134F and ground value Below 1 Ω
Predicted
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
and the Wire harness OFF position for fault diagnosis.
standard 2 short circuit
(GND) Resistance
value Between ① of CN-134F and 0# wire Above 1 MΩ
under value
normal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
conditions Proportioning OFF position for fault diagnosis.
3 valve coil
fault Remove the connector CN-134F, and measure the Resistance
17.5 Ω
part between ① and ② of solenoid valve value
The fault diagnosis cannot be carried out because it is an internal fault. (If the above
Controller
4 cause is eliminated, the controller shall be deemed to be defective and shall be
fault
replaced)
Controller
Bucket connection proportional
solenoid valve

Bucket converging
Signal
proportional solenoid valve
signal output port

Ground wire
Ground wire

Body harness

Fig. 7-82

Service Manual.12-2017 7-45

Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 53 (bucket connection proportional solenoid coil current abnormal B)
Displayed code Service code The bucket connection proportional solenoid coil current is
Fault
53 E453 abnormal, and the bucket movement is slow

Alarm triggering It detects that the load wire of the proportional solenoid coil is abnormal. The deviation current
conditions above 0.1 A lasts fr 1 s. The deviation current occurs on the drive protection circuit.
When stopping the drive of the solenoid coil at the detected time point, it shall be powered on
Controller response
again.
Phenomenon of the
The bucket movement is slow
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
OFF position for fault diagnosis.
Wire harness
1
open circuit Between ① of CN-134F and controller 99 pin Resistance Below 1 Ω
Between ② of CN-134F and ground value Below 1 Ω
Predicted
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
and the Wire harness OFF position for fault diagnosis.
standard 2 short circuit
(grounding) Resistance
value Between ① of CN-134F and 0# wire Above 1 MΩ
under value
normal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
conditions Proportioning OFF position for fault diagnosis.
3 valve coil
fault Remove the connector CN-134F, and measure the Resistance
17.5 Ω
part between ① and ② of solenoid valve value
The fault diagnosis cannot be carried out because it is an internal fault. (If the above
Controller
4 cause is eliminated, the controller shall be deemed to be defective and shall be
fault
replaced)

Controller
Bucket connection proportional
solenoid valve

Bucket converging
Signal
proportional solenoid valve
signal output port

Ground wire
Ground wire

Body harness

Fig. 7-83

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DTC 55 (boom priority 2 proportional solenoid coil current abnormal A)
Displayed code Service code The boom priority 2 proportional solenoid coil current is
Fault
55 E455 abnormal

Alarm triggering It detects that the load wire of the proportional solenoid coil is abnormal. The current above 1.8
conditions A lasts for 1 s. The deviation current occurs on the drive protection circuit.
When stopping the drive of the solenoid coil at the detected time point, it shall be powered on
Controller response
again.
Phenomenon of the
——
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
OFF position for fault diagnosis.
Wire harness
1
open circuit Between ① of CN-135F and controller 101 pin Resistance Below 1 Ω
Between ② of CN-135F and ground value Below 1 Ω
Predicted
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
and the Wire harness OFF position for fault diagnosis.
standard 2 short circuit
(grounding) Resistance
value Between ① of CN-135F and 0# wire Above 1 MΩ
under value
normal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
conditions Proportioning OFF position for fault diagnosis.
3 valve coil
fault Remove the connector CN-135F, and measure the Resistance
17.5 Ω
part between ① and ② of solenoid valve value
The fault diagnosis cannot be carried out because it is an internal fault. (If the above
Controller
4 cause is eliminated, the controller shall be deemed to be defective and shall be
fault
replaced)

Controller
Boom priority 2 proportional
solenoid valve

Signal output of boom

Signal
priority 2 proportional
solenoid valve

Ground wire
Ground wire

Body harness

Fig. 7-84

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
DTC 55 (boom priority 2 proportional solenoid coil current abnormal B)
Displayed code Service code The boom priority 2 proportional solenoid coil current is
Fault
55 E455 abnormal

Alarm triggering It detects that the load wire of the proportional solenoid coil is abnormal. The deviation current
conditions above 0.1 A lasts fr 1 s. The deviation current occurs on the drive protection circuit.
When stopping the drive of the solenoid coil at the detected time point, it shall be powered on
Controller response
again.
Phenomenon of the
——
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
OFF position for fault diagnosis.
Wire harness
1
open circuit Between ① of CN-135F and controller 101 pin Resistance Below 1 Ω
Between ② of CN-135F and ground value Below 1 Ω
Predicted
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
and the Wire harness OFF position for fault diagnosis.
standard 2 short circuit
value (GND) Resistance
Between ① of CN-135F and 0# wire Above 1 MΩ
under value
normal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
conditions Proportioning OFF position for fault diagnosis.
3 valve coil
fault Remove the connector CN-135F, and measure the Resistance
17.5 Ω
part between ① and ② of solenoid valve value
The fault diagnosis cannot be carried out because it is an internal fault. (If the above
Controller
4 cause is eliminated, the controller shall be deemed to be defective and shall be
fault
replaced)
Controller
Boom priority 2 proportional
solenoid valve

Signal output of boom

Signal
priority 2 proportional
solenoid valve

Ground wire
Ground wire

Body harness

Fig. 7-85

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
DTC 60 (high/low travel speed solenoid valve abnormal)
Displayed code Service code The high/low traveling speed solenoid coil connection is
Fault
60 E460 abnormal, and the high traveling speed function is disabled

Alarm triggering
It detects that the proportional solenoid coil is abnormal, open circuited or short circuited.
conditions
Controller response There is only alarm output
Phenomenon of the
The high traveling speed function of the machine is disabled
machine

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
Wire OFF position for fault diagnosis.
1 harness
Between ① of CN-132F and controller 100 pin Resistance Below 1 Ω
open circuit
Predicted Between ② of CN-132F and ground value Below 1 Ω
cause
Wire ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
and the
standard harness OFF position for fault diagnosis.
2 short circuit
value Resistance
under (GND) Between ① of CN-132F and 0# wire Above 1 MΩ
value
normal
conditions ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
Solenoid OFF position for fault diagnosis.
3 valve coil
fault Remove the connector CN-132F, and measure the part Resistance
17.5 Ω
between ① and ② of solenoid valve value
Controller The fault diagnosis cannot be carried out because it is an internal fault. (If the above
4
fault cause is eliminated, the controller shall be deemed to be defective and shall be replaced)

Controller
High/low speed traveling
solenoid valve

Signal output of high/low

Signal
travel speed solenoid valve

Ground wire
Ground wire

Body harness

Fig. 7-86

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 Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
Fault diagnosis of electrical system (E category)
Information of the fault diagnosis table
★ The following information is included in the fault diagnosis table and relevant circuit diagram. Carry
out fault diagnosis only after the content is fully understood.
Fault information Phenomenon of the machine
Relevant information Information and diagnosis of existing fault

Standard value under normal conditions and fault diagnosis

Predicted cause and the standard

Cause
value under normal conditions

reference value
1
2
3 Predicted fault cause <Content>
4 (The serial number is for the • The standard values under normal conditions can be used to
convenience of compilation and determine if the cause is ―good‖ or ―poor‖
reference, but it doesn’t • The reference value can be used to determine if it is ―good‖ or
represent any priority) ―poor‖
5

Relevant circuit diagram

This is part of the circuit diagram. It mainly shows

the defective part
● Connector number: It indicates the connector
● Arrow: It indicates the approximate installation
position of the machine

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

E-1 The engine cannot be started

Fault information The engine cannot be started (the engine doesn’t rotate)
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
Insufficient OFF position for fault diagnosis.
1 battery
capacity Voltage
Battery voltage Higher than 24 V
value

Internal fault ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
of engine OFF position for fault diagnosis.
2
starting Resistance
switch OFF position: Between 22# wire and 11# wire Above 1 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
OFF position for fault diagnosis.
Pilot switch Unlocking position of locking lever: Between 105 #
3
fault Below 1 Ω
wire and 27# wire Resistance
Locking position of locking lever: Between 105 # wire value
Above 1MΩ
and 27# wire
★Turn the engine starting switch to the OFF position for preparation, and keep the
Predicted engine running during fault diagnosis (if all of the power supply, grounding, and the
cause generated signals and engine input are normal and only the output of the engine is
and the abnormal, the engine starter motor will be deemed to have a fault.)
Starter motor
standard 4 Starting
fault Engine starter motor Voltage value
value switch
under
normal Power supply: B terminal and ground 20～30V
conditions Starting
Between input terminal S of starter motor and ground 20～30V
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
position for fault diagnosis.
Wire
5 harness 21# wire and starter motor B terminal Below 1 Ω
open circuit Resistance
12# wire and starting relay SW terminal Below 1 Ω
value
Starting relay L terminal and safety relay S terminal Below 1 Ω
Battery ―+‖ terminal (20# wire) and control knob 22# Resistance
6 Fuse fault Below 1 Ω
wire value
Wire ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
harness OFF position for fault diagnosis.
7 short circuit
(grounding Between starting relay SW terminal and ground Resistance Above 1MΩ
fault) Between engine input terminal S and ground value Above 1MΩ
7

★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Internal fault position for fault diagnosis.
8
of alternator Voltage
Between the alternator P terminal and ground Below 1 V
value

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

Power management
module

Engine

Throttle
Battery Battery relay knob

Adjustment
signal
Main Engine
controller controller

Ignition key switch

Pilot switch
Starting
signal

Power-on
signal

Fig. 7-87

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
E-2 Irregular fluctuation of engine speed
Fault information Irregular fluctuation of engine speed
Relevant information The engine speed can be observed in the display

Reason Standard value under normal conditions and fault diagnosis reference value
Predicted
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the OFF
and the CAN bus position for fault diagnosis.
1
standard fault Measure the resistance between CAN+ Resistance
value 120 Ω
and CAN- value
under
normal Internal
The fault diagnosis cannot be carried out because it is an internal fault. (If the fault is not
conditions 2 fault of
caused by the above cause, the controller shall be deemed to be defective)
controller

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

E-3 The complete vehicle can't be powered off

Fault information The engine cannot be stopped
When turning the engine starting switch to the OFF position, the engine
Relevant information
is stopped and there is no power off delay

Predicted Reason Standard value under normal conditions and fault diagnosis reference value
cause Battery When operating the engine starting switch, if the operation sound is heard from the contact
and the 1
relay fault of the battery relay, the battery can be judged to be normal. Starting switch OFF-ON-OFF.
standard
value ★ Turn the engine starting switch to the OFF position for preparation, and keep it in the
under CAN bus OFF position for fault diagnosis.
2
normal fault Resistance
conditions Measure the resistance between CAN+ and CAN- Above 120 Ω
value

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

Starter relay

Wiper
Power management
Sprinkler module

Engine
Horn

Work light
lamp/tail lamp
Cab ceiling

A/C
controller

Operation
Throttle panel
knob EGR
Battery Battery relay controller
Display
screen
Adjustment signal

Main Engine
controller controller

Ignition key switch

Pilot switch

Starting
signal

Power-on
signal

Fig. 7-88

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
E-4 It runs idly automatically and doesn’t work
Fault information The engine has no automatic idle speed
In case of the automatic idle speed mode, when the handle is not
Relevant information
working in the neutral position, the engine has no deceleration

Reason Standard value under normal conditions and fault diagnosis reference value

★Turn the engine starting switch to the OFF position for preparation, and then restart it and keep
the engine running for fault diagnosis.

1 Boom lifting signal fault Turn the control lever to the neutral position,
0 KG
and transmit pressure signal
Pressure value
Operate the control lever, and transmit
0～39 KG
pressure signal

★Turn the engine starting switch to the OFF position for preparation, and then restart it and keep
the engine running for fault diagnosis.
Turn the control lever to the neutral position,
2 Boom lowering signal fault 0 KG
and transmit pressure signal
Pressure value
Operate the control lever, and transmit
0～39 KG
pressure signal

★Turn the engine starting switch to the OFF position for preparation, and then restart it and keep
the engine running for fault diagnosis.
Turn the control lever to the neutral position,
3 Arm digging signal fault 0 KG
and transmit pressure signal
Pressure value
Operate the control lever, and transmit
0～39 KG
pressure signal

★Turn the engine starting switch to the OFF position for preparation, and then restart it and keep
the engine running for fault diagnosis.

4 Arm unloading signal fault Turn the control lever to the neutral position,
0 KG
and transmit pressure signal
Pressure value
Operate the control lever, and transmit
0～39 KG
pressure signal

Predicted ★Turn the engine starting switch to the OFF position for preparation, and then restart it and keep
cause the engine running for fault diagnosis.
and the
Turn the control lever to the neutral position,
standard 5 Bucket digging signal fault 0 KG
and transmit pressure signal
value Pressure value
under Operate the control lever, and transmit
normal 0～39 KG
pressure signal
conditions
★Turn the engine starting switch to the OFF position for preparation, and then restart it and keep
the engine running for fault diagnosis.

6 Bucket unloading signal fault Turn the control lever to the neutral position,
0 KG
and transmit pressure signal
Pressure value
Operate the control lever, and transmit
0～39 KG
pressure signal

★Turn the engine starting switch to the OFF position for preparation, and then restart it and keep
the engine running for fault diagnosis.
Turn the control lever to the neutral position,
7 Swing signal fault 0 KG
and transmit pressure signal
Pressure value
Operate the control lever, and transmit
0～39 KG
pressure signal

★Turn the engine starting switch to the OFF position for preparation, and then restart it and keep
the engine running for fault diagnosis.
Turn the control lever to the neutral position,
8 Traveling signal fault 0 KG
and transmit pressure signal
Pressure value
Operate the control lever, and transmit
0～39 KG
pressure signal

★Turn the engine starting switch to the OFF position for preparation, and then restart it and keep
the engine running for fault diagnosis.
Turn the control lever to the neutral position,
9 Accessory signal fault 0 KG
and transmit pressure signal
Pressure value
Operate the control lever, and transmit
0～39 KG
pressure signal
The fault diagnosis cannot be carried out because it is an internal fault. (If the fault is not caused
10 Controller fault
by the above cause, the controller shall be deemed to be defective)

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

E-5 Principle and diagnosis of preheating function

Warm-up function
● The warm-up function is designed to improve
engine starting performance in cold weather Starting

or at low coolant temperature.

Starter switch
1) Preheating and postheating
The running modes of the warm-up function Stop
Rotating
include preheating before engine start and Engine speed signal
subsequent heating after engine start. They
are controlled by the starter switch (S Preheating relay and
Time after heating
drive relay
terminal) signal, the engine coolant Time before heating

temperature signal and the engine rotation

signal.
Fig. 7-89
2) Running mode
● When the engine coolant temperature is
above 60°C. Starting

Starter switch

Preheating indicator
lamp Rotating
Engine speed signal Stop

Preheating relay and

drive relay

Fig. 7-90
● When the engine coolant temperature is 0°C
to 60°C. Starting

Starter switch
Preheating indicator
lamp
Engine speed signal Rotating

Preheating relay and Stop

drive relay
About 12 s

Time before heating

Fig. 7-91
● When the engine coolant temperature is
below 0°C. 7
Starting

Starter switch

Preheating indicator
lamp About 8 s
Rotating
Engine speed signal Stop
Preheating relay and About 20 s
drive relay About 12 s
Time after heating

Time before heating

Fig. 7-92

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
Engine DTC and troubleshooting list
Check based on DTC
DTC list

● The DTC displayed on the multi-purpose

tester is different from the DTC indicated by
flashing of the alarm lamp.
● The multi-purpose tester can display more
detailed DTCs.
Code Message Flashing Remarks Code Message Flashing Remarks
P0107 Barometric pressure sensor 19 P0403 EGR1 (actuator circuit) 67
P0108 Barometric pressure sensor 19 P0404 EGR system 02
P0112 Intake temperature sensor (low) 44 P0560 M/V supply voltage 79
P0113 Intake temperature sensor (high) 44 P0605 ECU system (hardware) 33
P0117 Water temperature sensor (low) 21 P0615 Starter safety relay (overload) 48
P0118 Water temperature sensor (high) 21 P0616 Starter safety relay (low) 48
Accelerator pedal 1 check P0617 Starter safety relay (high) 48
P0121 58
(simulation)
P1171 Q adjusting resistance (low) 34
P0122 Accelerator pedal sensor 1 24
P1172 Q adjusting resistance (high) 34
P0123 Accelerator pedal sensor 1 24
P1200 Fuel injector nozzle circuit 2 82
Fuel temperature sensor (inlet)
P0182 41 P1251 Common rail pressure M/V 1 63
low
Fuel temperature sensor (inlet) P1255 Common rail pressure M/V 1 63
P0183 41
high P1256 Common rail pressure M/V 1 63
P0192 CRS pressure sensor (low) 11 P1335 Speed and position sensor 14
P0193 CRS pressure sensor (high) 11 P1562 Sensor supply voltage 1 81
P0200 Fuel injector nozzle circuit 1 82 P1563 Sensor supply voltage 1 81
Fuel injector nozzle M/V - cylinder P1567 Sensor supply voltage 2 81
P0201 37
1 (loaded)
P1568 Sensor supply voltage 2 81
Fuel injector nozzle M/V - cylinder
P0202 38 P1572 Sensor supply voltage 3 81
2 (loaded)
Fuel injector nozzle M/V - cylinder P1573 Sensor supply voltage 3 81
P0203 39
3 (loaded)
P1577 Segment sensor supply voltage 81
Fuel injector nozzle M/V - cylinder
P0204 08 P1578 Segment sensor supply voltage 81
4 (loaded)
P1605 ECU system (EEPROM) 33
P0219 Engine overspeed 07
P1606 ECU system (software) 33
P0222 Accelerator pedal sensor 2 16
P1625 ECU relay 84
P0223 Accelerator pedal sensor 2 16
P1630 CAN(EGR1) 95
P0237 Charge air pressure sensor (low) 32
P0238 Charge air pressure sensor (high) 32
P0251 Common rail pressure abnormal 36
P0253 Common rail pressure abnormal 22
P0254 Common rail pressure abnormal 23
P0335 Engine speed sensor 15
P0340 Camshaft position sensor 12
P0380 Relay of glow relay 26

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

DTC trigger conditions and check items

● P0107: barometric pressure sensor (the alarm lamp flashes: 19)
Barometric pressure sensor (integrated in ECU) voltage is lower than standard value
Trigger conditions
(2 V)
If the signal becomes normal when the starter switch is turned ON, the system can be
Restorability
restored.
• Use backup value 101.3 kPa {1.03 kgf/cm2} for control (Exhaust gas emissions
ECU control contents deteriorate)
• Exhaust gas recirculation control stops.
Inspection and
38: barometric pressure
Inspection repair data
Other Replace ECU.

● P0108: barometric pressure sensor (the alarm lamp flashes: 19)

Barometric pressure sensor (integrated in ECU) voltage is lower than standard value
Trigger conditions
(4.7V)
If the signal becomes normal when the starter switch is turned ON, the system can be
Restorability
restored.
• Use backup value 101.3 kPa {1.03 kgf/cm2} for control (Exhaust gas emissions
ECU control contents deteriorate)
• Exhaust gas recirculation control stops.
Inspection and
38: barometric pressure
Inspection repair data
Other Replace ECU.
● P0112: intake air temperature sensor (low) (the alarm lamp flashes: 44)
Trigger conditions Intake air temperature sensor voltage is lower than standard value (0.15 V).
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents Control it with backup value (25°C).
Inspection and repair
27: Intake temperature
data
Inspection
ECU connector : Intake temperature sensor
Electric equipment #305: Intake temperature sensor
● P0113: Intake air temperature sensor (high) (alarm lamp flashes: 44)
Trigger conditions Intake air temperature sensor voltage is lower than standard value (4.85 V).
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents Control it with backup value (25°C).
Inspection and repair
27: Intake temperature
data
Inspection
ECU connector : Intake temperature sensor
Electric equipment #305: Intake temperature sensor
● P0117: Water temperature sensor (low) (alarm lamp flashes: 21) 7
Voltage of water temperature sensor is lower than the specified standard value
Trigger conditions
(0.2 V).
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
It is assumed that the water is at a constant temperature of -20°C when the engine is
started, and is at a constant temperature of 80°C while the vehicle is running.
ECU control contents
(Exhaust gas emissions increased); EGR control stops working; warm-up control
stops working.
Inspection and repair
35: Water temperature
data
Inspection
ECU connector : Water temperature sensor
Electric equipment #262: Water temperature sensor

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
● P0118: Water temperature sensor (high) (alarm lamp flashes: 21)
Trigger conditions Voltage of water temperature sensor is higher than the specified standard value (4.85 V).
Restorability If the signal becomes normal when the starter switch is turned ON, the system can be restored.
It is assumed that the water is at a constant temperature of -20°C when the engine is started, and is at
ECU control contents a constant temperature of 80°C while the vehicle is running. (Exhaust gas emissions increased); EGR
control stops working; warm-up control stops working.
Inspection and repair data 35: Water temperature

Inspection ECU connector : Water temperature sensor

Electric equipment #262: Water temperature sensor

● P0121: Accelerator pedal l inspection (stimulated) (alarm lamp flashes: 58)

Output voltage 1 and 2 of accelerator pedal position sensor have gone above standard range; or the
Trigger conditions
comparison value has gone above the specified range.
Restorability If the signal becomes normal when the starter switch is turned ON, the system can be restored.
ECU control contents – (low output)
Inspection and 22: Accelerator pedal position (unfiltered), 23: Accelerator pedal position (filtered)
Inspection
repair data 24: Accelerator pedal sensor voltage 1, 25: Accelerator pedal sensor voltage 2

● P0122: Accelerator pedal sensor 1 (alarm lamp flashes: 24)

Trigger conditions Voltage of accelerator pedal position sensor 1 is lower than the specified standard value.
Restorability If the signal becomes normal when the starter switch is turned ON, the system can be restored.
ECU control contents Control it with accelerator pedal position sensor 2.
Inspection and 22: Accelerator pedal position (unfiltered), 23: Accelerator pedal position (filtered)
Inspection
repair data 24: Accelerator pedal sensor voltage 1

● P0123: Accelerator pedal sensor 1 (alarm lamp flashes: 24)

Trigger conditions Voltage of accelerator pedal position sensor 1 is lower than the specified standard value.
Restorability If the signal becomes normal when the starter switch is turned ON, the system can be restored.
ECU control contents Control it with accelerator pedal position sensor 2.
Inspection and 22: Accelerator pedal position (unfiltered), 23: Accelerator pedal position (filtered)
Inspection
repair data 24: Accelerator pedal sensor voltage 1

● P0182: Low value from fuel temperature sensor (inlet) (alarm lamp flashes: 41)
Trigger conditions Voltage of fuel temperature sensor is lower than the specified standard value (0.15 V).
Restorability If the signal becomes normal when the starter switch is turned ON, the system can be restored.
ECU control contents Control it with backup value (40°C).
Inspection and repair data 36: Fuel temperature (inlet)

Inspection ECU connector : Fuel temperature sensor

Electric equipment #323: Fuel temperature sensor

● P0183: High value from fuel temperature sensor (inlet) (alarm lamp flashes: 41)
Trigger conditions Voltage of fuel temperature sensor is lower than the specified standard value (4.8 V).
Restorability If the signal becomes normal when the starter switch is turned ON, the system can be restored.
ECU control contents Control it with backup value (40°C).
Inspection and repair data 36: Fuel temperature (inlet)

Inspection ECU connector : Fuel temperature sensor

Electric equipment #323: Fuel temperature sensor

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
● P0192: CRS pressure sensor (low) (alarm lamp flashes: 11)
Voltage of common rail pressure sensor is lower than the specified standard
Trigger conditions
value (0.2 V).
If the signal becomes normal when the starter switch is switched from OFF to ON
Restorability
position, the system may go back to normal (supply voltage to ECU again)
• Open-loop control of common rail pressure is affected (output reduced, exhaust
ECU control contents gas emissions increased)
• Exhaust gas recirculation control stops.
Inspection and repair
0C: Common rail differential pressure
Inspection data
Electric equipment #319: Common rail pressure sensor

● P0193: CRS pressure sensor (high) (alarm lamp flashes: 11)

Voltage of common rail pressure sensor is lower than the specified standard
Trigger conditions
value (4.8 V).
If the signal becomes normal when the starter switch is switched from OFF to ON
Restorability
position, the system may go back to normal (supply voltage to ECU again).
• Open-loop control of common rail pressure is affected (output reduced, exhaust
ECU control contents gas emissions increased)
• Exhaust gas recirculation control stops.
Inspection and repair
0C: Common rail differential pressure
Inspection data
Electric equipment #319: Common rail pressure sensor

● P0200: Nozzle circuit 1 (alarm lamp flashes: 82)

Short circuit, open circuit or overload in injector solenoid valve circuit
Trigger conditions
(cylinder No. 1 and No. 4).
If the signal becomes normal when the starter switch is turned ON, the system
Restorability
can be restored.
• Failure circuit stops working, resulting in both cylinders operating again.
ECU control contents (Output decreased and exhaust gas emissions increased)
• Exhaust gas recirculation control stops.
Actuator test BB: Injector test 1, BE: Injector test 4
Inspection ECU connector : Injector solenoid valve
Electric equipment #582: Injector solenoid valve

● P0201: Injector M/V - Cylinder 1 (load) (alarm lamp flashes: 37)

Trigger conditions Short circuit or open circuit ininjector solenoid (cylinder No. 1).
For short circuit: If the signal becomes normal when the starter switch is switched 7
from OFF to ON position, the system may go back to normal (supply voltage to
Restorability ECU again)
For open circuit: If the signal becomes normal when the starter switch is switched
to ON position, the system may go back to normal.
• Exhaust gas recirculation control stops.
• For open circuit: power supply cut off.
ECU control contents
• Short circuit: Injector solenoid valves 1 and 4 stop working. (Output
decreased, fuel economy reduced, exhaust gas emissions increased)
Actuator test BB: Injector test 1
Inspection ECU connector : Injector solenoid valve
Electric equipment #582: Injector solenoid valve

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
● P0202: Injector M/V - Cylinder 2 (load) (alarm lamp flashes: 38)
Trigger conditions Short circuit or open circuit in injector solenoid valve (cylinder No. 3).
For short circuit: If the signal becomes normal when the starter switch is switched
from OFF to ON position, the system may go back to normal (supply voltage to
Restorability ECU again)
For open circuit: If the signal becomes normal when the starter switch is switched
to ON position, the system may go back to normal.
• Exhaust gas recirculation control stops.
• For open circuit: power supply cut off.
ECU control contents
• Short circuit: Injector solenoid valves 2 and 3 stop working. (Output
decreased, fuel economy reduced, exhaust gas emissions increased)
Actuator test BD: Injector test 3
Inspection ECU connector : Injector solenoid valve
Electric equipment #582: Injector solenoid valve

● P0203: Injector M/V - Cylinder 3 (load) (alarm lamp flashes: 39)

Trigger conditions Short circuit or open circuit in injector solenoid valve (cylinder No. 4)
For short circuit: If the signal becomes normal when the starter switch is switched
from OFF to ON position, the system may go back to normal (supply voltage to
Restorability ECU again)
For open circuit: If the signal becomes normal when the starter switch is switched
to ON position, the system may go back to normal.
• Exhaust gas recirculation control stops.
• For open circuit: power supply cut off.
ECU control contents
• Short circuit: Injector solenoid valves 1 and 4 stop working. (Output
decreased, fuel economy reduced, exhaust gas emissions increased)
Actuator test BE: Injector test 4
Inspection ECU connector : Injector solenoid valve
Electric equipment #582: Injector solenoid valve

● P0204: Injector M/V - Cylinder 4 (load) (alarm lamp flashes: 08)

Trigger conditions Short circuit or open circuit in injector solenoid valve (cylinder No. 2).
For short circuit: If the signal becomes normal when the starter switch is switched
from OFF to ON position, the system may go back to normal (supply voltage to
Restorability ECU again)
For open circuit: If the signal becomes normal when the starter switch is switched
to ON position, the system may go back to normal.
• Exhaust gas recirculation control stops.
• For open circuit: power supply cut off.
ECU control contents
• Short circuit: Injector solenoid valves 2 and 3 stop working. (Output
decreased, fuel economy reduced, exhaust gas emissions increased)
Actuator test BC: Injector test 2
Inspection ECU connector : Injector solenoid valve
Electric equipment #582: Injector solenoid valve

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
● P0219: Engine overspeed (alarm lamp flashes: 07)
Trigger conditions The engine speed has gone above specified range.
If the engine speed becomes normal when the starter switch is switched to ON
Restorability
position, the system may go back to normal.
• Injectors are turned OFF.
ECU control contents
• MPROP (common rail fuel pressure proportional valve) stops delivering fuel.
If this DTC is displayed when the needle is out of the red area of the tachometer,
Inspection ECU connector
replace the engine ECU.

● P0222: Accelerator pedal sensor 2 (alarm lamp flashes: 16)

Voltage of accelerator pedal position sensor 2 is lower than the specified
Trigger conditions
standard value.
If the signal becomes normal when the starter switch is turned ON, the system
Restorability
can be restored.
ECU control contents Control it with accelerator pedal position sensor 1.
Inspection and repair 22: Accelerator pedal position (unfiltered), 23: Accelerator pedal position (filtered)
Inspection
data 25: Accelerator pedal sensor voltage 2.

● P0223: Accelerator pedal sensor 2 (alarm lamp flashes: 16)

Voltage of accelerator pedal position sensor 2 is higher than the specified
Trigger conditions
standard value.
If the signal becomes normal when the starter switch is turned ON, the system
Restorability
can be restored.
ECU control contents Control it with accelerator pedal position sensor 1.
Inspection and repair 22: Accelerator pedal position (unfiltered), 23: Accelerator pedal position (filtered)
Inspection
data 25: Accelerator pedal sensor voltage 2

● P0237: Charge air pressure sensor (low) (alarm lamp flashes: 32)
Voltage of charge air pressure sensor is lower than the specified standard
Trigger conditions
value (0.3 V).
If the signal becomes normal when the starter switch is turned ON, the system
Restorability
can be restored.
Control it with backup value 101.3 kPa {1.03 kgf/cm2}. (Output decreased and fuel
ECU control contents
economy reduced
Inspection and repair
26: Charge air pressure
Inspection data
Electric equipment #318: Charge air pressure sensor

● P0238: Charge air pressure sensor (high) (alarm lamp flashes: 32)
7
Voltage of charge air pressure sensor is higher than the specified standard
Trigger conditions
value (4.7 V).
If the signal becomes normal when the starter switch is turned ON, the system
Restorability
can be restored.
Control it with backup value 101.3 kPa {1.03 kgf/cm2}. (Output decreased and fuel
ECU control contents
economy reduced)
Inspection and repair
26: Charge air pressure
Inspection data
Electric equipment #318: Charge air pressure sensor

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
● P0251: Common rail pressure abnormal (alarm lamp flashes: 36)
The difference between the target and actual pressures of common rail
Trigger conditions
injected fuel is higher than the standard value.
If the signal becomes normal when the starter switch is switched from OFF to ON
Restorability
position, the system may go back to normal (supply voltage to ECU again).
• Injection fuel is limited. (Output decreased)
ECU control contents
• Exhaust gas recirculation control stops.
Actuator test B9: Fuel leakage inspection
Discharge air from the fuel system (refer section 13).
Fuel pipeline (refer section 13).
Inspection Fuel filter (refer section 13).
Other
Fuel pump (performed by Bosch.)
Pressure limiting valve (performed by Bosch.)
Injector (performed by Bosch.)

● P0253: Common rail pressure abnormal (alarm lamp flashes: 22)

The actual pressure of common rail injected fuel is lower than the standard
Trigger conditions
value.
If the signal becomes normal when the starter switch is turned ON, the system
Restorability
can be restored.
• Engine is stopped.
ECU control contents
• Exhaust gas recirculation control stops.
Actuator test B9: Fuel leakage inspection
• Discharge air from the fuel system (refer section 13).
• Fuel pipeline (refer section 13).
Inspection • Fuel filter (refer section 13).
Other
• Fuel pump (performed by Bosch.)
• Pressure limiting valve (performed by Bosch.)
• Injector (performed by Bosch.)

● P0254: Common rail pressure abnormal (alarm lamp flashes: 23)

The actual common rail pressure is still very high or higher than the
Trigger conditions
specified standard value even when the supply rate is zero.
If the signal becomes normal when the starter switch is switched from OFF to ON
Restorability
position, the system may go back to normal (supply voltage to ECU again).
Injection fuel is limited. (Output decreased)
ECU control contents
EGR control stops working.
Inspection Other Fuel pump (performed by Bosch.)

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
● P0335: Engine speed sensor (alarm lamp flashes: 15)
Trigger conditions The engine speed sensor does not transmit pulse or transmit too many pulses.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
Control it with the cylinder recognition sensor. (Output decreased due to decrease in
ECU control contents
control accuracy)
Inspection and repair
01: Engine rpm
data
Inspection
ECU connector : Engine speed sensor
Electric equipment #263: Engine speed sensor

● P0340: Camshaft position sensor (alarm lamp flashes: 12)

The cylinder recognition sensor does not transmit pulse or transmit too many
Trigger conditions
pulses.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents Control it with the engine speed sensor.
Inspection and repair
01: Engine rpm
data
Inspection
ECU connector : Cylinder recognition sensor
Electric equipment #320: Cylinder recognition sensor

● P0380: Relay of glow relay (alarm lamp flashes: 26)

Trigger conditions Short circuit, open circuit or overload in preheating relay and drive relay
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents Preheating control stops working.
Inspection and repair
8D: Preheating relay
data
Inspection Actuator test AF: Relay of preheating relay
ECU connector : Preheating relay and drive relay
Electric equipment #201: Preheating relay and drive relay

● P0403: EGR1 (actuator circuit) (alarm lamp flashes: 67)

When one of the following conditions occurs:
Short circuit or open circuit in EGR motor.
Open circuit in EGR position sensor.
Trigger conditions Communication error occurred between the EDU and EGR valve (due to , e.g.,
data on target position has gone above the specified range or data is not
received).
Supply voltage abnormal (overvoltage or under-voltage)
The motor or sensor fails: If the signal becomes normal when the starter switch is 7
switched from OFF to ON position, the system may go back to normal. (ECU is
supplied with power again)
Restorability
Error in communication or abnormal supply voltage: If the signal becomes normal
when the starter switch is switched to ON position, the system may go back to
normal.
• Exhaust gas recirculation control stops.
ECU control contents
• Injection fuel is limited.
Inspection and repair
1F: EGR position
data
Inspection
Actuator test A1：EGR 1
Electric equipment #530: EGR valve

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
● P0404: EGR system (alarm lamp flashes: 02)
This condition lasts for 1 second after the EGR electronic drive receives the
Trigger conditions
CAN signal "EGR valve motor stuck".
If the signal becomes normal when the starter switch is switched to ON position, the
Restorability
system may go back to normal.
EGR control stops working. (EGR valve is completely closed)
ECU control contents
Throttle control stops working. (Intake air throttle is fully open)
Inspection and repair
1F: EGR position
data
Inspection
Actuator test A1：EGR1
Electric equipment #530: EGR valve

● P0560: M/V power supply voltage (alarm lamp flashes: 79)

Trigger conditions The circuit (solenoid valve power supply) in the ECU is abnormal.
If the signal becomes normal when the starter switch is switched from OFF to ON
Restorability
position, the system may go back to normal (supply voltage to ECU again).
ECU control contents No specific control is performed. Malfunction due to circuit abnormality.
Inspection Other Replace ECU.

● P0605: ECU system (hardware) (alarm lamp flashes: 33)

Trigger conditions The circuit (solenoid valve power supply) in the ECU is abnormal.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored. It cannot be restored unless the DTC system has been deleted.
ECU control contents Engine is stopped.
Inspection Other Replace ECU.

● P0615: Starter safety relay (overloaded) (alarm lamp flashes: 48)

Trigger conditions Safety relay is overloaded
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents The starter is always powered on to prevent interruption of the function.
Inspection and repair
8F: Starter safety relay
data

Inspection Actuator test B1: Starter safety relay

ECU connector : Starter safety relay
Electric equipment #201: Starter safety relay

● P0616: Starter safety relay (low) (alarm lamp flashes: 48)

Trigger conditions Short-circuit to ground or open circuit in the safety relay.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents The starter is always powered on to prevent interruption of the function.
Inspection and repair
8F: Starter safety relay
data
Ins
pec Actuator test B1: Starter safety relay
tion ECU connector : Starter safety relay
Electric equipment #201: Starter safety relay

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
● P0617: Starter safety relay (high) (alarm lamp flashes: 48)
Trigger conditions The safety relay circuit is shorted to power supply.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents The starter is always powered on to prevent interruption of the function.
Inspection and repair
8F: Starter safety relay
data
Inspection Actuator test B1: Starter safety relay
ECU connector : Starter safety relay
Electric equipment #201: Starter safety relay

● P1171: Q adjusting resistance (low) (alarm lamp flashes: 34)

Voltage of fuel injector adjustment resistor is lower than the specified
Trigger conditions
standard value (0.2 V).
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents Control it with backup value (No. 1). (Output decreased slightly.)
Inspection and repair
3E: Q adjusting resistance No.
data
Inspection
ECU connector : Fuel injector adjustment resistor
Electric equipment #828: Fuel injector adjustment resistor
● P1172: Q adjusting resistance (high) (alarm lamp flashes: 34)
Voltage of fuel injector adjustment resistor is higher than the specified
Trigger conditions
standard value (4.8 V).
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents Control it with backup value (No. 1). (Output decreased slightly.)
Inspection and repair
3E: Q adjusting resistance No.
data
Inspection
ECU connector : Fuel injector adjustment resistor
Electric equipment #828: Fuel injector adjustment resistor
● P1200: Nozzle circuit 2 (alarm lamp flashes: 82)
Short circuit, open circuit or overload in injector solenoid valve circuit
Trigger conditions
(cylinder No. 2 and No. 3).
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
• Failure circuit stops working, resulting in both cylinders operating again.
ECU control contents (Output decreased and exhaust gas emissions increased)
• Exhaust gas recirculation control stops.
Actuator test BC: Injector test 2, BD: Injector test 3
Inspection ECU connector : Injector solenoid valve
Electric equipment #582: Injector solenoid valve
● P1251: Common rail pressure M/V 1 (alarm lamp flashes: 63) 7
Current to MPROP (common rail fuel pressure proportional valve) is higher
Trigger conditions
than the specified standard value.
If the signal becomes normal when the starter switch is switched from OFF to ON
Restorability
position, the system may go back to normal (supply voltage to ECU again).
• Injection fuel is limited. (Output decreased, fuel economy reduced, exhaust gas
ECU control contents emissions increased)
• Exhaust gas recirculation control stops.
Actuator test B9: Fuel leakage inspection
Inspection ECU connector : MPROP (common rail fuel pressure proportional valve)
Electric equipment #574: MPROP (common rail fuel pressure proportional valve)

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
● P1255: Common rail pressure M/V 1 (alarm lamp flashes: 63)
Voltage of MPROP (common rail fuel pressure proportional valve) is lower than
Trigger conditions
the specified standard value.
If the signal becomes normal when the starter switch is switched from OFF to ON
Restorability
position, the system may go back to normal (supply voltage to ECU again).
• Injection fuel is limited. (Output decreased, fuel economy reduced, exhaust gas
ECU control contents emissions increased)
• Exhaust gas recirculation control stops.
Actuator test B9: Fuel leakage inspection
Inspection ECU connector : MPROP (common rail fuel pressure proportional valve)
Electric equipment #574: MPROP (common rail fuel pressure proportional valve)

● P1256: Common rail pressure M/V 1 (alarm lamp flashes: 63)

Voltage of MPROP (common rail fuel pressure proportional valve) is higher
Trigger conditions
than the specified standard value.
Excessively high voltage: If the signal becomes normal when the starter switch is set
to ON position, the system may go back to normal.
Restorability Short circuit: If the signal becomes normal when the starter switch is switched from
OFF to ON position, the system may go back to normal (supply voltage to ECU
again)
• Injection fuel is limited. (Output decreased, fuel economy reduced, exhaust gas
ECU control contents emissions increased)
• Exhaust gas recirculation control stops.
Actuator test B9: Fuel leakage inspection
Inspection ECU connector : MPROP (common rail fuel pressure proportional valve)
Electric equipment #574: MPROP (common rail fuel pressure proportional valve)

● P1335: Rotational speed and position sensor (alarm lamp flashes: 14)
The engine speed sensor and cylinder recognition sensor do not transmit
Trigger conditions
pulse or transmit too many pulses.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents Injectors are turned OFF. (Engine is stopped.)
Inspection and repair
01: Engine rpm
data
Inspection
ECU connector : Engine speed sensor, : Cylinder recognition sensor
Electric equipment #263: Engine speed sensor, #320: Cylinder recognition sensor

● P1562: Sensor supply voltage 1 (alarm lamp flashes: 81)

Voltage (sensor power voltage 1) of the circuit in the ECU is lower than the
Trigger conditions
specified standard value.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents No specific control is performed. Malfunction only resulted from circuit abnormality.
Inspection and repair
Inspection 24: Accelerator pedal sensor voltage 1, 3B: Idling speed voltage
data

● P1563: Sensor supply voltage 1 (alarm lamp flashes: 81)

Voltage (sensor power voltage 1) of the circuit in the ECU is higher than the
Trigger conditions
specified standard value.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents No specific control is performed. Malfunction only resulted from circuit abnormality.
Inspection and repair
Inspection 24: Accelerator pedal sensor voltage 1, 3B: Idling speed voltage
data

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
● P1567: Sensor supply voltage 2 (alarm lamp flashes: 81)
Voltage (sensor power voltage 2) of the circuit in the ECU is lower than the
Trigger conditions
specified standard value.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents No specific control is performed. Malfunction only resulted from circuit abnormality.
Inspection and repair
25: Accelerator pedal sensor voltage 2, 26: Charge air pressure
Inspection data
Electric equipment #318: Charge air pressure sensor

● P1568: Sensor supply voltage 2 (alarm lamp flashes: 81)

Voltage (sensor power voltage 2) of the circuit in the ECU is higher than the
Trigger conditions
specified standard value.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents No specific control is performed. Malfunction only resulted from circuit abnormality.
Inspection and repair
25: Accelerator pedal sensor voltage 2, 26: Charge air pressure
Inspection data
Electric equipment #318: Charge air pressure sensor

● P1572: Sensor supply voltage 3 (alarm lamp flashes: 81)

Voltage (sensor power voltage 3) of the circuit in the ECU is lower than the
Trigger conditions
specified standard value.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents No specific control is performed. Malfunction only resulted from circuit abnormality.
Inspection and repair
0C: Common rail differential pressure
Inspection data
Electric equipment #319: Common rail pressure sensor

● P1573: Sensor supply voltage 3 (alarm lamp flashes: 81)

Voltage (sensor power voltage 3) of the circuit in the ECU is higher than the
Trigger conditions
specified standard value.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents No specific control is performed. Malfunction only resulted from circuit abnormality.
Inspection and repair
0C: Common rail differential pressure
Inspection data
Electric equipment #319: Common rail pressure sensor
7
● P1577: Segment sensor power supply voltage (alarm lamp flashes: 81)
Supply voltage to cylinder recognition sensor is lower than the specified
Trigger conditions
standard value (0 V).
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents No specific control is performed. Malfunction only resulted from circuit abnormality.
Inspection and repair
01: Engine rpm
data
Inspection
ECU connector : Cylinder recognition sensor
Electric equipment #320: Cylinder recognition sensor

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
● P1578: Segment sensor power supply voltage (alarm lamp flashes: 81)
Supply voltage to cylinder recognition sensor is higher than the specified
Trigger conditions
standard value (5 V).
If the signal becomes normal when the starter switch is switched from OFF to ON
Restorability
position, the system may go back to normal (supply voltage to ECU again).
ECU control contents No specific control is performed. Malfunction only resulted from circuit abnormality.
Inspection and repair
01: Engine rpm
data
Inspection
ECU connector : Cylinder recognition sensor
Electric equipment #320: Cylinder recognition sensor

● P1605: ECU system (EEPROM) (alarm lamp flashes: 33)

Trigger conditions Reading or writing error occurs during access.
If the signal becomes normal when the starter switch is switched from OFF to ON
Restorability
position, the system may go back to normal (supply voltage to ECU again).
ECU control contents No specific control is performed. Malfunction only resulted from circuit abnormality.
Inspection Other Replace ECU.

● P1606: ECU system (software) (alarm lamp flashes: 33)

System overload occurs.
Trigger conditions
How long the task is performed exceeds duration limit.
If the signal becomes normal when the starter switch is switched from OFF to ON
Restorability
position, the system may go back to normal (supply voltage to ECU again).
ECU control contents Engine is stopped.
Inspection Other Replace ECU.

● P1625: EDU Relay (alarm lamp flashes: 84)

Trigger conditions Short circuit, open circuit or overload in EDU.
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents EGR control stops working. (Emissions will increase)
Inspection and repair
90: EDU power supply relay
data

Inspection Actuator test B2: EDU relay

ECU connector : EDU relay
Electric equipment #201: EDU relay

● P1630: CAN (EGR) (alarm lamp flashes: 95)

No communication with EGR EDU (CAN messages are not received for certain
Trigger conditions
period; or CAN bus is OFF)
If the signal becomes normal when the starter switch is turned ON, the system can
Restorability
be restored.
ECU control contents EGR control stops working. (Emissions will increase)
Inspection Actuator test A1：EGR1

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

Maintenance data of multi-purpose tester

● It is possible to check the maintenance data and actuator tests simultaneously.
No. Item Part name Inspection conditions Requirement
Value corresponds to the
01 Engine speed .rpm Overspeed (engine running)
indication of tachometer.
Reference injection
02
quantity ％ Starter switch at ON position 0%
Common rail differential
0C
pressure ％ Engine idling 0% or below
Engine idling 0%
1F EGR position ％ [Actuator test] A1: EGR1
Accelerator pedal not depressed 0%
Accelerator pedal Accelerator pedal is depressed
22
position (unfiltered) ％ gradually
Value gradually increases.
Accelerator pedal is fully depressed 100%
Accelerator pedal not depressed 0%
Accelerator pedal Accelerator pedal is depressed
23
position (filtered) ％ gradually
Value gradually increases.
Accelerator pedal is fully depressed 100%
Accelerator pedal sensor Accelerator pedal gradually
24
voltage 1 V pressed from released position
0.85-4.15 V
Accelerator pedal sensor Accelerator pedal gradually
25
voltage 2 V pressed from released position
0.85-4.15 V
Starter switch is set to ON position It shall correspond to
(engine is stopped) atmospheric pressure
26 Charge air pressure kPa Accelerator pedal is depressed
Value gradually increases
after the engine is started.
Value shall be correspond to
27 Intake temperature ℃ Cold engine
ambient temperature.
Value shall be correspond to
Cold engine
ambient temperature.
35 Water temperature ℃ Engine in process of warming up Value gradually increases.
Engine stopped after warming up Value gradually decreases.
Value shall be correspond to
Cold engine
ambient temperature.
36 Fuel temperature (inlet) ℃ Engine in process of warming up Value gradually increases.
Engine stopped after warming up Value gradually decreases.
Height: 0m 101 kPa
38 Atmospheric pressure kPa Height: 600 m 95 kPa
Number matches the
Q adjusting resistance 1/2/3/4/5/6/7/8/9
3E 一 number marked on fuel
No. /10/11/NON
injector adjustment resistor.
Value matches battery
42 Power voltage V Starter switch at ON position
voltage.
Engine cranked by means of starter
ON
switch
71 Starter switch (S) ON/OFF
Starter switch in position except
OFF
START 7
Starter switch in ON Position ON
72 Starter switch (M) ON/OFF
Starter switch in position except ON OFF
Accelerator pedal not depressed ON
73 Acceleration switch ON/OFF
Accelerator pedal is depressed OFF
Diagnostic switch OFF ON
83 Diagnostic switch ON/OFF
Diagnostic switch ON OFF
Memory clear switch OFF ON
84 Memory clear switch ON/OFF
Memory clear switch ON OFF

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

No. Item Part name Inspection conditions Requirement

Actuator test is performed ON
8D Glow relay ON/OFF Actuator test is not performed OFF
[Actuator test] AF: Relay of preheating relay
Actuator test is performed ON
8E Glow relay indicator ON/OFF Actuator test is not performed OFF
[Actuator test] B0: Preheating indicator
Actuator test is performed ON
8F Starter safety relay ON/OFF Actuator test is not performed OFF
[Actuator test] B1: Starter safety relay
Starter switch ON ON
90 EDU power supply relay ON/OFF Starter switch OFF OFF
[Actuator test] B2: EDU relay
Starter switch ON (engine not
ON
started)
91 MIL lamp ON/OFF
No error found after engine startup OFF
[Actuator test] B3: MIL lamp
Starter switch ON (engine not
ON
started)
92 Diagnostic light ON/OFF
No error found after engine startup OFF
[Actuator test] B4: Diagnostic light

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

Actuator tests performed using multi-purpose tester

● It is possible to check the maintenance data and actuator tests simultaneously.
No. Item Description Confirmation method
Switch the EGR valve ON/OFF repeatedly (it resets
automatically after 6 seconds).
Confirmed via the operational
[Test can be performed only if the following
sound of the EGR valve.
A1 EGR1 conditions are met]
[Maintenance data]
• Vehicle: Stationary (speed: 0 km/h)
1F: EGR position
• Starter switch: ON
• Engine: Stopped
Switch the preheating drive relay ON/OFF
repeatedly. (It resets automatically after 6 seconds). Conformed via the sound
generated when the preheating
[Test can be performed only if the following
drive relay is switched
AF Relay of glow relay conditions are met]
ON/OFF.
• Vehicle: Stationary (speed: 0 km/h)
[Maintenance data]
• Starter switch: ON
8D: Preheating relay
• Engine: Stopped
Switch the glow indicator lamp ON/OFF repeatedly.
(It resets automatically after 6 seconds). Check if the preheating
indicator lamp goes on or off as
[Test can be performed only if the following
commanded.
B0 Glow indicator lamp conditions are met]
[Maintenance data]
• Vehicle: Stationary (speed: 0 km/h)
8E: Preheating relay indicator
• Starter switch: ON
lamp
• Engine: Stopped
Switch the safety relay ON/OFF repeatedly. (It
resets automatically after 6 seconds). Conformed via the sound
[Test can be performed only if the following generated when the safety
B1 Starter safety relay conditions are met] relay is switched ON/OFF.
• Vehicle: Stationary (speed: 0 km/h) [Maintenance data]
• Starter switch: ON 8F: Starter safety relay
• Engine: Stopped

Switch the EDU relay ON/OFF repeatedly. (It resets

automatically after 6 seconds).
[Test can be performed only if the following Conformed via the sound
conditions are met] generated when the EDU relay
B2 EDU relay • Vehicle: Stationary (speed: 0 km/h) is switched ON/OFF.
• Starter switch: ON [Maintenance data]
• Engine: Stopped 90: EDU power supply relay
(Errors related to EDU may be detected while
performing actuator test.)
7
ON/OFF condition of alarm
lamp (orange)
B3 MIL lamp Switch the engine control alarm lamp ON/OFF
[Maintenance data]
repeatedly (it resets automatically after 6 seconds).
[Test can be performed only if the following 91: MIL lamp
conditions are met]
• Starter switch: ON ON/OFF condition of alarm
lamp (red)
B4 Diagnostic light • Engine: Stopped
[Maintenance data]
92: Diagnostic light

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

No. Item Description Confirmation method

Increase the common rail fuel pressure for a while
(6 s)
[Test can be performed only if the following Confirm that the fuel system
Fuel leakage conditions are met]
B9 (pipelines and hoses) is free
inspection
• Vehicle: Stationary (speed: 0 km/h) from fuel leakage.
• Gearbox: Neutral position
• Diagnostic switch: OFF position
Confirm that the injector
BB Injector test 1 solenoid valve of cylinder No. 1
has stopped.
Selected injector solenoid valve is forcibly stopped
[Test can be performed only if the following Confirm that the injector
BC Injector test 2 conditions are met] solenoid valve of cylinder No. 2
has stopped.
• Vehicle: Stationary (speed: 0 km/h)
• Engine speed ＜ 1500 rpm Confirm that the injector
BD Injector test 3 solenoid valve of cylinder No. 3
• Gearbox: Neutral position has stopped.
• No valid DTC is generated
Confirm that the injector
BE Injector test 4 solenoid valve of cylinder No. 4
has stopped.

Inspections performed at ECU connectors

● These inspections aid troubleshooting by enabling you to check whether ECU signals are being
correctly transmitted via the vehicle harness and connectors. The white-on-black numbers ( ,
and so on) correspond to the similarly printed reference numbers in ―Check based on DTC‖.
ECU connector terminal layout

Fig. 7-93

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
Inspection instructions
● Some inspections shall be performed with the connectors removed. Others shall be performed with
the connectors fitted.

CAUTION
● Do not touch any terminal except those specified for the inspection. Be particularly careful not to
cause short circuits between terminals using the tester probes.

Inspection Item Measurement method

[Conditions]
• Starter switch OFF
• Connector disconnected. Check the vehicle-side connector.
[Requirements]
Resistance of intake air temperature Terminal: A63-A32
sensor
• 0°C：15 （+3.38， -2.9） kΩ
• 20°C：6.514 （+1.437，-1.145）kΩ
• 90°C：0.874（+0.136，-0.115）kΩ
[Conditions]
• Starter switch OFF
• Connector disconnected. Check the vehicle-side connector.
[Requirements]
Resistance of water temperature sensor Terminal: A40-A41
• 20°C：2.45 ± 0.14 kΩ
• At 80°C: 0.32 kΩ (reference value)
• 110°C：147.1 ± 2 Ω
[Conditions]
• Starter switch OFF
• Connector disconnected. Check the vehicle-side connector.
[Requirements]
Terminal: A89-A65
Resistance of fuel temperature sensor
• 2 0°C：
• 80°C：0.318 ± 0.008 kΩ
• 110°C：0.1417 ± 0.0018 kΩ
[Conditions]
• Starter switch OFF 7
• Connector disconnected. Check the vehicle-side connector.
[Requirements]
Terminals:
Resistance of injector solenoid valve
A72-A23 (Injector solenoid valve: Cylinder No. 1)
A95-A48 (Injector solenoid valve: Cylinder No. 2)
A96-A24 (Injector solenoid valve: Cylinder No. 3)
A71-A46 (Injector solenoid valve: Cylinder No. 4) • 0.255 ± 0.04 Ω

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

Inspection Item Measurement method

[Conditions]
• Starter switch OFF
• Connector disconnected. Check the vehicle-side connector.
[Requirements]
Resistance of engine speed sensor Terminal: A10-A9
• 860 ± 86 kΩ (20°C)
[Conditions]
• Starter switch OFF
• Connector disconnected. Check the vehicle-side connector.
Resistance of cylinder recognition sensor [Requirements]
Terminal: A78-A83 (+5 V to GND)
• 200-1800 kΩ
[Conditions]
• Starter switch OFF
• Connector disconnected. Check the vehicle-side connector.
[Requirements]
Terminal: A35-A88
• Resistor No. 1: 270 ± 13.5 Ω
• Resistor No. 2: 510 ± 25.5 Ω
• Resistor No. 3: 820 ± 41 Ω
Resistance of fuel injector adjustment • Resistor No. 4: 1,300 ± 65 Ω
resistor
• Resistor No. 5: 2,000 ± 100 Ω
• Resistor No. 6: 3,300 ± 165 Ω
• Resistor No. 7: 5,600 ± 280 Ω
• Resistor No. 8: 15,000 ± 750 Ω
• Resistor No. 9: 390 ± 19.5 Ω
• Resistor No. 10: 4,300 ± 215 Ω
• Resistor No. 11: 9,100 ± 455 Ω
[Conditions]
• Starter switch OFF
• Connector disconnected. Check the vehicle-side connector.
Resistance of MPROP (common rail fuel [Requirements]
pressure proportional valve)
Terminals: A69-A21, A69-A2, A3-A21, A3-A2
2.6-3.15 Ω

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

Inspection Item Measurement method

[Conditions]
• Starter switch ON
• Connect the vehicle-side harness (to check the back of the connector).
• Perform the actuator test ―B1-Starter safety relay‖ with the multi-purpose
tester.
Voltage of starter safety relay [Requirements]
Terminals (+)-(–): A81-A49
• If the relay operates: value shall be consistent with the battery voltage
• If the relay does not operate: 0V
[Conditions]
• Starter switch ON
• Connect the vehicle-side harness (to check the back of the connector).
• Perform the actuator test ―B2-EDU relay‖ with the multi-purpose tester.
Voltage of EDU relay [Requirements]
Terminals (+)-(–): B39-B14
• If the relay operates: value shall be consistent with the battery voltage
• If the relay does not operate: 0V
[Conditions]
• Starter switch ON
• Connect the vehicle-side harness (to check the back of the connector).
• Perform the actuator test ―AF-Relay of preheating relay‖ with the
Voltage of preheating relay and drive multi-purpose tester.
relay [Requirements]
Terminals (+)-(–): A73-A7
• If the relay operates: value shall be consistent with the battery voltage
• Relay does not operate: 0 V

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

E-6 No equipment works

Fault information After starting the machine, it has no movement after operation
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and then restart it
and keep the engine running for fault diagnosis.
Safety
Safety lock Measurement item control Resistance value
1
switch fault lever
Predicted
cause Locking Below 1 Ω
Between 105# and 27# wires
and the Release Above 1 MΩ
standard
value ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
Wire short OFF position for fault diagnosis.
under
2 circuit
normal Resistance
(grounding) Between 105# and ground Above 1 MΩ
conditions value
Fault of ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
internal coil OFF position for fault diagnosis.
of PPC
3
locking Resistance
solenoid Between 1 and 2 of CN-136F About 34 Ω
value
valve

Pilot switch

Pilot solenoid valve

Body harness

Fig. 7-94

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
E-7 The boom lifting is slow and powerless
When excavator works, the boom moves slowly and the
Fault information
digging is powerless
The pilot pressure signal during boom movement can be
Relevant information
read from the display

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and then restart it
and keep the engine running for fault diagnosis.
Sensor Turn the control lever to the neutral position, and
1 0 KG
fault transmit boom lifting pressure signal Pressure
Predicted Operate the control lever, and transmit boom lifting value
0～39 KG
cause pressure signal
and the
Harness ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
standard
short OFF position for fault diagnosis.
value 2
under circuit Between the harness between controller pin 70 and A Resistance
normal (ground) Above 1 MΩ
of CN-126M and ground value
conditions
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
Harness OFF position for fault diagnosis.
3 open
circuit Resistance
Between pin 54 of controller and B of CN-126M Below 1 Ω
value
Controller The fault diagnosis cannot be carried out because it is an internal fault. (If the fault is not
4
fault caused by the above cause, the controller shall be deemed to be defective)

Controller

Boom lifting pressure

sensor
Boom lifting pressure Signal
sensor
Sensor ground wire Ground wire

Sensor 5 V

Body harness

Fig. 7-95
7

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
E-8 The arm movement is slow and powerless
Fault information The arm movement is slow and powerless when the excavator moves
The pilot pressure signal during arm movement can be read from the
Relevant information
display

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and then restart it
and keep the engine running for fault diagnosis.
Sensor Turn the control lever to the neutral position, and transmit
1 0 KG
fault arm digging and unloading pressure signal Pressure
Operate the control lever, and transmit arm digging and value
0～39 KG
Predicted unloading pressure signal
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
and the OFF position for fault diagnosis.
standard Harness
value short Between the harness between controller pin 71 and A of
2
under circuit CN-128M and ground Resistance
(ground) Above 1 MΩ
normal Between the harness between controller pin 52 and A of value
conditions CN-122M and ground
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
Harness OFF position for fault diagnosis.
3 open
circuit Between pin 54 of controller and B of CN-128M Resistance
Below 1 Ω
Between pin 54 of controller and B of CN-122M value
Controller The fault diagnosis cannot be carried out because it is an internal fault. (If the fault is not
4
fault caused by the above cause, the controller shall be deemed to be defective)

Arm unloading pressure

sensor
Signal

Ground wire

Controller

Arm unloading pressure Arm digging pressure

sensor sensor
Arm digging pressure
Signal
sensor
Sensor ground wire
Ground wire

Sensor 5 V

Body harness

Fig. 7-96

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
E-9 The bucket movement is slow and powerless
The bucket movement is slow and powerless when the excavator
Fault information
moves
The pilot pressure signal during bucket movement can be read
Relevant information
from the display

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and then restart it
and keep the engine running for fault diagnosis.
Sensor Turn the control lever to the neutral position, and transmit
1 0 KG
fault bucket digging and unloading pressure signal Pressure
Operate the control lever, and transmit bucket digging value
0～39 KG
and unloading pressure signal
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
Predicted Harness OFF position for fault diagnosis.
cause short Between the harness between controller pin 69 and A of
2
and the circuit CN-124M and ground Resistance
standard (ground) Above 1 MΩ
Between the harness between controller pin 50 and A of value
value
CN-127M and ground
under
normal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
conditions Harness OFF position for fault diagnosis.
3 open
circuit Between pin 54 of controller and B of CN-124M Resistance
Below 1 Ω
Between pin 54 of controller and B of CN-127M value

Bucket ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
converging OFF position for fault diagnosis.
4
solenoid Resistance
valve fault Between 1 and 2 of CN-134F About 17.5 Ω
value
Controller The fault diagnosis cannot be carried out because it is an internal fault. (If the fault is not
5
fault caused by the above cause, the controller shall be deemed to be defective)

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

Bucket unloading
pressure sensor
Signal

Ground wire

Controller

Bucket unloading Bucket digging

pressure sensor pressure sensor
Bucket digging Signal
pressure sensor
Sensor ground wire Ground wire

Sensor 5 V

Bucket converging
signal

Bucket converging
proportional valve
Signal

Ground wire

Body harness

Fig. 7-97

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
E-10 The traveling is slow and powerless
The bucket movement is slow and powerless when the excavator
Fault information
moves
The pilot pressure signal during traveling can be read from the
Relevant information
display

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and then restart it and
keep the engine running for fault diagnosis.
Sensor Turn the control lever to the neutral position, and transmit
1 0 KG
fault left/right traveling pressure signal Pressure
Operate the control lever, and transmit left/right traveling value
0～39KG
Predicted pressure signal
cause ★Turn the engine starting switch to the OFF position for preparation, and keep it in the OFF
and the position for fault diagnosis.
standard Harness
value short Between the harness between controller pin 49 and A of
2
under circuit CN-120M and ground Resistance
(ground) Above 1 MΩ
normal Between the harness between controller pin 67 and A of value
conditions CN-121M and ground
★Turn the engine starting switch to the OFF position for preparation, and keep it in the OFF
Harness position for fault diagnosis.
3 open
circuit Between pin 54 of controller and B of CN-120M Resistance
Below 1 Ω
Between pin 54 of controller and B of CN-121M value
Controller The fault diagnosis cannot be carried out because it is an internal fault. (If the fault is not
4
fault caused by the above cause, the controller shall be deemed to be defective)

Right traveling pressure

sensor
Signal

Ground wire

Controller

Left traveling pressure

Right traveling
sensor
pressure sensor
Left traveling Signal
pressure sensor
Sensor ground wire Ground wire
Sensor 5 V

Body harness 7

Fig. 7-98

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
E-11 The display is blank
Fault information The display is blank after the excavator is powered on
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value
Predicted
★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause
ON position for fault diagnosis.
and the
1 Fuse fault
standard Between 22# wire and ground Voltage About 24V
value value
under Between 29# wire and ground About 24V
normal Display
conditions The fault diagnosis cannot be carried out because it is an internal fault. (If the fault is not
2 screen
caused by the above cause, the display shall be deemed to be defective)
fault

Controller
Display screen

Power
management
module

Fig. 7-99

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
E-12 The display has no display
The display is on, but there is no display information after
Fault information
the excavator is powered on
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the OFF
Resistance position for fault diagnosis.
1
fault Resistance
Between 1 and 2 of CN-210 120 Ω
value

Predicted ★Turn the engine starting switch to the OFF position for preparation, and it in the OFF
cause Wire position for fault diagnosis.
and the 2 disconnection
fault
Between 3# pin of CN-701 and 60# pin of controller Resistance Below 1 Ω
standard
Between pin 4 of CN-701 and pin 78 of controller value Below 1 Ω
value
under ★Turn the engine starting switch to the OFF position for preparation, and it in the OFF
normal position for fault diagnosis.
conditions Wire short
3 Between 3# pin of CN-701 and 60# pin of controller
circuit Resistance Above 1 MΩ
and ground
value
Between pin 4 of CN-701 and pin 78 of controller Above 1 MΩ
Display or
controller The fault diagnosis cannot be carried out because it is an internal fault. (If the fault is not
4
caused by the above cause, the display or controller shall be deemed to be defective)
fault

Controller
Display screen

Power
management
module

Fig. 7-100

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
E-13 The high/low traveling speed is disabled
The excavator is only available for low traveling speed
Fault information
during operation
Operate the high/low traveling speed key of the display to
Relevant information
realize high/low speed switching

Reason Standard value under normal conditions and fault diagnosis reference value
Fault of ★Turn the engine starting switch to the OFF position for preparation, and it in the OFF
high/low position for fault diagnosis.
speed
1
traveling Resistance
Predicted solenoid Between A and B of CN-131F About 17.5 Ω
cause value
valve
and the
standard ★Turn the engine starting switch to the OFF position for preparation, and it in the OFF
value Wire position for fault diagnosis.
under 2 disconnection
Between pin A of CN-132F and pin 100 of controller Resistance Below 1 Ω
normal fault
conditions Between B# pin of CN-132F and 55# pin of controller value Below 1 Ω
★Turn the engine starting switch to the OFF position for preparation, and it in the OFF
Wire short position for fault diagnosis.
3
circuit Between A# pin of CN-131F and 100# pin harness of Resistance
Above 1 MΩ
controller and ground value
Controller

漏译

漏译 Signal

Ground wire Ground wire

Body harness

Fig. 7-101

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
E-15 The display of fuel level is inaccurate
The fuel level sensor of the engine cannot accurately reflect
Fault information
the current oil level
Relevant information The fuel level can be read from the display

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the OFF
position for fault diagnosis.
Oil level Pin Fuel level Resistance value
1
sensor fault
Full (upper limit) Approx. 10 Ω
Between 509# and ground
Empty (lower limit) 85-95 Ω
Predicted
cause ★Turn the engine starting switch to the OFF position for preparation, and it in the OFF
Wire position for fault diagnosis.
and the 2 disconnection
standard fault Resistance
value Between 509# wire and 11# pin of controller Below 1 Ω
value
under
normal ★Turn the engine starting switch to the OFF position for preparation, and it in the OFF
Wire short position for fault diagnosis.
conditions
3 circuit
(grounding) Resistance
Between 509# wire and ground Above 1 MΩ
value

★Turn the engine starting switch to the OFF position for preparation, and turn and keep
Short circuit it in the ON position for fault diagnosis.
4 of wire and
24 V Voltage
509# wire to ground Below 1 V
value
Controller

Fuel level sensor

Body harness

Fig. 7-102
7

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
E-16 The wiper doesn’t work
Fault information The wiper doesn’t work after operation
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the OFF
Internal fault position for fault diagnosis.
1 of wiper
motor Resistance
Between 25# wire of wiper and ground More than 10 Ω
value
Predicted
★Turn the engine starting switch to the OFF position for preparation, and it in the OFF
cause
position for fault diagnosis.
and the
standard Wire Between 1 of CN-241F and 2 of CN-1-110 Below 1 Ω
value 2 disconnection Between 35L# wire of wiper switch and 5 of
under fault Resistance Below 1 Ω
normal CN-1-110
value
conditions Between 35H# wire of wiper switch and 4 of
Below 1 Ω
CN-1-110
★Turn the engine starting switch to the OFF position for preparation, and it in the OFF
Wire short position for fault diagnosis.
3 circuit
(grounding) Between harness between 1 of CN-241F and 2 of Resistance
Above 1 MΩ
CN-1-110 and ground value
24 V power supply

Power management
module Operation
panel

Body harness

Fig. 7-103

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
E-17 The display of arm digging pilot pressure is inaccurate
Fault information The display of arm digging pilot pressure is inaccurate
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value

5 V ★Turn the engine starting switch to the OFF position for preparation, and it in the ON
power position for fault diagnosis.
1
supply Voltage
fault Between ① and ③ of CN-128M About 5V
value
Predicted Signal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause wire OFF position for fault diagnosis.
and the 2
open Resistance
standard circuit Between ② of CN-128M and controller 71 pin Below 1 Ω
value
value
under Signal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal wire OFF position for fault diagnosis.
conditions 3
short Resistance
circuit Between ② of CN-128M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between ② of CN-128M and ground 0.5V～ 4.5V
value

Controller

Arm digging pressure

sensor
Arm digging pressure Signal
sensor
Sensor ground wire
Ground wire

Sensor 5 V

Body harness

Fig. 7-104

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
E-18 The display of arm unloading pilot pressure is inaccurate
Fault information The display of arm unloading pilot pressure is inaccurate
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value

5 V ★Turn the engine starting switch to the OFF position for preparation, and it in the ON
power position for fault diagnosis.
1
supply Voltage
fault Between ① and ③ of CN-122M About 5V
value
Predicted Signal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the OFF
cause wire position for fault diagnosis.
and the 2
open Resistance
standard circuit Between ② of CN-122M and controller 52 pin Below 1 Ω
value
value
under Signal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the OFF
normal wire position for fault diagnosis.
conditions 3
short Resistance
circuit Between ② of CN-122M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between ② of CN-122M and ground 0.5V～ 4.5V
value

Controller

Arm unloading
pressure sensor
Arm unloading Signal
pressure sensor
Sensor ground wire
Ground wire

Sensor 5 V

Body harness

Fig. 7-105

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
E-19 The display of boom lifting pilot pressure is inaccurate
Fault information The display of boom lifting pilot pressure is inaccurate
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value

5 V ★Turn the engine starting switch to the OFF position for preparation, and it in the ON
power position for fault diagnosis.
1
supply Voltage
fault Between ① and ③ of CN-126M About 5V
value
Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause Signal OFF position for fault diagnosis.
and the 2 wire open
circuit Resistance
standard Between ② of CN-126M and controller 70 pin Below 1 Ω
value
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal OFF position for fault diagnosis.
conditions 3 wire short
circuit Resistance
Between ② of CN-126M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between ② of CN-126M and ground 0.5V～ 4.5V
value
Controller

Boom lifting pressure

sensor
Boom lifting pressure Signal
sensor
Sensor ground wire
Ground wire

Sensor 5 V

Body harness

Fig. 7-106

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
E-20 The display of boom drop pilot pressure is inaccurate
Fault information The display of boom drop pilot pressure is inaccurate
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value

5 V ★Turn the engine starting switch to the OFF position for preparation, and it in the ON
power position for fault diagnosis.
1
supply Voltage
fault Between ① and ③ of CN-125M About 5V
value
Predicted Signal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause wire OFF position for fault diagnosis.
and the 2
open Resistance
standard circuit Between ② of CN-125M and controller 51 pin Below 1 Ω
value
value
under Signal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal wire OFF position for fault diagnosis.
conditions 3
short Resistance
circuit Between ② of CN-125M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between ② of CN-125M and ground 0.5V～4.5V
value

Controller

Boom drop pressure

sensor
Boom drop pressure Signal
sensor
Sensor ground wire
Ground wire

Sensor 5 V

Body harness

Fig. 7-107

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
E-21 The display of bucket digging pilot pressure is inaccurate
Fault information The display of bucket digging pilot pressure is inaccurate
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value

5 V ★Turn the engine starting switch to the OFF position for preparation, and it in the ON
power position for fault diagnosis.
1
supply Voltage
fault Between ① and ③ of CN-124M About 5V
value
Predicted Signal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause wire OFF position for fault diagnosis.
and the 2
open Resistance
standard circuit Between ② of CN-124M and controller 69 pin Below 1 Ω
value
value
under Signal ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal wire OFF position for fault diagnosis.
conditions 3
short Resistance
circuit Between ② of CN-124M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between ② of CN-124M and ground 0.5V～ 4.5V
value

Controller

Bucket digging
pressure sensor
Bucket digging Signal
pressure sensor
Sensor ground wire
Ground wire

Sensor 5 V

Body harness

Fig. 7-108

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
E-22 The display of bucket unloading pilot pressure is inaccurate
Fault information The display of bucket unloading pilot pressure is inaccurate
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value

5 V ★Turn the engine starting switch to the OFF position for preparation, and it in the ON
power position for fault diagnosis.
1
supply Voltage
fault Between ① and ③ of CN-127M About 5V
value
Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause Signal OFF position for fault diagnosis.
and the 2 wire open
circuit Resistance
standard Between ② of CN-127M and controller 50 pin Below 1 Ω
value
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal OFF position for fault diagnosis.
conditions 3 wire short
circuit Resistance
Between ② of CN-127M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between ② of CN-127M and ground 0.5V～ 4.5V
value

Controller

Bucket unloading
pressure sensor
Bucket unloading Signal
pressure sensor
Sensor ground wire
Ground wire

Sensor 5 V

Body harness

Fig. 7-109

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
E-23 The display of swing pilot pressure is inaccurate
Fault information The display of swing pilot pressure is inaccurate
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1 supply
fault Voltage
Between ① and ③ of CN-123M About 5V
value
Predicted ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
cause Signal OFF position for fault diagnosis.
and the 2 wire open
circuit Resistance
standard Between ② of CN-123M and controller 68 pin Below 1 Ω
value
value
under ★Turn the engine starting switch to the OFF position for preparation, and keep it in the
normal Signal OFF position for fault diagnosis.
conditions 3 wire short
circuit Resistance
Between ② of CN-123M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between ② of CN-123M and ground 0.5V～ 4.5V
value

Controller

Swing pilot pressure

sensor
Swing pilot pressure Signal
sensor
Sensor ground wire
Ground wire

Sensor 5 V

Body harness

Fig. 7-110

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 Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
E-24 The display of left traveling pilot pressure is inaccurate
Fault information The display of left traveling pilot pressure is inaccurate
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value
Predicted cause and the standard value under normal

★Turn the engine starting switch to the OFF position for preparation, and it in the ON
5 V power position for fault diagnosis.
1 supply
fault Voltage
Between ① and ③ of CN-120M About 5V
value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the OFF
Signal wire position for fault diagnosis.
2 open
conditions

circuit Resistance
Between ② of CN-120M and controller 49 pin Below 1 Ω
value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the OFF
Signal wire position for fault diagnosis.
3 short
circuit Resistance
Between ② of CN-120M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON
Sensor position for fault diagnosis.
4
fault Voltage
Between ② of CN-120M and ground 0.5V～ 4.5V
value

Controller

Left traveling pilot

pressure sensor
Left traveling pilot Signal
pressure sensor
Sensor ground wire
Ground wire

Sensor 5 V

Body harness

Fig. 7-111

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 SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
E-25 The display of right traveling pilot pressure is inaccurate
Fault information The display of right traveling pilot pressure is inaccurate
Relevant information

Reason Standard value under normal conditions and fault diagnosis reference value
Predicted cause and the standard value under normal

★Turn the engine starting switch to the OFF position for preparation, and it in the ON position
5 V power for fault diagnosis.
1 supply
fault Voltage
Between ① and ③ of CN-121M About 5V
value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the OFF
Signal wire position for fault diagnosis.
2 open
conditions

circuit Resistance
Between ② of CN-121M and controller 67 pin Below 1 Ω
value
★Turn the engine starting switch to the OFF position for preparation, and keep it in the OFF
Signal wire position for fault diagnosis.
3 short
circuit Resistance
Between ② of CN-121M and ground Above 2 MΩ
value
★Turn the engine starting switch to the OFF position for preparation, and it in the ON position
Sensor for fault diagnosis.
4
fault Voltage
Between ② of CN-121M and ground 0.5V～ 4.5V
value

Controller

Right traveling pilot

pressure sensor
Right traveling pilot Signal
pressure sensor
Sensor ground wire
Ground wire

Sensor 5 V

Body harness

Fig. 7-112

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
Fault diagnosis of hydraulic and mechanical system (H fault category)
Table of Hydraulic and Mechanical System

Left pilot valve Travel pilot valve Right pilot valve

Arm Swing Left Right Boom Bucket

traveling traveling

Forward

Forward
Unloading

Unloading
Digging

Revers

Revers

Digging
Lower
Right
Left

Lift
e

e
Pilot valve
lock

Boom priority

Bucket converging

Swing priority

Traveling
speed control

Accumulator

Regulator Regulator

Servo Servo
mechanism mechanism

Fig. 7-113

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting
★ The system table is drawn after simplification of the whole hydraulic lines table, which can be used
as a reference for fault diagnosis of hydraulic system and mechanical system.

Sa: Safety valve

Su: Suction valve
S&S: Safety and
suction valve

Standby valve Bucket

converging connection
valve

Arm holding valve

Arm valve
With regeneration
valve
Arm 2 valve

Arm cylinder

Bucket cylinder Bucket Standby Standby actuator

valve valve
Boom holding
valve

Damping valve
Boom cylinder Boom Boom 2
valve
Swing motor

Damping valve
Left travel Swing
valve valve
Balancing valve

mechanism
Servo

Right traveling
valve
Straight
travel valve

Balancing valve

mechanism
Servo
Left travel motor

Right travel motor

Fig. 7-114

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 Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator
Information of the fault diagnosis table
★ The following information is included in the fault diagnosis table and relevant circuit diagram. Carry
out fault diagnosis only after the content is fully understood.
Fault information Phenomenon of the machine
Relevant information Information and diagnosis of existing fault

Standard value under normal conditions and fault diagnosis

Cause
Predicted cause and the standard

reference value
value under normal conditions

1
2

3 Predicted fault cause <Content>

(The serial number is for the • The standard values under normal conditions can be used to
4 convenience of compilation and determine if the cause is ―good‖ or ―poor‖
reference, but it doesn’t • The reference value can be used to determine if it is ―good‖ or
represent any priority) ―poor‖
5

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H-1 The work equipment moves slowly, or it has low traveling and rotation speed
Fault information ● The work equipment moves slowly, or it has low traveling and rotation
speed
Relevant information ● Set working mode to the S mode and the 10th gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
Predicted cause and the standard value under normal

value
★Stop the engine for preparation. Start fault diagnosis when the engine runs
at high idle speed.
Control lever Pressure of main relief valve
The main relief valve is
1 33~34.3 MPa
improperly adjusted or fails Arm ―digging‖
{337~350 kg/cm2}
conditions

If the pressure cannot return to normal conditions after adjustment, the main
relief valve may fail or internal fault may exist. In this case, check the valve.
★Stop the engine for preparation. Start fault diagnosis when the engine runs
at high idle speed.
2 Failure of pilot relief valve Control lever Pilot control pressure
All the control levers are in the 3.9~4.1 MPa
―neutral position‖ {40~42 kg/cm2}
3 Regulator failure The regulator may fail, and its servo mechanism shall be checked
The above cause is not discovered, the piston pump may have performance
4 Piston pump failure
deterioration and failure or internal fault may exist.

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 Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

H-2 The engine speed significantly drops or engine stalls

Fault information ● The engine speed significantly drops or engine stalls
Relevant information ● Relevant information.

Standard value under normal conditions and fault diagnosis reference

Cause
value
Predicted cause and the standard
value under normal conditions

1 Fuel injection pump fault The fuel injection pump may have fault. Check it.
2 Regulator failure The regulator may fail, and its servo mechanism shall be checked.
The fuel line blockage may be caused by blocking of fuel filter element.
3 Blocking of fuel filter element
Check it.
4 Carbon deposit of fuel nozzle The fuel nozzle may have carbon deposit. Check it.
5 Blocking of air filter The blocking of air filter may be caused by unsmooth intake. Check it.
6 Abnormal wear of engine The engine may have abnormal wear. Check it.

7 Fuel delivery pump fault The fuel delivery pump may have fault. Check it.

H-3 The work equipment has no movement, and traveling or swing function is
disabled
Fault information ● The work equipment has no movement, and traveling or swing function is
disabled.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
Predicted cause and the standard value under normal conditions

value
★Stop the engine for preparation. Start fault diagnosis when the engine runs
at high idle speed.

Failure of pilot safety solenoid Pilot safety lever Pilot relief pressure
1
valve Locking 0 {0}
3.9~4.1 MPa
Unlocking
{40~42 kg/cm2}
★Stop the engine for preparation. Start fault diagnosis when the engine runs
at high idle speed.
2 Fault of pilot pump relief valve Control lever Pilot relief pressure
All the control levers are in the 3.9~4.1 MPa
―neutral‖ position {40~42 kg/cm2}
The piston pump may have failure or internal fault. Diagnose it through
following methods.
3 Hydraulic pump fault
● Remove the oil pressure measuring plug and start the engine. If oil
flows out, it shall be normal.
The pump shaft cannot rotate due to internal fault of the coupler, check the
coupler.
4 Coupler fault
● If no oil flows out after the pilot pump outlet is released, the coupler may
have a fault.

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H-4 The hydraulic pump has unusual noise

Fault information ● Abnormal sound can be heard around the hydraulic pump.
Relevant information ―

Standard value under normal conditions and fault diagnosis reference

Cause
Predicted cause and the standard

value
value under normal conditions

1 The hydraulic oil level drops Visual inspection

2 The hydraulic oil is poor The oil may be mixed with air. Visual inspection.
The ventilator of the top cap of the hydraulic tank may be blocked, resulting in
Blocking of ventilator of the negative pressure in the tank.
3
top cap of the hydraulic tank Press down the release valve of the breathing valve, and check the sound
disappears.
The filter screen of the hydraulic tank may be blocked, resulting in negative
Blocking of filter screen of the pressure in the suction tank.
4
hydraulic tank
Carry out visual inspection.
5 Piston pump fault The piston pump may have internal fault. Check it.

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 Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

H-5 It runs idly automatically and doesn’t work

Fault information ● It runs idly automatically and doesn’t work
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Cause Standard value under normal conditions and fault diagnosis reference value
Predicted cause and the standard value under

★Stop the engine for preparation. Start fault diagnosis when the engine runs at high
idle speed.
All the control levers Pilot valve output pressure
1 Sensor failure
―Neutral position‖ 0 {0}
normal conditions

3.5~4.1MPa
Operation
{36~42 kg/cm2}
★Stop the engine for preparation. Start fault diagnosis when the engine runs at high
idle speed.
All the control levers Pilot valve output pressure
2 Pilot valve failure
―Neutral position‖ 0 {0}
3.5~4.1MPa
Operation
{36~42 kg/cm2}
3 Controller fault The controller may have fault. Check it.

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H-6 The boom moves slowly

Fault information ● The boom moves slowly.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
value
★Stop the engine for preparation. Start fault diagnosis when the engine
Predicted cause and the standard value under normal conditions

runs at high idle speed.

Failure of right pilot valve (on Boom control lever Pilot valve output pressure
1
the boom oil line) ―Neutral position‖ 0 {0}
Above 3.5MPa
―Lifting‖ or ―drop‖
{36 kg/cm2}
★Stop the engine for preparation. Start fault diagnosis when the engine
2 Pressure sensor fault runs at high idle speed.
Replace the old part with a new one for inspection
Failure of boom control valve
3 The boom control valve spool may have failure. Check the valve.
(spool)
Failure of boom control valve The holding valve of the boom control valve may have failure. Check the
4
(holding valve) valve.
Boom control valve (safety
The safety valve and refilling valve of the boom control valve may have
5 valve and refilling valve)
failure or the seal may have fault. Check these valves.
failure or seal failure
★Stop the engine for preparation. Start fault diagnosis when the engine
runs at high idle speed.
The bucket load is about 1,260 kg load. Cut off the oil line on high pressure
6 Boom cylinder fault cavity side of the cylinder, disconnect its connection with the main valve,
and measure the piston displacement for 15 minutes after cylinder becomes
stable. If its value is larger than 10 mm, the cylinder seal fault can be
determined. For detailed measurement methods, see the ―Inspection of
Hydraulic Drift of Work Equipment‖ (page 4-26).

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

H-7 The arm moves slowly

Fault information ● The arm moves slowly.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
value
★Stop the engine for preparation. Start fault diagnosis when the engine
Predicted cause and the standard value under normal conditions

runs at high idle speed.

Failure of left pilot valve (arm Arm control lever Pilot valve output pressure
1
oil line) ―Neutral position‖ 0 {0}
Above 3.5MPa
―Digging‖ or ―Unloading‖
{36 kg/cm }
★Stop the engine for preparation. Start fault diagnosis when the engine
2 Pressure sensor fault runs at high idle speed.
Replace the old part with a new one for inspection
Failure of arm control valve
3 The arm control valve spool may have failure. Check the valve.
(spool)
Failure of arm control valve The regeneration valve of arm control valve may have failure. Check the
4
(regeneration valve) valve.
Arm control valve (safety valve
The safety valve and refilling valve of the arm control valve may have failure
5 and refilling valve) failure or
or the seal may have fault. Check it.
seal failure
★Stop the engine for preparation. Start fault diagnosis when the engine
runs at high idle speed.
For detailed measurement methods, see the ―Inspection of Hydraulic Drift of
6 Arm cylinder fault Work Equipment‖ (page 4-26). Cut off the oil line on high pressure cavity
side of the cylinder, disconnect its connection with the main valve, and
measure the piston displacement for 15 minutes after cylinder becomes
stable. If its value is larger than 10 mm, the cylinder seal fault can be
determined.

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H-8 The bucket moves slowly

Fault information ● The bucket moves slowly.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
value
Predicted cause and the standard value under normal conditions

★Stop the engine for preparation. Start fault diagnosis when the engine
runs at high idle speed.

Failure of right pilot valve Bucket control lever Pilot valve output pressure
1
(bucket oil line) ―Neutral position‖ 0 {0}
Above 3.5MPa
―Digging‖ or ―Unloading‖
{36 kg/cm }
★Stop the engine for preparation. Start fault diagnosis when the engine
2 Pressure sensor fault runs at high idle speed.
Replace the old part with a new one for inspection
Failure of bucket control valve
3 The bucket control valve spool may have failure. Check the valve.
(spool)
Arm control valve (safety valve
The safety valve and refilling valve of the bucket control valve may have
4 and refilling valve) failure or
failure or the seal may have fault. Check it.
seal failure
★Stop the engine for preparation. Start fault diagnosis when the engine
runs at high idle speed.
The bucket load is about 1,260 kg load. Cut off the oil line on high pressure
5 Bucket cylinder fault cavity side of the cylinder, disconnect its connection with the main valve,
and measure the piston displacement for 15 minutes after cylinder becomes
stable. If its value is larger than 10 mm, the cylinder seal fault can be
determined. For detailed measurement methods, see the ―Inspection of
Hydraulic Drift of Work Equipment‖ (page 4-26).

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 Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

H-9 The single cylinder of the work equipment has no movement

● The boom cylinder has no movement in case of independent operation.
Fault information ● The arm cylinder has no movement in case of independent operation.
● The bucket cylinder has no movement in case of independent operation.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
Predicted cause and the standard value

value
★Stop the engine for preparation. Start fault diagnosis when the engine
under normal conditions

runs at high idle speed.

Work equipment control lever Pilot valve output pressure
1 Pilot valve failure
―Neutral position‖ 0 {0}
Above 3.5MPa
―Digging‖ or ―Unloading‖
{36 kg/cm2}
★Stop the engine for preparation. Start fault diagnosis when the engine
2 Pressure sensor fault runs at high idle speed.
Replace the old part with a new one for inspection
Failure of work equipment
3 The work equipment control valve spool may have failure. Check the valve.
control valve (spool)

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H-10 The cylinder drift of the work equipment is too large

Fault information (1) ● The boom sinks too quickly.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
Predicted cause and the standard value

value
★Stop the engine for preparation. Start fault diagnosis when the engine
runs at high idle speed.
under normal conditions

The bucket load is about 1,260 kg load. Cut off the oil line on high pressure
1 Boom cylinder fault cavity side of the cylinder, disconnect its connection with the main valve, and
measure the piston displacement for 15 minutes after cylinder becomes
stable. If its value is larger than 10 mm, the cylinder seal fault can be
determined. For detailed measurement methods, see the ―Inspection of
Hydraulic Drift of Work Equipment‖ (page 4-26).
2 Boom holding valve fault The boom holding valve and pilot valve may be worn out or seized. Check it.
Failure of boom control valve
The seal of the safety valve and refilling valve of the boom control valve may
3 (safety valve and refilling
have failure. Check it.
valve)
4 Boom valve spool fault The boom valve spool may be worn out. Check it.

Fault information (2) ● The arm sinks too quickly.

th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
Predicted cause and the standard value under

value
★Stop the engine for preparation. Start fault diagnosis when the engine runs
at high idle speed.
For detailed measurement methods, see the ―Inspection of Hydraulic Drift of
1 Arm cylinder fault Work Equipment‖ (page 4-26). Cut off the oil line on high pressure cavity
normal conditions

side of the cylinder, disconnect its connection with the main valve, and
measure the piston displacement for 15 minutes after cylinder becomes
stable. If its value is larger than 10 mm, the cylinder seal fault can be
determined.
The seal of the safety valve and refilling valve of the arm control valve may
Failure of seal of the arm have failure. Check it.
2 control valve (safety valve and ★The failure of the seal can be determined by replacing other safety valves
refilling valve) and refilling valves. (Do not replace it with the boom ―Drop‖ safety valve
and refilling valve, for the setting pressure is different.)
7
3 Arm holding valve fault The arm holding valve and pilot valve may be worn out or seized. Check it.
4 Arm valve spool fault The arm valve spool may be worn out. Check it.

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 Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

Fault information (3) ● The bucket sinks too quickly.

th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Predicted cause and the standard value

Cause
value
★Stop the engine for preparation. Start fault diagnosis when the engine
under normal conditions

runs at high idle speed.

1 Bucket cylinder fault
Bucket control lever Oil leakage of cylinder
Digging overflow 20 ml/min
The seal of the safety valve and refilling valve of the bucket control lever
Failure of seal of the bucket may have failure. Check the seal.
2 control valve (safety valve and ★The failure of the seal can be determined by replacing other safety valves
refilling valve) and refilling valves. (Do not replace it with the boom ―Drop‖ safety
valve and refilling valve, for the setting pressure is different.)
Failure of seal of the bucket
3 The seal of the bucket control valve spool may have failure. Check it.
control valve (spool)

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 SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

H-11 The work equipment moves slowly

Fault information ● The work equipment moves slowly
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Cause Standard value under normal conditions and fault diagnosis reference value
Predicted cause and the standard
value under normal conditions

Arm regeneration valve

1 The arm regeneration valve may have failure. Check it.
failure

The safety valve and refilling valve of the control valve may have failure. Check it.
Failure of the control ★ For the arm and boom, the failure of the valve can be determined by
2 valve (safety valve and replacing other safety valves and refilling valves.
refilling valve) (Do not replace it with the boom ―Drop‖ safety valve and refilling valve, for the
setting pressure of each valve is different.)

H-12 Other work equipment moves when a single oil line has an overflow
● Other work equipment moves when a single oil line of the specific work equipment
Fault information
has an overflow.
Relevant information ● Set working mode to the S mode for fault diagnosis.
Predicted cause and the standard
value under normal conditions

Cause Standard value under normal conditions and fault diagnosis reference value

Failure of seal of the

1 The seal of the control valve may have failure. Check it.
control valve

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 Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

H-13 The traveling speed drops obviously during rotation+traveling

Fault information ● The traveling speed drops obviously during rotation+traveling
● If the traveling speed is low in a single traveling operation, the H-15 inspection
Relevant information
can be carried out first.
Predicted cause and the standard

Standard value under normal conditions and fault diagnosis reference

value under normal conditions

Cause
value

The straight travel valve has no movement, check the valve spool and the
1 Straight travel valve fault
logical oil line outlet

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SY215CCM3K Hydraulic Excavator Fault Diagnosis and Troubleshooting

H-14 The machine has off-tracking during traveling

Fault information ● The machine has off-tracking tendency during traveling
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Cause Standard value under normal conditions and fault diagnosis reference value
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.

Traveling pilot valve Travel lever Pilot valve output pressure

1
failure 3.5~3.9 MPa
Forward or backward
{ 36~40 kg/cm2}
The left/right outputs are different 0.4 MPa {4 kg/cm2}
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
Failure of pilot relief
Predicted cause and the standard value under normal conditions

2 Control lever Control oil line source pressure

valve
All the control levers are in the ―neutral 3.5~3.9 MPa
position‖ { 36~40 kg/cm2}
3 Regulator fault It can be checked by exchanging the front and rear regulators
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
Seizure of proportional
4 Travel lever Proportioning valve output pressure
solenoid valve
The difference is not larger than 0.1
Operate both sides
MPa
Seizure of traveling
5 Check whether the valve spool moves flexibly
valve spool
Internal leakage of
6 It can be checked by exchanging the pipes
central swing connector
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
7 Travel motor failure
Travel lever Oil leakage of travel motor
Traveling overflow 27.2 ml/min
The final drive may have internal fault. Check inside of the final drive directly.
8 Final drive fault ★ The internal failure of the final drive can be determined by unusual noise,
abnormal heat and metal powder or debris in the oil.
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
Travel lever Pilot valve output pressure
7
Fault of traveling pilot The 3.5~3.9 MPa is displayed on the
9
pressure sensor Forward or backward display
{ 36~40 kg/cm2}
The left/right outputs are different 0.4 MPa {4 kg/cm2}
It can be checked by exchange

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Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

H-15 The machine travels at low speed

Fault information ● The machine has low traveling speed.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
value
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
Travel lever Pilot valve output pressure
1 Traveling pilot valve failure 3.5~3.9 MPa
Forward or backward
{ 36~40 kg/cm2}
The left/right or front/rear outputs are Below 0.4 MPa
Predicted cause and the standard value under normal conditions

2
different {Below 4 kg/cm }
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
2 Failure of pilot relief valve Control lever Control oil line source pressure
All the control levers are in the ―neutral 3.5~3.9 MPa
position‖ { 36~40 kg/cm2}
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
The pressure is
Traveling speed Travel lever displayed on the
display
3 Sensor fault 3.5~3.9 MPa
Low speed Operation
{ 36~40 kg/cm2}
3.5~3.9 MPa
High speed Operation
{ 36~40 kg/cm2}
It can be checked by exchanging the parts
Failure of traveling control
4 The traveling control valve spool may have failure. Check the valve spool.
valve (spool)
Failure of traveling control The refilling valve of the traveling control valve may have failure. Check the
5
valve (refilling valve) valve.
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
6 Travel motor fault
Travel lever Oil leakage of travel motor
Traveling overflow 27.2 ml/min
The final drive may have internal fault. Check inside of the final drive directly.
7 Final drive fault ★ The internal failure of the final drive can be determined by unusual noise,
abnormal heat and metal powder or debris in the oil.

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H-16 The machine is hard to turn or powerless

Fault information ● The machine is hard to turn.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
value
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
Predicted cause and the standard value under normal conditions

Travel lever Pilot valve output pressure

1 Traveling pilot valve failure
On ―neutral position‖ on both sides 0 {0}
3.5~3.9 MPa
Operate only on one side
{ 36~40 kg/cm2}
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
Travel lever Solenoid valve output pressure
Failure of traveling pilot
2 3.5~3.9 MPa
pressure sensor Operate both sides
{ 36~40 kg/cm2}
3.5~3.9 MPa
Operate only on one side
{ 36~40 kg/cm2}
Failure of traveling control
3 The traveling control valve spool may have failure. Check the valve spool.
valve (spool)
Failure of traveling control The refilling valve of the traveling control valve may have failure. Check the
4
valve (refilling valve) valve.
The internal seal of the safety valve of the travel motor may have failure. Check
Failure of travel motor the seal.
5
(safety valve) ★The failure of the seal can be determined by replacing front/rear or left/right
motors.
The internal seal of the check valve of the travel motor may have failure. Check
Failure of travel motor the seal.
6
(check valve) ★The failure of the seal can be determined by replacing front/rear or left/right
motors.

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H-17 The traveling speed cannot be shifted

Fault information ● The traveling speed cannot be shifted.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Predicted cause and the standard

Cause
value under normal conditions

value
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
Solenoid valve output
Failure of high/low speed Traveling speed Travel lever
1 pressure
changeover solenoid valve
Low speed Operation 0 {0}
3.5~3.9 MPa
High speed Operation
{ 36~40 kg/cm2}
Fault of travel motor
2 The travel motor may have speed shift fault Directly check the speed shift part.
(speed shift)

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H-18 It cannot travel (only on one side)

Fault information ● The track shoe can't turn (only on one side).
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
value
Predicted cause and the standard value under normal conditions

Fault of traveling control The refilling valve seat of the traveling control valve may have fault. Check the
1
valve (refilling valve) seat valve seat.
Fault of travel motor
2 The safety valve seat of the travel motor may have fault. Check the valve seat.
(safety valve) seat
Fault of travel motor
3 The check valve seat of the travel motor may have fault. Check the valve seat.
(refilling valve) seat
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
Deceleration of the travel high idle speed.
4
motor Travel lever Oil leakage of travel motor
Traveling overflow 27.2 ml/min
The final drive may have internal fault. Check inside of the final drive directly.
5 Final drive fault ★ The internal failure of the final drive can be determined by unusual noise,
abnormal heat and metal powder or debris in the oil.
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
Travel lever Pilot valve output pressure
Fault of pilot pressure The 3.5~3.9 MPa is displayed on the
6
sensor Forward or backward display
{ 36~40 kg/cm2}
The left/right outputs are different 0.4 MPa {4 kg/cm2}
It can be checked by exchange

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H-19 The machine cannot swing

Fault information (1) ● The machine cannot turn left and right.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
value
Predicted cause and the standard value under normal

Failure of swing motor

1 The parking brake part of the swing motor have failure. Check it directly.
(parking brake)
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.

The swing valve (safety Swing control lever Swing relief pressure
2 valve) is improperly 25.5~28.5 MPa
adjusted or fails Swing overflow
conditions

{260~291 kg/cm2}
If the oil pressure cannot return to normal conditions after adjustment, the safety
valve may fail or internal fault may exist. Check the valve.
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
3 swing motor fault
Swing control lever Oil leakage of swing motor
Swing overflow Above 10 ml/min
The upper structure may have internal fault. Directly check inside of the upper
structure.
4 Upper structure fault
★ The internal failure of the upper structure can be determined by unusual
noise, abnormal heat and metal powder or debris in the oil.

Fault information (2) ● The machine cannot turn in one direction.

th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
value
Predicted cause and the standard
value under normal conditions

★ Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
1 Pilot valve failure Left control lever Pilot valve output pressure
―Neutral position‖ 0 {0}
2
Swing operation Above 3.5 MPa {above 36 kg/cm }
Failure of the swing control
2 The swing control valve spool may have failure. Check the valve spool.
valve (spool)
The seal of the swing motor refilling valve may have failure. Check the seal.
Failure of seal of the swing
3
motor (refilling valve) ★ Determine whether the seal fails by exchanging left/right refilling valves and
observing for changes.

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H-20 It has low swing acceleration performance or low swing speed

Fault information (1) ● It has low swing acceleration performance or low swing speed
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
Predicted cause and the standard value under normal

value
Failure of swing motor
1 The parking brake part of the swing motor have failure. Check it directly.
(parking brake)
★Stop the engine for preparation. Start fault diagnosis when the engine runs
at high idle speed.
Swing control lever swing relief valve
The swing valve (safety
25.5~28.5 MPa
conditions

2 valve) is improperly Swing overflow

adjusted or fails {260~291 kg/cm2}
If the oil pressure cannot return to normal conditions after adjustment, it can be
predicted that the safety valve may fail or internal fault may exist. Check the
valve.
★Stop the engine for preparation. Start fault diagnosis when the engine runs
at high idle speed.
3 swing motor fault
Swing control lever Oil leakage of swing motor
Swing overflow 10 ml/min or below
Blocking of the brake
4 Remove and clean it for inspection.
control pipe

● It has low swing acceleration performance only on one side or low swing
Fault information (2)
speed
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
value
Predicted cause and the standard value under normal

★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
1 Pilot valve failure Swing control lever Pilot valve output pressure
―Neutral position‖ 0 {0}
2
Left or right Above 3.5 MPa {above 36 kg/cm }
Failure of swing motor
conditions

The pressure compensation valve of the swing motor may have failure. Check 7
2 (pressure compensation
it.
valve)
The seal of the swing motor refilling valve may have failure. Check the seal.
Failure of seal of the swing
3
motor (refilling valve) ★ Determine whether the seal fails according to the results by exchanging
left/right refilling valves.
★Stop the engine for preparation. Start fault diagnosis when the engine runs at
high idle speed.
Unilateral leakage of shuttle
4 valve of the swing pilot Swing control lever Pilot valve output pressure
pressure sensor ―Neutral position‖ 0 {0}
Left or right 3.5~3.9MPa {36~40 kg/cm2}

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H-21 The overrun is too large when swing stops

Fault information (1) ● The overrun of the work equipment is too large when swing stops
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
value
Predicted cause and the standard value

★Stop the engine for preparation. Start fault diagnosis when the engine runs
at high idle speed.
under normal conditions

Swing control lever Swing relief pressure

The travel motor (safety
1 valve) is improperly 25.5~28.5 MPa
Swing overflow
adjusted or fails {260~291 kg/cm2}
If the oil pressure cannot return to normal conditions after adjustment, it can be
predicted that the safety valve may fail or internal fault may exist. Check the
valve.
★Stop the engine for preparation. Start fault diagnosis when the engine runs
at high idle speed.
2 swing motor fault
Control lever Oil leakage of swing motor
Swing overflow 10 ml/min or below

● It has poor swing acceleration performance on one side or low swing

Fault information (2)
speed.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
value
Predicted cause and the standard
value under normal conditions

★Stop the engine for preparation. Start fault diagnosis when the engine runs
at high idle speed.
1 Pilot valve failure Swing control lever Pilot valve output pressure
―Neutral position‖ 0 {0}
2
Left or right Above 3.5 MPa {above 36 kg/cm }
Failure of the swing control
2 The swing control valve spool may have failure. Check it.
valve (spool)
The seal of the swing motor refilling valve may have failure. Check the seal.
Failure of seal of the swing
3
motor (refilling valve) ★ Determine whether the seal fails according to the results by exchanging
left/right refilling valves.

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H-22 The impact is too large when swing stops

Fault information ● It will generate too large impact when swing stops.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
Predicted cause and the standard

value
value under normal conditions

★Stop the engine for preparation. Start fault diagnosis when the engine runs
at high idle speed.
1 swing pilot valve failure Swing control lever Pilot valve output pressure
―Neutral position‖ 0 {0}
2
Left or right Above 3.5 MPa {above 36 kg/cm }
The swing damping valve may have failure. Check the valve.
Failure of swing damping
2
valve ★The failure of the valve can be determined by replacing old valves with new
ones.
3 Failure of swing relief valve The swing relief valve is worn out or seized.

H-23 The unusual noise is too loud when swing stops

Fault information ● The unusual noise is too loud when swing stops.
th
Relevant information ● Set working mode to the S mode and the 10 gear for fault diagnosis.

Standard value under normal conditions and fault diagnosis reference

Cause
Predicted cause and the standard

value
value under normal conditions

1 Backpressure valve failure The backpressure valve may have failure. Check it.
Failure of the swing valve
2 The safety valve of the swing motor may have failure. Check it.
(safety valve)
The seal of the swing motor refilling valve may have failure. Check the seal.
Failure of swing motor
3
(refilling valve) ★ Determine whether the seal fails according to the results by exchanging
left/right refilling valves.
The swing mechanical device may have internal fault. Check inside of the
swing mechanical device swing mechanical device.
4
fault ★ The internal failure of the upper structure can be determined by unusual
noise, abnormal heat and metal powder or debris in the oil.

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 Fault Diagnosis and Troubleshooting SY215CCM3K Hydraulic Excavator

H-24 The natural drift during swing is too large

● The natural drift during swing is too large (when the parking brake
Fault information (1)
works).
● The swing is fixed by the disc brake when the swing and parking brake
Relevant information
works.

Standard value under normal conditions and fault diagnosis reference

Cause
Predicted cause and

value
the standard value
under normal

Fault of the swing brake

conditions

1 The swing brake control pipe and brake pilot valve may have fault. Check it.
control pipe

Failure of swing motor The parking part of the swing motor may have failure or internal fault may exist.
2
(parking brake part) Check it.

● The natural drift during swing is too large (when the parking brake is
Fault information (2)
released).
● The swing can only be kept by hydraulics for the swing and parking brake
Relevant information
is released.

Standard value under normal conditions and fault diagnosis reference

Predicted cause and the standard value

Cause
value
Failure of the swing control
1 The seal of the swing control valve spool may have failure. Check it.
under normal conditions

valve (spool)
Fault of the swing motor
2 The seal of the relief valve of the swing motor may have failure. Check it.
(relief valve)

Fault of the swing motor

3 The seal of the refilling valve of the swing motor may have failure. Check it.
(refilling valve)

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Removal and refitting

Contents
How to read this manual.......................................................................................................................... 8-3
Precautions during operation .................................................................................................................. 8-5
Removal and installation of starter motor assembly ............................................................................... 8-8
Removal and installation of fuel injection pump assembly ..................................................................... 8-9
Removal and installation of fuel injection pump assembly ................................................................... 8-10
Removal and installation of engine front oil seal .................................................................................. 8-13
Removal and installation of engine rear oil seal ................................................................................... 8-14
Removal and installation of cylinder head assembly ............................................................................ 8-15
Removal and installation of rocker cover .............................................................................................. 8-18
Removal and installation of rocker and camshaft ................................................................................. 8-20
Cylinder head and valve mechanism .................................................................................................... 8-32
Piston, connecting rod and cylinder liner .............................................................................................. 8-51
Removal and installation of radiator assembly ..................................................................................... 8-61
Removal and installation of engine and hydraulic pump assembly ...................................................... 8-62
Removal and installation of final drive assembly .................................................................................. 8-64
Disassembly and reassembly of final drive assembly .......................................................................... 8-66
Removal and installation of swing motor and swing mechanism assembly ......................................... 8-75
Disassembly and reassembly of swing motor and swing mechanism assembly ................................. 8-77
Disassembly and reassembly of idler assembly ................................................................................... 8-87
Removal and installation of sprocket .................................................................................................... 8-91
Removal and installation of track assembly .......................................................................................... 8-92
Removal and installation of swing bearing assembly ........................................................................... 8-95
Removal and installation of turntable assembly ................................................................................... 8-97
Removal and installation of center swivel joint assembly ................................................................... 8-100
Disassembly and reassembly of center swivel joint assembly ........................................................... 8-102
Removal and installation of hydraulic tank assembly ......................................................................... 8-104
8
Removal and installation of control valve assembly ........................................................................... 8-107
Removal and installation of hydraulic pump assembly ....................................................................... 8-112
Removal and installation of oil seal in the input shaft of hydraulic pump ........................................... 8-117
Disassembly and reassembly of pilot valve assembly of work equipment ......................................... 8-118
Disassembly and reassembly of travel pilot valve assembly .............................................................. 8-119

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Removal and Refitting SY215CAM3K Hydraulic Excavator
Disassembly and reassembly of hydraulic cylinder assembly ............................................................ 8-120
Removal and installation of work equipment assembly ...................................................................... 8-129
Removal and installation of HVAC assembly...................................................................................... 8-132
Removal and installation of counterweight assembly ......................................................................... 8-136
Removal and installation of cab assembly .......................................................................................... 8-138
Removal and installation of cab windows ........................................................................................... 8-142
Removal and installation of front window assembly ........................................................................... 8-158
Removal and installation of display screen ......................................................................................... 8-167
Removal and installation of controller assembly ................................................................................. 8-168
Ignition key switch ............................................................................................................................... 8-174
Relay.................................................................................................................................................... 8-181
Sensor ................................................................................................................................................. 8-182
Terminal insertion and removal ........................................................................................................... 8-184

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SY215CAM3K Hydraulic Excavator Removal and Refitting
How to read this manual
Removal and installation of assembly

Special tool Installation of parts

● Special tools for removing and installing the ● Parts should be installed in the reverse order
parts are listed. of removal unless otherwise specified.
● The necessities of tools are explained in the ● The mark used in Section “Installation”
catalog of special tools: indicates the rules and precautions for
■: A special tool that is irreplaceable and installation of parts.
indispensable. ● The various symbols used in Section
●: Very important tool that may be replaced “Installation” are as follows:
with the purchased one.
This symbol indicates the relevant
Removal of parts safety precautions that must be
● Section “Removal” involves the procedures, observed at work.
precautions, and the volume of oil or water to
be discharged. This symbol lists the instructions
★ and precautions in the operation
● The various symbols used in Section procedures.
“Removal” and their meanings are as follows:
This symbol indicates that the
This symbol indicates the relevant specified coating agent must be
safety precautions that must be used.
observed at work.
This symbol means the required
This symbol lists the instructions and lubricant.
★
precautions in the operation steps.
This mark indicates the specified
This symbol means the relevant torque.
provisions and cautions to be abode
by during installation of parts. This symbol indicates the volume
of oil or water to be added.
This mark indicates the volume of oil
or water to be discharged.

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Removal and Refitting SY215CAM3K Hydraulic Excavator

Disassembly and reassembly of assembly

Special tool Reassembly

● The special tools necessary for the ● Section “Reassembly” involves the
disassembly and reassembly are listed in this procedures, precautions, technical
section. requirements and the volume of oil or water to
be added.
● The necessities of tools are explained in the
catalog of special tools: ● The various symbols used in Section
“Reassembly” are as follows:
■: A special tool that is irreplaceable and
indispensable.
This symbol indicates the relevant
●: Very important tool that may be replaced safety precautions that must be
with the purchased one. observed at work.
Disassembly
This symbol lists the instructions and
● Section “Disassembly” involves the ★ precautions in the operation
procedures, precautions, and the volume of procedures.
oil or water to be discharged.
This symbol indicates that the
● The various symbols used in Section
specified coating agent must be used.
“Disassembly” and their meanings are as
follows:
This symbol means the required
lubricant.
This symbol indicates the relevant
safety precautions that must be
This mark indicates the specified
observed at work.
torque.
This symbol lists the instructions and
★ This symbol indicates the volume of oil
precautions in the operation steps.
or water to be added.
This symbol means the relevant
provisions and cautions to be abode by
during installation of parts.

This mark indicates the volume of oil or

water to be discharged.

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SY215CAM3K Hydraulic Excavator Removal and Refitting

Precautions during operation

The following precautions must be observed during the removal or installation (disassembly or
reassembly) of the equipment.
1. Precautions for removal of the equipment
● If the engine coolant contains antifreeze, it should be treated properly.
● After disconnecting hoses or pipes, be sure to cap them or install blind plugs to them,
preventing dirt or dust from entering inside.
● Before draining oil, prepare an appropriate container to catch it.
● Before removal operation, make marks where necessary to prevent mismatch during
installation.
● Do not tug wires or cables, otherwise they may come off from the contacts. To avoid heavy
tensile load, always grip the connector when disconnecting a wire or cable.
● Tag wires and hoses to indicate their installation positions, preventing mismatch during
installation.
● Record and check the numbers of gaskets with different thickness, and keep them at a proper
place.
● Use a reliable crane or other lifting equipment with sufficient strength to lift part(s).
● When using forcing screws to remove parts, evenly tighten them in order.
● Before removing the equipment, clean the surrounding area; after removal, cover it to prevent
dust or dirt from entering.
★ Precautions for handling hoses during disassembly
After disconnecting hoses in disassembly operation, install the following blind plugs to the hose
ends.
A． Hoses with threaded connection

Hose ID (mm) Code Name

Light duty thread
6 B210780001189 Hose end plug
8 B210780001190 Hose end plug
10 B210780000077 Hose end plug
12 B210780000078 Hose end plug
15 B210780000883 Hose end plug
20 B210780000079 Hose end plug
22 60056667 Hose end plug
Heavy duty thread
12 B210780001142 Hose end plug
16 60002397 Hose end plug
20 B210780000080 Hose end plug 8
25 B210780000081 Hose end plug

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Removal and Refitting SY215CAM3K Hydraulic Excavator
B． Transition fittings with threaded connection (hoses and transition fittings are matched with each
other into a complete set)
Hose ID
Code Name Code Name
(mm)
Light duty thread
6 B210780000903 Cone plug 23002925 Nut
8 B210780001146 Plug B210770000011 Nut
10 B210780000088 Plug B210334000011 Nut
12 B210780000089 Plug B210334000012 Nut
15 B210780000882 Plug B210334000004 Nut
20 B210780000090 Plug B210334000010 Nut
22 B210780000091 Plug B210780000112 Nut
Heavy duty thread
12 B210780001143 Plug B210780000406 Nut
16 A820205001523 Plug B210780000405 Nut
20 B210780000902 Plug B210780000904 Nut
25 B210780001172 Plug B210334000006 Nut
2. Precautions during installation
● Tighten all bolts and nuts (sleeve nuts) to the specified torques.
● No twist or interference is allowed when installing hoses.
● Replace every removed bushing, O-ring, cotter pin and locking plate.
● Bend each split pin or locking plate properly.
● Clean the part to ensure it is free of oil and dust, and then apply a small amount of adhesive
onto the thread.
● Clean oil and dust off the surface, check for dirt or damage, and then evenly apply gasket
sealant to the surface.
● Remove any damage, dent, burr or rust on parts.
● Lubricate all movable and sliding parts with oil.
● Be sure to install all snap rings into the grooves properly.
● Eliminate oil, dirt or water from wire connectors, and then firmly connect them.
● Before using eye bolts, check if they are deformed or damaged, and then screw them down
and align them with the hook.
● Tighten split flanges evenly in order, avoiding excessive tightness on one side.
★ Bleed air as follows from the repaired cylinders, pumps or other hydraulic equipment after
reinstalling them for use:
1. Start the engine and allow it to run at low idling.
2. Operate the work equipment control lever to move the hydraulic cylinder back and forth 4~5
times, and stop the hydraulic cylinder at 100 mm of the end of its stroke.
3. Continue to operate the hydraulic cylinder 3~4 times, and stop it at the stroke end.
4. After the above operation, run the engine at normal speed.
★ When reusing the machine after repair or long-term storage, follow the same procedures
above.

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SY215CAM3K Hydraulic Excavator Removal and Refitting
5. Precautions after completing operations
● After draining engine coolant, screw down the drain valve, and add coolant to the specified
level. Run the engine to circulate the coolant in the system, and check the coolant level again.
● After removing the hydraulic equipment and reinstalling them, add hydraulic oil to the
specified level. Run the engine to circulate the hydraulic oil in the system, and check the oil
level again.
● Bleed air from the pipelines or hydraulic equipment after removing, repairing and installing
them.
★ Refer to the Section “Test and Adjustment” for detailed information related to air bleeding.
● Add specified amount of grease (molybdenum disulfide) to the parts of work equipment.

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Removal and Refitting SY215CAM3K Hydraulic Excavator
Removal and installation of starter motor assembly
Removal

Remove the cable from the negative (-)

terminal of the battery before removing the
Starter
starter motor assembly and insulate the cable
and negative (-) terminal with the insulating
Terminal B
tape.
1. Open the engine hood.

Terminal S

Starter relay

Fig. 8-1

2. Remove the cables (1), (2), (3), (4) and (5).

3. Remove the set bolts of the starter motors (6)
and (7) and remove the starter motor
assembly.

Fig. 8-2

Installation
● Perform the installation in reverse order of the
removal.

Engine starter motor terminal B lock

nuts:
18~25N·m{1.8~2.6kgf·m}

Starter motor set bolts:

43±6N·m{4.4±0.6kgf·m}

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SY215CAM3K Hydraulic Excavator Removal and Refitting

Removal and installation of fuel

injection pump assembly
Removal

Disconnect the negative (-) terminal of the

battery.
1. Open the engine hood.

Fig. 8-3

2. Remove the air inlet steel tube 1

Fig. 8-4

3. Remove the fuel supply pipe (2), the fuel inlet

hose (4), the fuel return hose (3) and the fuel
supply pipe (5).
★ When disconnecting the hose, in order
to prevent the fuel from flowing out, a
wooden plug can be inserted into the
hose.

Fig. 8-5

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Removal and installation of fuel injection pump assembly

Fig. 8-6
● Removal sequence

1 Eye bolt 5 Fuel pipe *a Fuel injection pump transmission

2 Fuel return pipe C 6 Feed pump
3 Fuel pipe 7 Driving disc : Non-reusable parts
4 Eye bolt (with the filter screen) 8 O-ring

WARNING
• The fuel can be easily combustible. Do not operate near the fire or heat source.
• The spilled fuel must be cleaned thoroughly as it may cause fire hazard.
CAUTION
• The impurities in the feed pump, even if the tiny impurities, will seriously affect the engine performance. Use
a cap to plug the opening when removing the pipes, hoses or other parts. The eye bolts and the gaskets shall
be cleaned with the light fuel to make them free of impurities.
• For the repair of the feed pump, please contact the Bosch service station.
Installation sequence
Perform installation in reverse order of the removal.
Tightening torque (unit: N·m{kgf·m})
Symbol Parts to be tightened Tightening torque Nut
Eye bolt (for installation of fuel return pipe C)
23~27{2.4~2.8} -
Eye bolt (for installation of fuel pipe)
Tighten the fuel pipe
Fuel pipe 40.5±2.5{4.1±0.25} connector using a wrench or
similar tools.

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SY215CAM3K Hydraulic Excavator Removal and Refitting
Lubricant and/or sealant
Specified lubricant and/or
Symbol Application Qty.
sealant
O-ring Engine oil As needed

Installation method
Installation of the feed pump:
• Adjust the match mark “P” on the protrusion of
Oldham coupling to the specified position
shown in the figure.

Protrusion

Fig. 8-7
• Set the No. 1 piston to the top dead center
position of the compression stroke as follows.
• Rotate the engine until the pointer is aligned
with “I, IV” or “1-4” marks on the flywheel.
Make sure that the match mark “P” on the
protrusion of Oldham coupling is in the Pointer
position shown in the figure.
• If the match mark is not in the position shown
in the figure, rotate the engine again. Please
note that when the crankshaft rotates three
turns, the Oldham coupling rotates four turns.

Protrusion

Fig. 8-8
• Align the marks “O” on the transmissions of Protrusion
the driving disc and fuel injection pump with
the marks “P” on the feed pump and the
driving disc when installing the fuel injection
pump transmission and the feed pump. Driving
disc

Fig. 8-9

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Installation of the fuel injection pipe and fuel pipe:

• Ensure the mounting surface between the
pipe and the connector is flat and undamaged.
Pipe
• Rest the pipes evenly against the mounting
surface of the connector closely and do not Mounting Mounting
surface surface
apply brute force to the pipes and fix the pipes
temporarily.
Connector
• After the pipes are fixed temporarily, install the
torque wrench on and tighten it to the
specified torque.

Fig. 8-10

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Removal and installation of engine front oil seal

Removal
1. Remove the radiator assembly according to
Section “Removal and installation of radiator
assembly” on page 6-18 of this Manual.
Water pump
2. Remove the fan (1), the belt (2) and the
pulley (3) of the engine.

Fig. 8-11

3. Remove the mounting nut (4), replace the

cone (5) and O-ring (6), and then take off the
crankshaft pulley (7).

Fig. 8-12

4. Remove the front oil seal (8).

Installation
● Perform the installation in reverse order of the
removal.

Nut: 490N·m{50kgf·m}
8
Fig. 8-13

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Removal and installation of engine rear oil seal

Removal
1. Remove the hydraulic pump assembly
according to Section “Removal and
installation of hydraulic pump assembly” in
this Manual.
2. Remove the bolt (1), the lock plate (2) and the
bearing (3).
3. Remove the flywheel (4).
4. Remove the engine speed sensor (5) and
flywheel housing (6).

Fig. 8-14
5. Remove the rear oil seal (7).

lip

Fig. 8-15
Installation
● Perform the installation in reverse order of the
removal. Sealant

Bolt: 39N·m{4.0kgf·m}+47°
● The installation mode of the rear oil seal is as
follows:
1) Apply the engine oil to the lip of the rear
oil seal.
2) Clean the oil seal surface.
Line
3) Apply the sealant evenly and
continuously along the line of the rear oil
seal.
Sealant (Tianshan 1596). Fig. 8-16
4) Install the rear oil seal within 3 min after
applying the sealant. Note that the
sealant shall not deviate.

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Removal and installation of cylinder head assembly

1. Remove the rocker cover and the fuel injector as per the removal sequence shown in the figure.

Fig. 8-17

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2. Remove the rocker and the camshaft as per the removal sequence shown in the figure.

10 pieces

4 pieces

13 pieces
2 pieces

Fig. 8-18

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3. Remove the cylinder head and the cylinder gasket as per the removal sequence shown in the figure.

Shallow
dent

Fig. 8-19
4. Perform installation in reverse order of the removal.

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Removal and installation of rocker cover

Fig. 8-20

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SY215CAM3K Hydraulic Excavator Removal and Refitting
● Removal sequence
1. Oil filler cap 10. Washer
2. Cover 11. Cylinder recognition sensor
3. Rocker cover rubber 12. Rocker cover
4. Snap ring 13. Rocker cover gasket A
5. Potentiometer 14. Rocker cover gasket B
6. Fuel injector pipe : Non-reusable parts
7. Bolt (with the hex hole)
8. Fuel injector
9. O-ring
● Installation sequence
Perform installation in reverse order of the removal.
Tightening torque (unit: N·m{kgf·m})
Symbol Parts to be tightened Tightening torque Remarks
Bolt (for installation of cover) –
23.2{2.4}
Bolt (for installation of rocker cover) –
Fuel injector pipe 30.4~35{3.1~3.6} –
Bolt (for installation of fuel injector) 5.2~7.2{0.53~0.73} –
Bolt (for installation of cylinder
4.9{0.5}
recognition sensor)
Lubricant and/or sealant
Specified lubricant and/or
Symbol Application Qty.
sealant
O-ring Engine oil As needed

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Removal and Refitting SY215CAM3K Hydraulic Excavator

Removal and installation of rocker and camshaft

10 pieces

4 pieces

13 pieces
2 pieces

Fig. 8-21

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SY215CAM3K Hydraulic Excavator Removal and Refitting
● Removal sequence

1． Exhaust rocker shaft 8. Intake camshaft

2． Intake rocker shaft 9. Exhaust camshaft

3． Rocker box 10. Lower camshaft bearing

4． Gasket : Non-reusable parts

5． O-ring : dowel pin

6． Upper camshaft bearing : idler

7. Gasket

CAUTION
● The rocker box and the cylinder head are manufactured in sets. Do not replace the rocker
box or the cylinder head separately.
● Do not change the combination of upper and lower camshaft bearings. Do not interchange
the pistons of the upper and lower camshaft bearings.
● Perform installation in reverse order of the removal.
Repair standard (unit: mm)
Limit Calibration
Position Item Standard value
value: method
– Backlash Idler and camshaft gear 0.080〜0.126 0.3 Replacement
Axial
– Camshaft 0.10〜0.2 0.3 Inspection
clearance
Clearance between camshaft bearing
6,8,10 0.07〜0.12 0.16 Replacement
and intake camshaft
Clearance between camshaft bearing
6,9,10 0.07〜0.12 0.16 Replacement
and exhaust camshaft
6,10 Span of camshaft bearing in a free state – 35.5 Replacement
Tightening torque (unit: N·m{kgf·m})

Symbol Parts to be tightened Tightening torque Remarks

Bolt (for installation of rocker shaft:
Wet cylinder liner
10 places)
27.5{2.8}
Bolt (for installation of rocker box:
–
13 places)
Bolt (for installation of camshaft: 2
23.2{2.4} –
places)
Bolt (for installation of rocker box: 4
23.5{2.4} –
places) 8

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Lubricant and/or sealant
Specified lubricant and/or
Symbol Application Qty.
sealant
Thread and seat of bolts
Camshaft bearing inner surface Engine oil As needed
Journal and cam of camshaft
Mounting surface of rocker box
cylinder head ThreeBond1217H As needed
Periphery of the gasket
Operations before removal

● Check the backlash of gear:

1. Measure the backlash of each pair of gears at
more than three places.
2. Replace the defective parts if the measured
value exceeds the specified limit.

Fig. 8-22

● Check the axial clearance of the camshaft:

1. Replace the defective parts if the measured
value of the axial clearance is not within the
standard value range.

Fig. 8-23

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● Release the valve spring tension Adjusting

screw
1. Loosen the adjusting screw on the rocker Valve spring
pressing the valve spring before removing the Rocker
bolts in the next step (for the rockers are lifted
by the cam). The tension of the valve spring
shall be released by above operation, so as to
prevent improper force bearing of other parts
when removing the bolts.
Cam

Fig. 8-24

Removal method

● Remove the rocker shaft and rocker box:

1. According to the sequence shown in figure
(1~23), loosen the mounting bolts of the
rocker shaft (10 places) and the mounting Engine forepart
bolts of the rocker box (13 places) in multiple
times. Then, remove the rocker shaft and the
rocker box.

Fig. 8-25

Check method

● Check the span of camshaft bearing in a free

state:

CAUTION
● Do not open the bearing forcibly.

1. Replace the upper and lower bearings in sets

if the measured value is lower than the limit
value.
8

Fig. 8-26

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● Check the clearance between the camshaft Upper

bearing and camshaft: bearing

1. Replace the defective parts if the measured

value is not within the standard value range.
Lower Camshaft
bearing

Fig. 8-27

Installation method

● Install the camshaft: Rocker box

1. Install the upper camshaft bearing onto the Tongue

rocker box and install the lower camshaft Tongue

bearing onto the cylinder head, refit their

tongues into the grooves of the rocker box Tongue
Upper bearing
and the cylinder head.
Tongue
Engine forepart
Lower bearing

The cylinder head

Fig. 8-28

2. Set the No. 1 cylinder piston to the top dead

Alignment mark
center position of the compression stroke.
3. Align the match mark on the camshaft gear
with that on the rocker box when installing the Alignment mark
camshaft.
4. The match marks on the camshaft gear such
as “L” or “R” are used to align the idler. These
match marks may not be aligned with the
marks on the idler completely, for the position
of installed idler may cause the misalignment.
This misalignment may not cause the
adverse effect. Fig. 8-29

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● Install the rocker shaft and rocker box:

1. Clean the surface of parts on which the
sealant is applied.
2. Apply the sealant evenly and continuously on Rocker box
the periphery of four gaskets. Sealant
3. Apply the sealant evenly and continuously on
the rocker box.
4. Install the rocker box and the gasket on the Sealant

cylinder head within three minutes after

Rubber gasket
applying the sealant, and avoid the Dowel pin

degumming during the process.

Fig. 8-30
CAUTION
● Do not run the engine within one hour
after installing the rocker shaft and the
rocker box.
5. Install the rocker shaft while installing the
Bolts (10 pieces)
rocker box on the cylinder head. And tighten the Rocker shaft
assembly
rocker shaft bolts (10 places) and the rocker box
bolts (13 places) according to the sequence shown
below.
Bolts (13 pieces)

CAUTION
● Reapply the sealant on the specified
area aforementioned if the bolts are
loosened or removed after the
Rocker box
installation of rocker shaft and rocker
box.

Fig. 8-31
6. Tighten the bolts (1~23) to the specified
torque according to the sequence shown in the
figure.
Engine forepart

Fig. 8-32

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Rocker shaft and rocker

Engine forepart

Fig. 8-33
● Removal sequence

1． Adjusting screw 8. Exhaust rocker shaft

2． Rocker bushing 9. Intake rocker shaft
3． Short rocker : Non-reusable parts
4． Rocker shaft spring : Mounting hole of rocker box dowel pin
5． Adjusting screw
6． Rocker bushing
7. Long rocker
● Perform installation in reverse order of the removal.

CAUTION
● The short and long rockers must be installed alternately. Please note that the installation
sequence of the intake rocker is different from that of the exhaust rocker.
Repair standard (unit: mm)
Standard value Calibration
Position Item Limit value:
0.01~0.08 method
2,6, Clearance between rocker bushing
0.12 Replacement
8,9 and rocker shaft
3,7 Radial clearance of rocker (roller) 0.038〜0.1 – Replacement

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Tightening torque (unit: N·m{kgf·m})
Symbol Parts to be tightened Tightening torque Remarks
Lock nut (adjusting the tightness of
20.6{2.1} –
screw)
Lubricant and/or sealant
Specified lubricant and/or
Symbol Application Qty.
sealant
Inner surface of rocker bushing Engine oil As needed

Special tool (unit: mm)

Symbol Tool name and shape Part No. Purpose
Rocker bushing
remover
Removal and
MH062536 installation of rocker
bushing

Check method

● Check the clearance between rocker bushing

and rocker shaft
1. Replace the rocker bushing if the measured
value exceeds the specified limit.

Fig. 8-34

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Replacement of rocker bushing

Press
● [Removal]
Rocker

Bushing

Fig. 8-35

● [Installation] Long rocker

Bushing junction
1. Press the rocker bushings to the rockers, with
the end of bushings facing the direction Groove on
bushing
shown in figure.
Bushing

Bushing Oil hole (small)

Oil hole (large)
Short rocker

Bushing junction
Groove on
bushing

Bushing

Oil hole (large) Bushing Oil hole (small)

Fig. 8-36

● Check the radial clearance of rocker (roller):

1. Replace the rocker if the measured value of
radial clearance is not within the standard Roller
value range.

Radial clearance

Fig. 8-37

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Camshaft

● Removal sequence
1． Intake camshaft gear Sensor board

2． Key
3． Intake camshaft
4． Exhaust camshaft gear
5． Key
6． Exhaust camshaft
: Non-reusable parts
Engine forepart

Fig. 8-38

● Reassembly sequence
Perform the reassembly in reverse order of the
disassembly.

Note: the exhaust camshaft gear is equipped

with the sensor board. Do not mix the exhaust
camshaft gear with the intake camshaft gear. If
the gear is installed incorrectly, the engine will
be faulty.

Repair standard (unit: mm)

Standard Limit
Position Item Calibration method
value value:
1,3,4, Interference between the camshaft gear and the
- Replacement
6 camshaft 0.007~0.041
Lobe height: 42.219
Long
7.21 7.16 Base
rocker 35.009
diameter:
Intake Cam lift Replacement
3 Lobe height: 44.281
camshaft Short
9.269 9.219 Base
rocker 35.012
diameter:
Bending 0.01 0.03 Replacement
Lobe height: 42.279
Long
7.184 7.134 Base
rocker 35.095
diameter:
Exhaust Cam lift Replacement
6 Lobe height: 44.359
camshaft Short 8
9.242 9.192 Base
rocker 35.117
diameter:
Bending 0.01 0.03 Replacement

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Removal method
Camshaft gear Parts for removal
● Remove camshaft gear:
1. Press the camshaft with the press machine to Camshaft

remove the camshaft gear.

CAUTION
● Do not remove the camshaft gear with
the hammer. Be sure to remove the
camshaft gear with the press machine.

Fig. 8-39

Check method
● Check the interference between the camshaft
gear and camshaft:
1. Replace the defective parts if the measured
value is not within the standard value range.

Fig. 8-40

● Check the camshaft:

Measuring point Measuring point
1. Cam lift: please replace the camshaft if the
difference between the measured values of Lobe height

lobe height and the base diameter is lower

than the limit value. Base diameter

Exhaust camshaft

Intake camshaft

Long rocker cam

Short rocker cam

Fig. 8-41

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1. Bending: 1) Place the support on the journal

Journal
at the end of the camshaft, and measure the
bending of the intermediate journal of the
camshaft. Rotate the camshaft by one turn
and divide the reading of dial gauge by two to
obtain the bending of the camshaft. 2)
Journal
Replace the camshaft if the measured value
exceeds the specified limit.
Intermediate journal

Fig. 8-42

Installation method

● Install the camshaft gear:

1. Use a gas burner to heat the camshaft gear Camshaft gear
to approximately 150 ºC.

WARNING
● The contact with the heated gear may
cause burns.
Camshaft
2. Install the camshaft gear on the camshaft,
with the match marks (“R” or “L”) facing the
direction shown in figure.
3. Press the gear until its end contacts with the Fig. 8-43
camshaft flange tightly.

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Cylinder head and valve mechanism

Shallow dent

Fig. 8-44

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● Removal sequence
1 Connecting plate 12 Cylinder head bolt
2 Glow plug 13 Cylinder head
3 Idler 14 Cylinder head gasket
4 Set bolt : Non-reusable parts
5 Snap ring : dowel pin
6 Pinion : idler
7 Spring
: Upper crankcase
8 Pin
9 Idler bushing : Front case
10 Idler
11 Thrust plate

CAUTION
● Be careful not to damage the glow plug and the fuel injector when placing the cylinder head
on the workbench, for the glow plug and the fuel injector protrude from the cylinder head
bottom.
● Reassembly sequence
Perform the reassembly in reverse order of the disassembly.

CAUTION
● Do not forget to install the thrust plate.
Repair standard (unit: mm)
Calibration
Position Item Standard value Limit value:
method
– Axial clearance of idler 0.1〜0.2 0.3 Replacement
Clearance between the idler and
3,9 0.01〜0.05 0.1 Replacement
idler bushing
Tightening torque (unit: N·m{kgf·m})
Symbol Parts to be tightened Tightening torque Remarks
Nut (for installation of
1.0~1.5{0.1~0.15} –
connecting plate)
Glow plug 19.6~24.5{2~2.5} –
Bolt (for installation of the idler) 71.5{7.3} Wet cylinder liner
• Wet cylinder liner
Cylinder head bolt 147{15}+90° • The cylinder head bolt can
be reused three times at most.
8

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Lubricant and/or sealant
Specified lubricant
Symbol Application Qty.
and/or sealant
Bolt thread and base surface (for
installation of idler)
Engine oil As needed
Periphery of the idler
Thread of cylinder head bolt
Top mating surface between the front case
ThreeBond1217H As needed
and the upper crankcase
Special tool (unit: mm)
Symbol Tool name and shape Part No. Purpose
Idler bushing remover

Removal and installation

MH061779
of idler bushing

Pin wrench arm

assembly
MH063473 Installation of pinion

Check before removal

● Check the axial clearance of the idler
bushing:
1. Replace the defective parts if the measured
value exceeds the specified limit.

Fig. 8-45

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Removal method

● Remove the cylinder head:

1. Loosen the cylinder head bolts (1~18) in
multiple times in the sequence as shown in
the figure and remove them in the same
sequence.

● Remove the cylinder head gasket:

Fig. 8-46
CAUTION
● When removing the cylinder head
gasket, be careful not to scratch the
cylinder head, upper crankcase and the
front case.
Check method
● Check the clearance between the idler and
idler bushing:
1. Replace the rocker bushing if the measured
value exceeds the specified limit.

Fig. 8-47

1) Replace the idler bushing.

[Removal]

Bushing

Fig. 8-48

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Removal and Refitting SY215CAM3K Hydraulic Excavator
[Installation]

● Place the bushings on the idler, with the

bushing ends facing the direction shown in Chamfered edge

the figure and their oil holes in the same line.

● Press the bushing into the idler using Bushing
until the bushing is flush with the lower edge Oil hole
of the idler chamfer.
● Re-measure the clearance between the
bushing and the idler.
● If the measured value is lower than the
standard value, ream the bushing.
Fig. 8-49

Installation method

● Install the pinion: Bolt

1. Install the idler to the bench vise. Protect the

gear with the shop towel and avoid the gear
contacting the bench vise directly.
2. Remove the set bolts on the idler.

Fig. 8-50

3. Install the pinion, the spring and pin onto the Pinion
idler.
Pin
4. Hook the spring end A to the pin. Spring

Pin

Pin

Fig. 8-51

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5. Install the snap ring.

Snap ring

Fig. 8-52

6. Install onto the pinion hole B, and rotate

it anti-clockwise. Pinion

7. Align the pinion hole C with the idler hole D,

Idler
then tighten the set bolts.

Bolt

Fig. 8-53

● Install the cylinder head:

CAUTION Punch mark

● Check the punch marks on the bolt

heads before installing the cylinder
head bolts. (The bolts with no more than
two punch marks on heads can be
reused.)
● The number of punch marks indicates
the times the bolt was tightened in
plastic range. If there are three punch
marks (indicating the bolt was tightened
three times), the bolt shall be replaced. Fig. 8-54
8

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Removal and Refitting SY215CAM3K Hydraulic Excavator

1. The cylinder head gaskets are available in

three sizes. Please select the proper cylinder
head gasket according to the following
methods.
2. Measure the piston protrusion of cylinders.
(Refer to the Section of “Piston, connecting
rod and cylinder liner”)
3. Select the cylinder head gasket whose
thickness is suitable for the average
measured value of piston protrusions from
the table below.
4. If the measured value of piston protrusion is
0.05 mm greater than the average value, use
the gasket whose grade higher than the
grade used in the average value (A→B,
B→C)
Unit: mm Size mark “A”, “B” or “C”

Cylinder head gasket

Piston protrusion Thickness when the
Dimension
gasket is tightened
0.088〜-0.027 “A” 0.75±0.04
0.027〜0.033 “B” 0.80±0.04 Fig. 8-55
0.033〜0.094 “C” 0.85±0.04
5. The size grade of the gaskets can be
determined by the size mark and notch shape
on the edge of the cylinder head gasket.

CAUTION
● The piston protrusion may be changed
when the piston or the connecting rod
is replaced. Be sure to measure the
piston protrusion after the piston or
connecting rod is replaced or both of
them are replaced.
6. Clean the surface of parts on which the Sealant
sealant is applied. Cylinder head gasket
7. Apply the sealant on the top surface of the
junction between the upper crankcase and
the front case (2 places).
8. Install the cylinder head and the cylinder
Sealant
head gasket on the upper crankcase within
three minutes after applying the sealant, and
avoid the degumming.

CAUTION
● Do not run the engine within one hour Fig. 8-56
after installing the cylinder head. Be
sure to reapply the sealant on the
surface aforementioned if the cylinder
head bolts are loosened or removed.

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9. Tighten the cylinder head bolts (1~18) to the

torque of 147N·m{15kgf·m} (wet cylinder
liner) according to the sequence shown in the
figure. Then, tighten them again by 90°in the
same sequence.
10. After tightening the bolts, make the punch
marks on the head of bolts to indicate the
times of use.

CAUTION
● Do not tighten the cylinder head bolts
that are tightened by the torque-rotating Fig. 8-57
method further after the final angle is
tightened.

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Removal and Refitting SY215CAM3K Hydraulic Excavator
The cylinder head

Fig. 8-58
● Removal sequence
1 Value clip 12 Sealing cap
2 Upper protective ring (Diameter: 22mm)
3 Outer valve spring 13 Sealing cap
4 Inner valve spring (Diameter: 30mm)
5 Valve stem seal ring 14 Sealing cap
6 Bleed valve (Diameter: 40mm)
7 Intake valve 15 Conical plug
8 Bleed valve guide 16 Stud (short)
9 Intake valve guide 17 Stud (long)
10 Bleed valve seat 18 Cylinder head
11 Intake valve seat : Non-reusable parts
● Reassembly sequence
Perform the reassembly in reverse order of the disassembly.

CAUTION
● Be sure to replace the valve stem seal ring when removing the intake valve or bleed valve.

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SY215CAM3K Hydraulic Excavator Removal and Refitting
Repair standard (unit: mm)
Limit Calibration
Position Item Standard value
value: method
Free length 87.8 83.4
Mounting load 360±18N
3 Outer valve spring - Replacement
(Mounting length: 57) 36.7±1.8kgf)
Inclination - 2.0
Free length 78.8 74.9
Mounting load 168±8.3N
4 Inner valve spring - Replacement
(Mounting length: 52.3) {17.1±0.85kgf)
Inclination - 2.0
Valve stem outer
φ7.85 Replacement
diameter
Valve seat surface angle 45°±15' - Repair
6 Bleed valve
Valve edge thickness 1.5 1.2 Repair or replace
Sunken depth below the
1.5±0.25 2.0 Inspection
cylinder head bottom
Clearance between bleed valve stem and valve
6,8 0.07〜0.10 0.2 Replacement
guide
Valve stem outer
φ7.85 Replacement
diameter
Valve seat surface angle 45°±15' - Repair
7 Intake valve
Valve edge thickness 1.5 1.2 Repair or replace
Sunken depth below the
1.5±0.25 2.0 Inspection
cylinder head bottom
Clearance between intake valve stem and valve
7,9 0.03〜0.06 0.2 Replacement
guide
10 Bleed valve seat width 2.5±0.2 3.5 Repair or replace
11 Intake valve seat width 2±0.2 2.8 Repair or replace
Bottom deformation Below 0.05 0.2 Repair or replace
Height from the top to
107±0.5 106.5 Replacement
18 The cylinder head the bottom
Valve seat hole
- Replacement
diameter

Tightening torque (unit: N·m{kgf·m})

Symbol Parts to be tightened Tightening torque Remarks
Conical plug 14{1.4} –
Stud 20{2.0} –

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Lubricant and/or sealant
Symbol Application Specified lubricant and/or sealant Qty.
Valve stem seal ring lip
Valve stem and valve end Engine oil As needed

Special tool (unit: mm)

Symbol Tool name and shape Part No. Purpose
Valve lifter MH061668

Valve lifter
MH061772
seat
Removal and
installation of valve clip
Valve lifter
hook
MH061679
A
φ38
Installation tool of valve seal
ring

Installation of valve
MH063607
stem seal ring

Grinding of valves
Valve (intake valve and
30091-07500
grinding tool bleed valve) and valve
seats

Valve guide remover

Removal of valve
31391-10500
guide

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Symbol Tool name and shape Part No. Purpose

Installation tool of valve guides

Installation of
MH063604
valve guide

Caulking
31391-13100
tool body
Installation of
valve seat
Caulking
MH063605
ring

Removal method

● Remove the valve clip:

1. Remove the valve clip by compressing the
valve spring evenly.
Value clip

Fig. 8-59

Check method

● Check the intake valve and bleed valve:

1. If the valve is repaired or replaced with a new
valve because of the following checks, please
grind the valve and the valve seat.
(1) Valve stem outer diameter
If the outer diameter of the valve stem is lower
than the limit value or worn severely, please
replace the valve.

Fig. 8-60

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(2) Valve seat surface angle

Repair the valve if the measured value is not
within the standard value range.
(3) Valve edge thickness
Repair or replace the valve if the measured
value exceeds the specified limit.
Valve seat
surface angle
Valve edge thickness

Fig. 8-61

2. Repair
(1) The grinding amount shall be controlled to the
required minimum limit.
(2) After the valve is ground, if the valve edge
thickness is lower than the limit value, please
replace the valve.
(3) After the valve is ground, be sure to grind the
valve and the valve seat.

Fig. 8-62

● Measure the clearance between valve stem

and valve guide:
1. Replace the defective parts if the clearance
exceeds the specified limit.

Fig. 8-63

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1) Replace the valve guide

[Removal]

Valve guide

Fig. 8-64

[Installation]
Install the valve guide until the valve guide falls on The cylinder
the cylinder head closely. head

CAUTION
● The valve guide has a specified depth. Valve guide

Be sure to achieve the specified depth

using .
● The intake valve guide is longer than
the bleed valve guide. Be sure to install
the guide of proper type at each Fig. 8-65
position.
● Check the contact between the valve and
valve seat: Red lead

1. Make sure that the valve and the valve guide

valve
are intact before checking.
2. Apply the red lead evenly on the valve
contact surface of the valve seat.
3. Tap the valve seat using the valve. Do not
rotate the valve during this operation.

Fig. 8-66

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4. When the poor contact is determined by the

amount of red lead adhering to the valve, one
of the following measures can be adopted.
Contact condition Repair measures
Minor defect Grinding
Repair or replace the
Serious defect the standard NG
valve and valve seat

Fig. 8-67

(1) Valve grinding

• Grind the valve in the following sequence.
• Apply a thin layer of the abrasive paste on the Valve stem
contact surface of valve seat.
• Use the abrasive paste of medium fine grain
(120~150 mesh) first, and use the abrasive Abrasive paste
paste of fine grain (higher than 200 mesh)
finally.
• Add a little engine oil can make it easy to
apply the abrasive paste evenly.
Fig. 8-68
CAUTION
● Do not stick the abrasive paste to the
valve stem.
• Tap the valve seat using the valve for several
times, and rotate the valve slowly.
• Wash off the abrasive paste with the diesel.
valve
• Apply the engine oil on the contact surface of
the valve seat and rub against the valve and Valve seat

the valve seat thoroughly.

• Recheck the contact between the valve and
valve seat.
• Replace the valve seat if the contact is still
defective.
Fig. 8-69

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● Check the valve seat:

1. If the valve is repaired or replaced with a new

valve because of the following checks, please
grind the valve and the valve seat. Valve seat

(1) Valve seat width

Valve seat
width
Repair or replace the valve seat if the
measured value exceeds the specified limit.

Fig. 8-70

(2) Valve sunken depth at the cylinder head

bottom Valve seat

The measurement shall be performed along the

valve seat tightly.
Replace the defective parts if the measured
value exceeds the specified limit.

Sunken depth

Fig. 8-71

2. Repair the valve seat

(1) Grind the valve seat using the valve seat Valve sunken depth Valve seat
surface angle
cutter or the valve seat grinding head.
(2) After the grinding, put a sandpaper of 400
particle size between the cutter and the valve
Valve seat
seat to grind the valve seat slightly. width
Valve seat
(3) Repair the valve seat with the 15°or 75°cutter
until the valve seat width is within the standard Valve

range. If the valve seat cannot be repaired,

please replace the valve.

CAUTION
Fig. 8-72
● Make sure that the repair of the valve
seat will not exceed the specified limit
of valve sunken depth.

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3. Grind the valve and its seat after correction.

Valve seat
1) Replacement of valve seat
[Removal]
The valve seat is mounted by means of flaring fit.
To remove the valve seat, first grind the inner
surface of its metallics to decrease its wall
0.5-1.0mm
thickness, and then demount the valve seat at
room temperature. Portion to be ground off

Fig. 8-73

[Installation]
• Measure the aperture of the valve seat inside
the cylinder head.
• Replace the cylinder head if the measured
value deviates from the standard value.

Valve seat hole diameter

Fig. 8-74

• Soak the valve seat in liquid nitrogen for During installation During caulking
complete cooling.
• Install the valve seat into the cylinder head
with and , directing the chamfering Chamfer

edge of towards the valve seat.

• Flip to make its chamfering edge
face , and caulk the valve seat.
Chamfer
• Grind the valve seat and the valve.

Valve seat

Fig. 8-75

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● Check the deformation of the cylinder head Measuring

bottom position

1. If the deformation exceeds the limit, correct it

with a surface grinder.

CAUTION
● Ensure that the height of the cylinder
head from top to bottom won’t be
reduced below the limit value.

Fig. 8-76

Installation method

● Install the sealing cap

1. Drive the sealing cap into the cylinder head at
the specified depth.

Fig. 8-77

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● Install the valve stem seal ring

1. Apply the engine oil to the lip of the valve stem
seal ring.
2. Install the valve stem seal ring till is closely
lip
seated on the cylinder head. Valve stem seal ring

3. After installation, confirm that the spring is free

of deformation or damage.

Fig. 8-78

● Install the valve lock clamp

1. For installation of the valve lock clamp, please
follow the removal sequence. (Refer to
“Remove the valve lock clamp”.)

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Piston, connecting rod and cylinder liner

Fig. 8-79
● Removal sequence
1 Lower connecting rod bearing
2 Connecting rod cap
3 Upper connecting rod bearing
4 Piston and connecting rod assembly
5 Cylinder liner
: dowel pin

● Reassembly sequence
Perform the reassembly in reverse order of the disassembly.

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Repair standard (unit: mm)
Standard Limit Calibration
Position Item
value value: method
(Average) protrusion of piston from the top
- -0.088〜0.094 - Inspection
surface of the crankcase
- Axial clearance of connecting rod 0.15〜0.45 0.6 Replacement

Connecting rod Span in free state - 74.5

1,3 Replacement
bearing Oil clearance 0.034〜0.093 0.2
4,5 Clearance between piston and cylinder liner 0.181〜0.201 - Replacement
Flange protrusion of the
top surface of the 0.01〜0.07 -
crankcase
Inner diameter Φ114 - 114.02 φ114.25
5 Cylinder liner Roundness Below 0.08 - Replacement
Cylindricity Below 0.03 -
Difference with the flange
protrusion of the adjacent Below 0.04 -
cylinder liner
Tightening torque (unit: N·m{kgf·m})
Symbol Parts to be tightened Tightening torque Remarks
Bolt (for installation of
29{3.0}+90° Wet cylinder liner
connecting rod cap)
Lubricant and/or sealant
Symbol Application Specified lubricant and/or sealant Qty.
Bolt thread
Inner surface of connecting rod
bearing
Contact surface of upper crankcase Engine oil As needed
of cylinder liner
Outer surface of piston
Arm surface of the cylinder liner

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Special tool (unit: mm)
Symbol Tool name and shape Part number Purpose
Piston guide
MH064332 For installing the
clamp
piston and
Piston guide connecting rod
MH061658 assembly
rod

Cylinder liner For removing the

MH062537
removal tool cylinder liner

Installation tool for

cylinder liner

For installing the

MH063606
cylinder liner

Transition For measuring the

MH063433
ring protrusion of the
Bolt cylinder liner flange
MF130625 above the top
surface of the upper
crankcase and the
difference between
Washer MH005012 flange protrusion of
adjacent cylinder
liners

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Check before removal

● Position the cylinder head Upper crankcase

1. The cylinder liner tends to slip out of the upper Bolts and washers
crankcase when the upper crankcase is
turned over and the crankshaft is turned with
the piston located at the inner side of the
Cylinder liner
cylinder liner. To prevent the circumstance
above, bolts, washers or other parts shall be
used to maintain the flange of each cylinder
liner in place.

Fig. 8-80

● Check the piston protrusion from the top

surface of the upper crankcase

CAUTION
● The piston protrusion affects the engine
performance, therefore it must be
inspected.

1. Set the piston at the top dead center.

2. As shown in the figure, mark reference point A Upper crankcase

(five points in total) on the top surface of the
upper crankcase. With each mark as the null
point, measure the piston protrusion relative to
the null point (the height of measuring point B
- the height of measuring point A).
3. Measure the two measuring points B (eight
points in total) of each cylinder with the
reference point A, which is closest to each
measuring point, and calculate the mean of all
measured values.
4. If the mean isn’t within the standard value
range, check the clearance between all
related components.
5. Cylinder head gaskets compatible to the mean
piston protrusion (the mean of eight measured
Fig. 8-81
values) shall be adopted. (Refer to “Cylinder
head”)

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● Check the axial clearance of the connecting

rod
1. Measure the axial clearance of each
connecting rod.
2. Replace the defective parts if the measured
value exceeds the specified limit.

Fig. 8-82

● Check the difference between the flange

Flange
protrusion of adjacent cylinder liners
1. Install onto the upper crankcase, ensuring
it isn’t located at the top of any flange part.
2. Place into the piston, and tighten to Cylinder liner

49N·m{5kgf·m}.

Fig. 8-83

3. Measure the flange protrusion of the cylinder

Cylinder liner
liner on the top surface of the upper
crankcase.
4. If the measured value isn’t within the standard Protrusion

value range, check the mounting state of the

cylinder liner and then replace the defective
parts.
5. If the difference between the protrusion of
adjacent cylinder liners isn’t within the
standard value range, check the mounting
state of the cylinder liner and then replace the
defective parts. Fig. 8-84

CAUTION
● Insufficient flange protrusion will cause
the surrounding pressure of the cylinder
head gasket hole to decrease, thus 8
leading to gas leakage.

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Check method

● Check the span of connecting rod bearing in

free state

CAUTION
● It is forbidden to expand the bearing
with hand.

1. Replace the upper and lower bearings in sets

if the measured value is lower than the limit
value.

Fig. 8-85

● Check the oil clearance of the connecting rod

bearing and crankshaft Upper bearing

1. Assemble the lower bearing onto the

connecting rod cap and the upper bearing
onto the connecting rod, and then tighten the
bolts to 29N·m{3.0kgf·m}. Lower bearing

2. Measure the inner diameter of the bearing and

the diameter of the crankshaft pin. Diameter of the
crankshaft pin

3. If the clearance exceeds the limit, replace the

defective parts.
4. If it is necessary to replace the bearing with a
smaller one, the crankshaft pin shall be
machined to the specified smaller diameter.
(Refer to crankshaft section)

Fig. 8-86

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● Check the clearance between the piston and

the cylinder liner
1. If the measured value isn’t within the standard
value range, please take one of the following
measures as appropriate.
A: measure the cylinder bore in the crankcase (in
the axial direction of the crankshaft)
B: measure the cylinder bore in the crankcase (in
the direction vertical to crankshaft axis)
C: measure the piston (in the direction vertical to
the piston pin hole)

Fig. 8-87

1) Replace the cylinder liner

[Removal]

Cylinder liner

Fig. 8-88

[Installation] Cylinder liner

1) For replacement of the cylinder liner, choose

one the same as the size mark on the
crankcase and the piston.
Upper crankcase size Cylinder liner size Piston size mark
mark mark

Upper Engine
crankcase forepart

CAUTION
● Be sure to use the piston and the
cylinder liner with identical sizes.
Otherwise it may cause the engine to be
8
stuck.
Fig. 8-89

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2) Apply a thin layer of engine oil to the

surrounding surface of the cylinder liner of
upper crankcase (hatched area in the figure).

Fig. 8-90

3) Push downward slowly at constant speed

with hands to insert the cylinder liner into the Cylinder liner
upper crankcase. Upper
crankcase

CAUTION
● It cannot be too careful to operate the
cylinder liner because its wall is
relatively thin, and is easily to be
damaged.

Fig. 8-91

Installation method
Lower bearing Upper bearing
● Install the connecting rod bearing Oil hole Tongue

CAUTION Tongue

● During the installation, do not reverse

the lower bearing and the upper one
(with oil holes); otherwise it may cause
the engine to be stuck.

Fig. 8-92

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● Install the piston and connecting rod assembly

1. Confirm that the closed end of the piston ring
is in the right position.
A: closed end of the 1st compression ring
B: closed end of the 2nd compression ring
C: closed end of the oil ring
D: docking part of the oil ring support spring
“O”: forward mark on the piston

Fig. 8-93

2. Check if size marks (“A” or “B”) of the piston Size mark

and the cylinder liner are identical.
3. Install the piston to the cylinder liner. Be
careful not to make the connecting rod scratch
the inner surfaces of the cylinder liner and the
crankshaft pin.

Fig. 8-94

4. Direct the forward mark “O” on the piston

towards the front of the engine.
5. Adjust the inner diameter of with the
adjusting bolt of to match it with the outer
diameter of the piston.
Adjusting bolt
6. Remove tools from the piston and apply
engine oil to the following parts, and then
reinstall the tools around the piston ring.
• Outer surface of the piston
• Inner surface of
Engine
• Inner surface of the cylinder liner forepart

Fig. 8-95

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7. After installation of the piston and connecting

Bolt
rod assembly, align the matching marks on
the connecting rod and the connecting rod Connecting
cap, and alternately tighten the bolts with the rod cap

methods below. Matching

marks
• First tighten the bolts to 29N·m{3.0kgf·m}.
• Further tighten the bolts by rotating them by
90°clockwise.

Fig. 8-96

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Removal and installation of radiator assembly

Removal
1. Open the pressure cap of the radiator, remove
the bottom cover plate, and drain all of the
coolant in the radiator.
2. Remove the surrounding covering part 1.
3. Remove the air inlet and outlet pipe 2, water
inlet and outlet pipe 3 and fan cover 4 on the
radiator.

Fig. 8-97

4. Remove the oil inlet and outlet pipes (steel

pipe) 5 and condenser 6.
5. Remove the radiator support and the set bolts
at the bottom of the radiator.
6. Install the set bolts and lift the radiator
assembly.
7. The installation is in reverse order of the
removal.

Fig. 8-98

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Removal and installation of engine and hydraulic pump assembly

1. Drain all of the coolant in the radiator, and
remove the engine hood 1 and the covering
parts.
2. Remove all hydraulic pipelines 2 and
harnesses 3 from the main pump.
3. Remove the engine oil pipelines.
4. Remove the air inlet and outlet pipe 4, water
inlet and outlet pipe 5, fan cover 6 and fuel
pipe 7.

Fig. 8-99

Fig. 8-100

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5. Remove the starter motor harness and the

harness assembly of speed sensor and other
parts.
6. Remove the compressor pipeline 8 and
harness 9.
7. Remove the set bolt 10 from the damping pad,
and lift the engine and main pump assembly.
8. The installation is in reverse order of the
removal.

Fig. 8-101

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Removal and installation of final drive assembly

Removal

1. Remove the sprocket. See the section

“Remove the sprocket” in this manual.

Lower the work equipment to the ground for

safety, stop the engine, and operate the
breather valve to release the pressure inside.

2. Remove the motor cover (1).

Fig. 8-102

3. Remove 4 travel motor hoses (2) and remove

the hose fittings.

Fig. 8-103

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4. Remove the 30 mounting bolts of the final

drive assembly (3), and lift the final drive
assembly for removal.
★ Be careful not to damage the sealing surface
at the hose base.

★ When lifting the final drive assembly, do not

employ the threaded holes to lift the cover.

Final drive assembly: 250kg

Fig. 8-104

Installation

● Carry out the installation in reverse order of

the removal.

Mounting bolts of final drive assembly:

245~309N·m{25~31kgf·m}
● Add hydraulic oil again.
Add hydraulic oil to the specified level
through the oil filler cap, start the engine to
circulate the oil in the hydraulic system, and
check the oil level again.
● Bleed air.
See the section “Bleeding air from each
equipment” in chapter “Test and adjustment”
of this manual (pages 4-32).

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Disassembly and reassembly of final drive assembly

Disassembly
1. Drain oil
Loosen the drain plug, and drain oil from the
final drive case.

Final drive case: about 4.7 L

2. Cover

Remove the mounting bolts, and use the eye

bolt ① to remove the cover (1).

Fig. 8-105

3. Spacer
Remove the spacer (2).

Fig. 8-106

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4. No.1 planetary carrier assembly

1) Remove the No. 1 planetary carrier
assembly (3).

Fig. 8-107

2) Disassemble the No.1 planetary carrier

assembly.
3) Remove the screw (4), and take the
cover plate (5) from the planetary carrier
(6).
4) Remove the thrust washer (7), gear (8),
bearing (9), bearing inner race (10) and
thrust washer (11).

Fig. 8-108

5. No. 1 sun gear axle

Remove the No.1 sun gear axle (12).

8
Fig. 8-109

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6. Thrust washer
Remove the thrust washer (13).
7. No. 2 sun gear
Remove the No. 2 sun gear (14).

Fig. 8-110

8. Disassemble the No.2 planetary carrier

assembly.
1) Remove the screw (15), and remove the
retaining plate (16) and planetary gear
(17) from the planetary carrier (22).
2) Remove the bearing inner race (19) and
outer race (18), and retaining plate (20).
3) Remove the screw (21), and remove the
planetary carrier (22) and adjusting shim
(23) from the body.

Fig. 8-111

9. Hub assembly
1) Use the eye bolts ② to remove the hub
assembly (24) from the travel motor.

Fig. 8-112

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2) Disassemble the hub assembly as

follows.
3) Remove the floating seal (25).
4) Remove the bearings (26) and (27) from
the hub (28).
★ When removing the bearing (26),
do not damage the bearing retainer.

Fig. 8-113

5) Remove the floating seal (29) from the

travel motor (30).

Fig. 8-114

Reassembly
★ Clean all parts, check for dirt or damage, and
apply engine oil to the sliding surface of the
parts before installation.

1. Hub assembly
1) Fit the bearings (26) and (27) to the hub
(28).
2) Install the floating seal (25).

Fig. 8-115

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★ Clean oil and dirt off the O-ring and the

contact surface, and dry the parts before
installing the floating seal.
★ After installing the floating seal, check if
the seal ramp is within 1mm.
★ After installing the floating seal, apply a
thin coat of engine oil to the sliding
surface.

Fig. 8-116

3) Install the floating seal (29) to the travel motor

(30).
★ The installation procedure is the same as
step 2 above.

Fig. 8-117

4) Use the eye bolts ② to lift and lower the hub

assembly (24) to the travel motor, and
carefully fit the bearing.

Fig. 8-118

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2. Calculating the thickness of adjusting shim

1) Measure the boss height H of the No.2
planetary carrier (22).

Fig. 8-119

2) Measurement of height difference of the

bearing under load. Apply a load of 3,000 Kg
to the bearing, and measure the projection h
of the bearing.
★ Rotate the hub 2-3 times prior to Applying a load of 3,000
application of thrust. kg

★ Never use a torch to heat the bearing up.

★ Do not push or hit the holding valve.
3) Calculate the thickness of the adjusting shim:
C=H-h

Fig. 8-120

4) Set the adjusting shim on the body, insert the

dowel pin, fit the planetary carrier to the dowel
pin, and fasten it with the screw (21). Apply
the thread-locking adhesive to threads of the
screw.
Push-pull scale
Thread locking adhesive (LOCTITE
1277)
Screw (21):
539±28N·m{55±2.9kgf·m}
★ Use a tension gauge to measure the
tangential force of the hub against the
motor case in the rotation direction.
8
● Tangential force: Max. 294N {30kg} Fig. 8-121
● The tangential force is the largest at
the start of the rotation.

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3. Reassemble the No.2 planetary carrier

assembly.
1) Reassemble the No. 2 planetary carrier
assembly as follows.
★ Replace the retaining plate (20) and (16)
with new ones.
2) Install the bearings (18) and (19) to the gear
(17), install the top retaining plate (16) and
bottom retaining plate (20), and set the gear
assembly on the planetary carrier (22).
3) Fix them with the screw (15).
Screw (15):
539±28N·m{55±2.9kgf·m} Fig. 8-122

★ After assembling the planetary carrier

assembly, check if the gear (17) is able
to rotate freely.

4. Thrust washer
Install the thrust washer (13).
5. No. 2 sun gear
Install the No. 2 sun gear (14).

Fig. 8-123

6. No. 1 sun gear axle

Install the No. 1 sun gear axle (12)

Fig. 8-124

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7. No.1 planetary carrier assembly

1) Install the No. 1 planetary carrier assembly as

follows.
★ Replace the thrust washers (7) and (11)
with new ones.
2) Install the bearings (9) and (10) to the gear
(8), install the top thrust washer (7) and
bottom thrust washer (11), and set the gear
assembly in the planetary carrier (6).
3) Fix the cover plate (5) to the planetary carrier
(6) with the screw (4).

Fig. 8-125

4) Install the No. 1 planetary carrier assembly

(3).

Fig. 8-126

8. Spacer
Install the spacer (2).

Fig. 8-127

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9. Cover
Using eye bolts ①, install the cover (1), and
use a torque wrench to tighten the mounting
bolts.
Mounting bolts:
73.4±3.63N·m{7.5±0.4kgf·m}
Torque wrench
10. Refilling with oil
Tighten the drain plug, and add engine oil
through the oil filler cap.

Final drive case: about 4.7 L

★ After installing the final drive assembly to Fig. 8-128
the chassis, check the oil level at the
specified position.

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Removal and installation of swing motor and swing mechanism

assembly
Removal

Release the residual pressure from the

hydraulic circuit by referring to Section “Release
of residual pressure from hydraulic circuit” in
Chapter “Test and adjustment” of this Manual
(pages 4-28).

Lower the work equipment to the ground for

safety and stop the engine. Operate the bleed
valve of the breather valve to release the
residual pressure from the hydraulic tank, and
move the safety lock control lever to “LOCK”
position.
1. Remove the hose (1) through (7)
respectively.
(1) Between the tank and the swing motor
(port DR)

(2) Between the center swivel joint and the

swing motor (port DR)
(3) Between the swing motor and main valve
(port M)
(4) Between the swing motor and main valve
(port HA)
(5) Between the swing motor and main valve
(port HB)
(6) Between the swing motor and main valve
port Px (port SH)
(7) Between the swing motor and solenoid Fig. 8-129
valve block (port PG)

8. Remove the 11 bolts (8).

9. Lift the swing motor and swing mechanism
assembly (9) for removal.
★ Slowly lift the swing motor and swing
mechanism assembly to avoid
damaging hoses and other parts.

Swing motor and swing mechanism

assembly: 260 kg
8

Fig. 8-130

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Installation

● Perform the installation in reverse order of the

removal.

Mounting bolts of the swing motor and

swing mechanism assembly:
490~608N·m{50~62kgf·m}
● Re-add hydraulic oil
Add hydraulic oil to the specified level
through the oil filler, start the engine to
circulate the oil in the hydraulic system, and
then check the oil level.
● Air bleeding
See the section “Bleeding air from each
equipment” in chapter “Test and adjustment”
of this manual (pages 4-32).

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Disassembly and reassembly of swing motor and swing mechanism

assembly
Disassembly
1. Drain oil
Loosen the drain plug, and drain oil from the
swing gearbox.

Swing gearbox: about 4.4 L

2. Swing motor assembly

1) Move and lower the swing motor and
swing mechanism assembly to the
frame, and be careful not to damage the
drive gear or touch the ground.
2) Remove 14 mounting bolts to remove the
swing motor assembly (1).

Swing motor assembly: 70kg

Fig. 8-131

3. No. 1 sun gear

1) Remove the No. 1 sun gear (2).

Fig. 8-132

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4. No.1 planetary carrier assembly

1) Remove the No. 1 planetary carrier
assembly (3) and backing plate (4).

Fig. 8-133
2) Disassemble the No. 1 planetary carrier
First loosen the riveted portion of the shaft
(8), remove the shaft (8), and then remove
the gear (6), bearing (9) and backing plate (7)
successively.

Fig. 8-134
5. Ring gear
Remove the mounting bolts and then the ring
gear (10).

Fig. 8-135

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6. No. 2 sun gear

Remove the No. 2 sun gear (11).

Fig. 8-136

7. No. 2 planetary carrier assembly

1) Remove the No. 2 planetary carrier
assembly (12).

Fig. 8-137

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2) Disassemble the No. 2 planetary carrier

assembly with hand as follows.
3) Insert the pin (13) totally into the shaft
(14), and push out the shaft (14) from the
planetary carrier (19).
★ After removing the shaft, pull out the pin
(13).
4) Remove the thrust washer (16), gear
(17) and thrust washer (19).
5) Insert the pin (15), remove the bearing
(18) from the shaft, and pull out the pin
(15).
Fig. 8-138

8. Snap ring
Remove the snap ring (20).

Fig. 8-139

9. Disassembly of the main shaft Press out

1) Set the shaft housing assembly on the

press machine, and push the shaft
assembly (21) out of the shaft housing
assembly (22).

Fig. 8-140

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2) Disassemble the shaft assembly as Press out

follows.
Remove the bearing (23) from the shaft
(24).

Fig. 8-141
10. Bearing
Withdraw the bearing (25) and oil seal (26)
from the housing (27).

Fig. 8-142

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Reassembly

★ Clean all parts, check for dirt or damage, and

apply oil to the sliding surface of the parts
before reassembly.

1. Bearing
Fit the bearing (23) to the housing (27).

Fig. 8-143

2. Oil seal
Fit the oil seal (26) to the housing (27).
Oil seal installation surface: Gasket
sealant (LOCTIT 515)

Fig. 8-144

3. Housing assembly
1) Set the plate (28) on the shaft (24).
2) Set the housing assembly (22) on the
shaft (24), and fit the bearing.

Fig. 8-145

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4. Bearing
Fit the bearing (25).
★ When fitting the bearing, press the inner
race and the outer race at the same time,
and do not press the inner race only.
★ After fitting the bearing, check if the
housing rotates freely.

Fig. 8-146

5. No. 2 planetary carrier assembly

1) Reassemble the No. 2 planetary carrier
as follows.
2) Install the backing plate (16) to the
planetary carrier (19).
3) Install the gear (17) to the planetary
carrier (19). Fit the bearing (18) to the
shaft (14). Align the pin holes, and gently
knock in the pin (15) using a rubber
hammer. Note that the pin (15) shall not
extrude from the bearing (18).
4) Push the shaft assembly into the
planetary carrier (19), avoiding damaging
the gear and the backing plate. Align the Fig. 8-147
pin holes on the shaft and the planetary
carrier, and carefully knock the pin (13)
into the pin hole with a rubber hammer.
★ When installing the shaft, rotate the
planetary gear. Be careful not to
damage the thrust washer.

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6. Successively install the snap ring (20), No. 2

No.2 planetary
planetary carrier and No. 2 sun gear (11). carrier

Fig. 8-148
7. Install the ring gear.
Apply sealant to the mating face C as shown
in the figure, and fix it with a screw. Be careful
not to apply sealant to the ring gear (10).
Mating face: Sealant (LOCTITE
515).

Fig. 8-149
8. No.1 planetary carrier assembly
1) Reassemble the No. 1 planetary carrier
as follows.
2) Set the backing plate (7) on the planetary
carrier (5).
3) After installing the bearing (9) to the
gear, set the gear (6) on the backing
plate.
4) Fit the shaft (8) to the gear (6) and
planetary carrier (5), and rivet one end of
the shaft. Fig. 8-150
★ Check if the gear is able to rotate
freely.

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5) Install the No. 1 planetary carrier

assembly (3) and backing plate (4).

Fig. 8-151

9. No. 1 sun gear assembly

Install the No. 1 sun gear (2).

Fig. 8-152

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10. Install the swing motor assembly

After applying sealant to the contact surface
between the ring gear and the motor cover,
install the swing motor assembly.
Mating face: Sealant (LOCTITE 515)

Swing motor assembly: 55kg

Mounting bolts of the swing motor:
156±5N·m{16±0.5kg}
★ The 14 mounting holes of the swing
motor and swing mechanism assembly
are not uniformly distributed. Their
aligning is unique, as shown in the right
figure. When mounting the swing motor,
be sure to correctly align the threaded
holes.
11. Re-add lubricating oil
Tighten the drain plug, and add lubricating oil
to the specified level (“High” scale of the oil
dipstick) from the oil filler.

Swing gearbox: about 4 L

Fig. 8-153

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Disassembly and reassembly of idler assembly

Disassembly
1. Remove the dowel pin (1) and support (2).
2. Remove the floating seal (3) from the support
(2) and idler (4).
3. Remove the O-ring (11), and remove the idler
(4) from the shaft (5) and support assembly
(7).
★ Before disassembling the idler, drain the
accommodated oil (about 80 ml). Lay a
piece of cloth on the floor for protection.

Fig. 8-154

4. Remove the other floating seal (6) from the

idler (4), shaft (5), and support assembly (7).

Fig. 8-155

5. Remove the dowel pin (8), and remove the

support (7) from the shaft (5).
6. Remove the bushings (9 and 10) from the idler
(4).

Fig. 8-156

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Reassembly
1. Fit the bushings (9 and 10) to the idler (4).

Fig. 8-157

2. Install the O-ring, and install the support (7) to

the shaft (5) using the dowel pin (8).

Fig. 8-158

3. Install the floating seal (6) to the idler (4), shaft

(5) and support assembly (7).
★ Floating seal
Before installing the floating seal, eliminate
the grease on the contact surface between
the O-ring and the floating seal (hatched area
in the figure). Besides, make sure there is no
dust on the contact surface of floating seals.

Fig. 8-159

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★ After installing the floating seals, check

that the seal ramp is not more than 1mm,
and check that the projection a is kept
within 5-7mm.

Fig. 8-160
4. Install the shaft (5) and support assembly (7)
to the idler (4).

Fig. 8-161
5. Install the floating seal (3) to the idler (4) and
support (2).
★ Apply oil to the sliding surface of the
floating seal, and make sure it is free of
dirt or dust.
★ Eliminate oil and dust from the contact
surface between the O-ring and the
floating seal.

Fig. 8-162

Fig. 8-163

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6. Install the O-ring, and install the support (2)

using the dowel pin (1).
7. Add oil and tighten the plug.

Oil: about 80 ml (No. 18 hypoid gear oil)

Plug: 205.8±49N·m {21±5kgf·m}

Fig. 8-164

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Removal and installation of sprocket

Removal

1. Remove the track shoe assembly. See

“Removal of track shoe assembly” for details.
2. Swing the work equipment by 90°, push up the
chassis with the work equipment, and place
the block ① between the track frame and the
track shoe.

3. Remove the sprocket (1).

Sprocket: 58kg

Fig. 8-165

Installation
● Perform installation in reverse order of the
removal.

Threads of sprocket mounting bolts:

Thread sealant (LOCTITE 1277)
Sprocket mounting bolts:
339±20N·m{35±2kgf·m}

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Removal and installation of track assembly

Special tool
Symbol Part name Necessity Quantity
Manual and
electric
M hydraulic ● 1
track pin
press
Removal of track assembly

1. Select a field which has enough space to

spread the track. Stop the machine when the
king pin is located in the middle of the idler
and the support roller.
2. Lower down the work equipment, loosen the
oil nipple (1), and release the track tension.

Keep the cylinder in extreme high

pressure through adjustment. Loosen the
oil nipple by not more than one turn. If no
oil flows out, move the machine back and
forth.

Fig. 8-166

3. Pull out the main pin (2) using the tool M.

Fig. 8-167

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4. Remove the tool M, move the machine

forward till the temporary pin ② is in front of
the idler, and place the block ①.
5. Remove the temporary pin ②, remove the
dust seal, and move the machine backward to
spread the track (3).

Fig. 8-168

Installation
● Perform the installation in reverse order of the
removal.

Corner Track shoe nut

★ Refer to “Inspection and adjustment of track (square)

shoe tensioner” in chapter “Test and

adjustment” of this manual (pages 4-17).
● The installation procedures for track shoe bolt
and nut
Corner
1) Turn the R side of the track shoe nut (1)
to the surface of the link rod seat. The Corner
track shoe shall be so installed that the
two seat surfaces contact closely.
★ If the track shoe bolt is installed in
Seat surfaces
reverse, the corner of the nut will must contact
interfere with the surface of the link rod closely

seat, leading to rise of the nut and

looseness of the bolt.
2) Tighten the track shoe bolt to the
following torque.
Bolt of track shoe:
750±30N·m{77±3kgf·m}

8
Fig. 8-169

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★ Use the tool M to fit the king pin, satisfying the

projection dimension a.
Projection a of the king pin: 2.5±1mm

Fig. 8-170

★ Before installing the dust seal, apply grease

(No. 2 lithium base grease) to the contact
surface of the dust seal and bushing.

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Removal and installation of swing bearing assembly

Removal
1. Remove the turntable assembly according to
section “Removal of turntable assembly”.

2. Remove the 36 mounting bolts (1) to remove

the swing bearing assembly.

Fig. 8-171

3. Lift the swing bearing assembly (2).

Swing bearing assembly: 314kg

Fig. 8-172

Installation
● Perform the installation in reverse order of the
removal.

Threads of mounting bolts of swing

bearing:
Thread locking adhesive (Tianshan 1277)
Mounting bolts of swing bearing:
8
Step 1:
Use a pneumatic wrench to tighten the bolts.
Step 2:
Tighten the bolts to 549±59N·m {56±6kgf·m}.

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1) When using a torque wrench to tighten the

bolts, first tighten the bolts at four corners, and
mark them.
2) The remaining bolts shall be tightened in an
clockwise or anticlockwise order. Tighten one
bolt, then tighten the other diagonally
opposite, and mark them.
3) Follow the above manner till the bolts are all Inner race soft zone
tightened.

★ As shown in the figure, install the swing

bearing to the track frame, with the mark
S on the inner race soft zone facing right.
Fig. 8-173
★ Apply grease to the ring rear of the swing
bearing.
● Gears shall be fully applied with
grease.
Swing bearing:
Grease (Molybdenum disulfide lithium base
grease) 15 L

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Removal and installation of turntable assembly

Removal

Fully extend the arm and bucket, lower the work

equipment to the ground, and place the safety
lock control lever in the Lock position.
1. Disassemble the work equipment assembly
according to section “Disassembly of work
equipment assembly” of this manual.
2. Remove the counterweight assembly
according to section “Removal of
counterweight assembly” of this manual.

3. Remove the 4 hoses (1) from the boom

cylinder.
★ Plug the hoses to prevent oil from
escaping.

Fig. 8-174

4. Lift the boom cylinder assembly (2).

Fig. 8-175

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5. Remove the plate (3) and pin (4), and lift the
boom cylinder assembly (2) for removal.
★ Remove the other boom cylinder in the
same manner.

Boom cylinder assembly: 230kg

Fig. 8-176
6. Air inlet hose (6) and fan cover (7).

★ When removing the turntable, remove

other parts that would interfere with its
lifting.

Fig. 8-177
7. Remove the 6 hoses above the rotary joint
assembly on the side of swivel joint.
(8): Between the center swivel joint (port A)
and
the left travel control valve (port BTL)
(9): Between the center swivel joint (port C)
and
the left travel control valve (port ATL)
(10) Between the center swivel joint (port F)
and the solenoid valve
(11): Between the center swivel joint (port G)
and
the swing motor (port T)
(12): Between the center swivel joint (port D) Fig. 8-178
and
the right travel control valve (port ATR)
(13): Between the center swivel joint (port B)
and
the right travel control valve (port BTR)
8. Remove the bolt (14).

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9. Remove the 32 mounting bolts of the

turntable, remove the turntable assembly (15),
and then lift and move it away.
★ First remove the two front and rear
mounting bolts, use a lever block to
adjust the turntable, making it balanced
horizontally and vertically, and then
remove the remaining two bolts.

When removing the turntable, avoid

bumping with the center swivel joint
assembly.

Turntable assembly
Turntable only
Assembly
(reference value)
Fig. 8-179
8,427kg 1,689kg
Installation
● Perform the installation in reverse order of the
removal.

Clamping screw of air inlet hose:

5.4~6.4N·m{0.55~0.65kgf·m}

Swing bearing mating face:

Flange sealant (Tianshan 1596)
Threads of the mounting bolts of
turntable:
Thread locking adhesive (Tianshan 1277)
Mounting bolts of the turntable:
Step 1: Use a pneumatic wrench to
tighten the bolts
Step 2: Tighten the bolts again
490~608N·m{50~62kgf·m}
● Re-add hydraulic oil
Add hydraulic oil to the specified level
through the oil filler, start the engine to
circulate the oil in the hydraulic system, and
then check the oil level.
● Bleed air
Bleed air from the travel motor according to
section “Bleeding air from each equipment” in
chapter “Test and adjustment” of this manual
(Pages 4-32). 8

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Removal and installation of center swivel joint assembly

Removal

Release the residual pressure from the hydraulic

circuit according to the content related to release
of residual pressure from hydraulic circuit in
chapter “Test and adjustment”.
★ Tag all pipelines for easy installation.

1. Disconnect the following 6 hoses from the

center swivel joint of travel motor.
(1) Between the center swivel joint (port T)
and the left travel motor (port T)
(2) Between the center swivel joint (port T)
and the right travel motor (port T)
(3) Between the center swivel joint (port B)
and the left travel motor (port PA)
(4) Between the center swivel joint (port D)
and the right travel motor (port PB)
(5) Between the center swivel joint (port A)
and the left travel motor (port PB)
(6) Between the center swivel joint (port C) Fig. 8-180
and the right travel motor (port PA)

2. Disconnect the hose (7) through (14).

(7) Between the center swivel joint (port F)
and the left travel motor (port P)
(8) Between the center swivel joint (port F)
and the right travel motor (port P)
(9) Between the center swivel joint (port G)
and the swing motor (port T)
(10) Between the center swivel joint (port F)
and the solenoid valve
(11) Between the center swivel joint (port C)
and the left travel control valve (port ATL)
(12) Between the center swivel joint (port A)
and the left travel control valve (port BTL) Fig. 8-181
(13) Between the center swivel joint (port D)
and the right travel control valve (port
ATR)
(14) Between the center swivel joint (port B)
and the right travel control valve (port
BTR)
3. Remove the bolt (15).

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15. Remove the 4 mounting bolts (16).

Fig. 8-182
16. Remove the 6 mounting bolts (17) from the
transition plate, and remove the center swivel
joint assembly (18).

Center swivel joint: 56kg

Transition plate

Fig. 8-183
Installation
● Perform the installation in reverse order of the
removal.

Center swivel joint

Install the center swivel joint in such a way
that it faces the direction indicated in the
Sprocket
figure. (The figure is the top view of the
machine.)
● Refilling with oil (hydraulic tank)
★ Add oil through the oil filler cap to the
specified level. Start the engine to
circulate the oil in the system. Check the
oil level again.
8
● Air bleeding Fig. 8-184
★ Bleed air from the travel motor according
to the content related to bleeding air from
each equipment in chapter “Test and
adjustment”.

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Disassembly and reassembly of center swivel joint assembly

Disassembly
1. Remove the mounting bolt (1) and spring
washer (2).
2. Remove the cover (3).
3. Remove the gasket (4), O-ring and snap ring
(6).
4. Remove the swivel shaft from the swivel rotor
(9).
★ Be careful not to damage the sliding
surface of the swivel shaft (13) seal.
5. Remove the spacer (7) and gasket (8) from
the swivel rotor (9).
6. Remove the dust ring (12) from the swivel
shaft (13).
7. Remove the O-ring (11) and rotary seal (10)
from the swivel rotor (9).

Fig. 8-185

Fig. 8-186

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Reassembly

1. Install the dust ring (12) onto the swivel shaft

(13).
★ Install the dust seal with the lip facing the Dust seal
swivel rotor.
2. Install the 6 rotary seal (10) to the swivel rotor
(9). lip

3. Fix the swivel shaft (13) to the work bench.

Install the swivel rotor (9) to the swivel shaft
(13). Swing body

★ The clearance between the swivel rotor

(9) and the swivel shaft (13) is about 0.1
mm. Therefore, the swivel shaft must be
inserted vertically and slowly in the axial
direction. Be careful not to damage the Fig. 8-187
rotary seal and O-ring.
4. Strike the swivel rotor (9) with a rubber
hammer to fit it to the swivel shaft in place.
5. Install the spacer (7) and gasket (8) to the
swivel rotor (9).
6. Install the gasket (4), O-ring (5) and snap ring
(6) to the swivel shaft (13).
7. Install the cover (3), and tighten the fixing bolt
(1) and spring washer (2).
Fixing bolt: 49N·m{5kgf·m}

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Removal and installation of

hydraulic tank assembly
Removal
1. Drain oil from the hydraulic tank.

Hydraulic oil: about 225L

2. Open the engine hood.
3. Remove the engine hood (1), cover plate (2),
and control valve cover (3).
4. Remove the hydraulic tank trim cover (4).

Fig. 8-188

5. Remove the bolt (5) for fixing an oil filter

bracket, and the upper partition (6) of main
pump.
6. Remove the return hose (7) of main pump.

Fig. 8-189

7. Remove the radiator return steel pipes (8) and

(9).

Fig. 8-190

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8. Remove 6 hoses
(10): Return hose Dr1/Dr3 of main valve
(11): Return hose Dr2 of main valve
(12): Temperature sensor
(13): Return hose of swing motor
(14): Return hose of pilot block T
(15): Return hose of solenoid valve
★ Tag the removed hoses.
★ Use sleeve nuts to protect pipe joints
and cone seals against damage.
9. Remove the set bolt (16). Fig. 8-191
10. Lift the hydraulic tank assembly and remove
the 6 mounting bolts (17).

11. Lift and move away the hydraulic tank

assembly for removal.

Hydraulic tank assembly: 130kg

Fig. 8-192

Fig. 8-193

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Installation

● Perform the installation in reverse order of the

removal.

Hydraulic tank drain plug:

58.8~78.5N·m{6.0~8.0kgf·m}

★ After tightening the hose clamping

screw, check that the screw is located
within the indicated range as shown in Screw
the figure.
Hose clamping screw:
8.8±0.5N·m{0.9±0.05kgf·m}
Upper
★ Install the hose clamp and tighten the side

clamping screw as shown in the right Lower

side
figure.

Fig. 8-194

Mounting bolts: Clamp

Tube Hose
245.2~308.9N·m{25~31.5kgf·m}
● Refilling with oil (hydraulic tank)
★ Add oil through the oil filler to the
specified level. Start the engine to
circulate the oil in the system. Check the
oil level again.
● Air bleeding
Clamp boss
★ See “Bleeding air from each equipment”
in “Test and adjustment” for details.
Fig. 8-195

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Removal and installation of control valve assembly

Removal

Lower the work equipment to the ground for

safety, and stop the engine. Use the breather
valve to release the residual pressure from the
hydraulic tank, and set the safety lock control
lever to the LOCK position.
★ Tag each pipeline for easy installation.
1. Open the engine hood (1).
2. Remove the cover (2) over the control valve.

Fig. 8-196

3. Remove the noise shield (3) of the engine.

Fig. 8-197

4. Remove and tag the pilot pipeline (4) through

(9).
(4): XAK Bucket digging
(5): XBb1 Boom lowering
(6): XAtL Left travel
(7): XBa1 Arm digging
(8): XBs Right swing
(9): XAtr Right travel

Fig. 8-198

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5. Remove and tag the pilot pipeline (10) through

(18).
(10): XBtr Right travel
(11): XAs Left swing
(12): PSP Swing priority
(13): XAa1 Arm dumping
(14): XBp2 Bucket converging
(15)：XBtL Left travel
(16): XAb1 Boom lifting
(17): XBK Bucket digging
(18): XAa2 Arm dumping Fig. 8-199

6. Remove the accumulator to the solenoid valve

port (19) and the pilot filter to the accumulator
port (20), and remove the mounting pipe
clamp (21) connecting the center swivel joint
hose.
7. Remove the bucket hoses (22 and 23), and
seal the ports.
Fig. 8-200
8. Remove the arm hoses (24 and 25), and seal
the ports.
9. Remove the steel boom pipes (26 and 27),
and seal the ports.

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10. Remove the center swivel joint hoses (28, 29,

30 and 31), remove the high/low speed
switching hose (32), and seal the ports.

Fig. 8-201

11. Remove the swing motor hoses (33 and 34),

remove the swing motor feed hose (35), and
seal the ports.

Fig. 8-202

12. Remove the steel pipe (36) between the main

valve and radiator.

Fig. 8-203

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13. Remove the oil return hose (37) between the

oil radiator and hydraulic tank, and seal the
ports.

Fig. 8-204

14. Remove the hydraulic pump hoses (38 and

39).

Fig. 8-205

15. Remove and tag the solenoid valve hose (40)

through (44).
(40): Swing priority
(41)：bypasscut2
(42)：bypasscut1
(43): Secondary pressurization
(44): In and out of arm 2 Fig. 8-206

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16. Remove the set bolt (45), and lift the control
valve assembly (46) for removal.

Control valve assembly: 220kg

Fig. 8-207

Installation
● Perform the installation in reverse order of the
removal.
● Refilling with oil (hydraulic tank)
★ Add oil through the oil filler to the
specified level. Start the engine to
circulate the oil in the system. Check the
oil level again.
● Air bleeding
★ Bleed air from the circuit between the
valve and hydraulic cylinder. See
“Bleeding of each equipment” in chapter
“Test and adjustment” for details.

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Removal and installation of hydraulic pump assembly

Removal

Lower the work equipment to the ground and

stop the engine. Press down the relief button of
the breather valve on the hydraulic tank to
release the pressure from the tank.

Before operation, remove the cable from the

negative terminal of the battery.
Oil stopper
★ Tag all pipelines for easy installation.
1. Remove the suction filter from the hydraulic
tank, and use a stopper to prevent oil from
escaping.
★ If the stopper is not available, remove the
drain plug, and drain oil from the Fig. 8-208
hydraulic tank and pipelines.

Hydraulic tank: about 225 L

2. Lift the engine hood (1).

Fig. 8-209

3. Remove the engine hood strut (2) and

mounting bolt (3), and then lift the engine
hood for removal.

Fig. 8-210

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4. Remove the upper right cover plate (4)

Fig. 8-211

5. Remove the inlet hose (5) of proportional

valve and outlet hose (6) of pilot pump, and
seal the port.
6. Remove the lower partition (7) of main pump.

Fig. 8-212

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7. Remove the right door (8).

8. Remove the hydraulic pump cover (9).

Fig. 8-213

9. Remove the drain hose (10) and seal the port.

10. Remove the high-pressure hoses (11 and 12)
to the control valve, and seal the ports.
11. Remove the pressure sensor harness (13).
12. Remove the suction hose (14) from the pilot
pump and cap the joint.
13. Remove the suction pipe (15) from the
hydraulic pump and seal the port.

Fig. 8-214

14. Remove the solenoid valve harnesses (16 and

17) and clamps (18 and 19).

Fig. 8-215

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15. Remove the 4 set bolts (20) of hydraulic pump, and lift
the hydraulic pump assembly (21) for removal.

Hydraulic pump assembly: 112kg

Fig. 8-216

Installation
● Perform the installation in reverse order of the
Screw
removal.

★ After tightening the hose clamping

screw, check that the screw is located as Upper
shown in the right figure. side

Lower
Clamping screw of the suction hose: side

8.8±0.5N·m{0.9±0.05kgf·m}

Fig. 8-217

★ Install the hose clamp and tighten the

clamping screw as shown in the right
figure. Tube Clamp Hose

Fig. 8-218 8

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Mating face of hydraulic pump housing:

Gasket sealant (LOCTIT 515)
● Add the oil again (hydraulic tank)
Add oil through the oil filler to the specified
level. Start the engine to circulate the oil in
the system. Check the oil level again.

Hydraulic tank: about 225 L

● Air bleeding
See “Bleeding air form each equipment” in
chapter “Test and adjustment” of this manual.

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Removal and installation of oil seal in the input shaft of hydraulic pump
Removal

1. Remove the hydraulic pump assembly (1)

according to section “Remove the hydraulic
pump assembly”.
2. Remove the screw (2), and separate the
bearing cover plate (3).
3. Use a screwdriver to pry the oil seal (4) out.
★ When prying the oil seal out, be careful
not to damage the shaft.

Fig. 8-219

Installation

● Perform the installation in reverse order of the

removal.

Oil seal lip: Grease (No.1

Calcium-based grease)
Oil seal periphery: Grease (No.1
Calcium-based grease)
★ Apply a thin coat of grease to oil seal
periphery.

Fig. 8-220

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Disassembly and reassembly of pilot valve assembly of work equipment

★ This section will only focus on the precautions that should be observed during reassembly of the
pilot valve assembly of work equipment.

Fig. 8-221
Reassembly

● Reassemble the pilot valve assembly of work

equipment.

1. Install the port connecting plate (9) to the ★ Apply thread-locking adhesive (Tianshan
housing (8) with O-ring, and tighten the socket 1277) to the two inner threaded points
head screw (10). indicated in the figure below, 0.02g for
each.
Socket head screw:
25~33N·m{2.55~3.36kgf·m} Joint (3):

2. Install the spring (7) into the spool cavity of the 98~133N·m{10~13.5kgf·m}
housing (8), and insert the spool (6) into the ★ Be sure to tighten the joint to the
spring. Install the push rod (5) on the spool, specified torque.
and press the push rod (5) into the spool
cavity by hand.
3. Install the fixing plate (4) to the push rod (5),
and tighten the joint (3).
4. Install the circular plate (2) and adjust it
properly. Tighten the set nut (1).
Set nut:
98~133N·m{10~13.5kgf·m}
★ The position of each oil port is stamped
at the bottom of the valve body.
Push rod (5) periphery: Fig. 8-222

Grease (No.1 Calcium-based grease) Contact surface between the push rod
(5) and circular plate (2):
Moving surface of the joint (3):
Grease 0.3~0.8 cc (No. 1 Calcium-based grease)
Grease (No.1 Calcium-based grease)
★ After reassembly of circular plate, refer to
Inner threads of valve housing: section “Adjustment of work equipment
Thread locking adhesive (Tianshan 1277) and swing pilot valve” in chapter “Test
and adjustment” of this manual (pages
4-25).

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Disassembly and reassembly of travel pilot valve assembly

★ This section will only focus on the precautions that should be observed during reassembly of the
travel pilot valve assembly.

Push rod

Fig. 8-223
Reassembly
● Reassemble the foot controlled pilot valve assembly.
1. Install the springs (8) into the spool cavity of the body (9), insert the spools (7) into the springs. Set
the body (6) on the top of the spools, and hold the body (6) with hand.
2. After aligning the mounting holes, install the cover plate (4) and tighten the socket head screws (1).
Socket head screw: 98~114N·m {10~11.6kgf·m}
3. Install the dust rings (3) to the push rods. Install the cams (2), and fix them with the camshafts (5).
Contact area between the push rod and dust ring (5): Grease (No.1 Calcium-based grease)

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Disassembly and reassembly of hydraulic cylinder assembly
Special tool
Tool name Sketch Necessity Quantity

Bushing removal
■ 1
and installation

Dust ring
■ 1
installation

Seal installation
■ 1
and correction

Insertion tool Correction tool

Cylinder head
■ 1
installation

Piston
■ 1
installation

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Disassembly
1. Drain oil and remove all connected
pipes/hoses.
2. Secure the cylinder.
★ Secure the cylinder horizontally or
vertically. A cylinder secured vertically is
easier for disassembly and reassembly.
● Install a pin shaft to the pin hole on the
larger chamber against rotation.
★ If the pipes/hoses would interfere with
the above operation, they shall be
removed in advance.

Secure the
cylinder

Fig. 8-224

3. Removal of the cylinder head About 1.5 m

★ Use a hex wrench to loosen and remove

the bolts.
★ As shown in the right figure, use a hex
wrench with an extension handle to
loosen bolts easily.

Fig. 8-225

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4. Withdraw the piston rod.

★ Confirm that the covers of all attached
pipes/hoses have been removed.
★ Prepare a container to catch the oil
drained from the ports.
★ Withdraw the piston rod (1) to the limit
position, and slowly separate the cylinder
head. Wooden
blocks
★ Withdraw the piston rod (1) and cylinder
head (2) together, and place them on
wooden blocks.
Fig. 8-226
5. Secure the piston rod.
★ Secure the piston rod by using the pin
holes or plane area at the end to prevent Secure
rotating.

Fig. 8-227
6. Removal of the piston nut (5) Drilling bit

1) Remove the set screw (3) of the piston

nut.
★ Two positions on the outer
periphery of the set screw shall be
punched to avoid looseness. Use a
hand drill to remove the riveted part,
and loosen and remove the set
screw (3).
2) Remove the steel ball (4) from the set
screw.
3) Remove the piston nut (5). Fig. 8-228
★ The piston nut (5) has been
tightened to a large torque. To
loosen the piston nut (5), prepare a
hydraulic jack or a power wrench of
hydraulic cylinder. To loosen the
nut using a manually operated
wrench, prepare an extension rod
prior to the operation. Hydraulic jack

Hydraulic
cylinder

Fig. 8-229

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7. Remove the piston and others.

Successively remove the piston (7), buffer bushing
(6) and cylinder head (2).

Fig. 8-230
8. Removal of the buffer bushing (8) on the rodless Thread
chamber side
1) First remove the piston nut (5). Otherwise, the
removal would not continue.
Piston rod
2) Without damaging the piston rod and buffer
bushing (8), use a rubber hammer or other tools
to strike the circlip (9) and remove it.
3) Slide the buffer bushing (8) in the direction of the
piston threads, and remove the split-type stop
ring.
4) Remove the buffer bushing (8). (Split type)
An opening
5) The buffer seal (10) has an opening. Employ this
opening to remove it.
Fig. 8-231
9. Remove the piston seal. Screwdriver
1) Remove the slide ring (12) and guard ring (13)
manually.
Piston
2) Use a hammer to strike a flat screwdriver
vertically, and cut off the seal ring (14).
3) Pry the O-ring (15) out. Bench clamp
★ The removed seal would not be used
anymore.

Fig. 8-232
10. Removal of the buffer ring (16)
★ The buffer ring (16) is installed in the inner
groove of the cylinder head. When removing the
buffer ring, use a pointed tool to pry it up, and
then insert a spatula to remove it.
11. Remove the U-ring (17) and dust ring (18).
1) Remove the U-ring (17) with tools, like a
screwdriver.
2) Use a screwdriver or other tools to pry the dust
8
ring (18) off by striking the screwdriver.
★ The removed seal would not be used
anymore.

Fig. 8-233

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12. Removal of the bushing (19)

1) Use a screwdriver to remove the circlip Press equipment

(20) from the cylinder head (2).

2) Push out the bushing (19) with the fixture
and press machine. Block

13. Removal of the pin bushing (21)

1) Use a screwdriver or other tools to
remove the dust ring (22) on the cylinder
tube and piston rod side. The operation
is the same as the removal of the
cylinder head dust ring. Support

2) Use a proper block to remove the pin

bushing (21). Fig. 8-234

Reassembly
1. Installation of pin bushing (21)
Press equipment
1) Use the installation tool to press it into
the bushing on the piston rod and
Installation tool
cylinder tube side (applied with hydraulic
oil prior to installation). Block
Piston rod
2) Use a proper block to install the dust ring
(22).

Fig. 8-235

2. Reassembly of the cylinder head assembly (2)

Hydraulic press
equipment
1) Use the press equipment to press the
bushing (19) in place.
★ Apply hydraulic oil to the inside of Tool
cylinder head prior to the operation,
and check the installed bushing
(19) for projected shoulder.
2) Use the press equipment to press the
dust ring (18) in place.
Surface under
pressure

Fig. 8-236

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3) Successively install the guard ring and U-ring

(17) to the U-ring groove (strictly following the
operation order). Tool
U-ring groove
★ First check that the U-ring (17) is free of
damage, and then install the U-ring as per
the correct direction. Using the press
equipment for
★ Installation in reverse direction would lead installation
to oil leak.
★ After installation, check the U-ring (17) for
wrinkle, permanent deformation, etc.
4) Install the buffer ring (16).
★ Note that the installation direction of the Fig. 8-237
seal ring shall be correct. If the ring is
installed in the reverse direction, the
extremely high pressure formed between
the ring and the U-ring (17) would lead to
cylinder deformation or damage.
5) To prevent the fall-off of the bushing (19), be
sure to install the circlip (20).
3. Reassembly of the piston assembly
1) Install the seal ring (14).
★ Install the O-ring and guard ring (13) to the
piston, place the piston on the press
machine, and install the seal ring (14) as
shown in the right figure. Fig. 8-238
2) Correct the seal ring (14) installed. Using the press equipment
Using the press equipment
for installation
Block for installation
★ After installing the seal ring (14) and the
guard ring (13) on the other side, be sure Tool
to correct the installed seal ring (14)
immediately. Since the seal ring (14) is
Tool
expanded during installation, the piston Correction tool

rod would not be inserted into the cylinder Piston

tube successfully if the seal ring were not
corrected properly. O-ring

3) Install the slide ring (12).

★ Using hands, expand the slide ring with
minimum effort and install it axially.
Expanding with too much effort would lead Fig. 8-239
to failure of installation.
4. Reassembly of the piston rod assembly. Assembly tool
1) Secure the piston rod (1).
2) Install the cylinder head (2) to the piston rod.
★ Note that the lips of the dust ring and
U-ring shall not be held against by the
projected shoulder. Use the tool to install
the cylinder head and piston rod.
3) Except the bucket cylinder, If there is a buffer on
the rodless chamber side, install the buffer
bearing and buffer seal in the following order.
4) Install the buffer seal (10) into the groove, with
the gap facing the piston. 8
Fig. 8-240

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5) The plane machining part of the buffer With the opening facing
the threads
bushing (8) should be installed as shown Thread

in the right figure.

6) Install the stop ring (11) into the groove.
Piston rod
Press the buffer bushing (8) to the end in
the direction of the stop ring, and install
the circlip. To avoid damaging the piston
rod and buffer bearing, use a rubber
hammer to strike gently.
7) If there is buffer on the rod chamber side,
install the buffer bushing (6) and buffer An opening (Split type)
seal (23) in the following order.
Buffer on the rodless
chamber side
8) Install the buffer bearing prior to the
installation of the piston nut. Otherwise, Fig. 8-241
the buffer bearing cannot be installed
anymore.
9) Install the buffer seal (23) into the
groove, with the gap facing the piston.

10) The plane machining part of the buffer

bushing (6) should be installed as shown
in the right figure.
11) Tighten the piston nut (5).
Piston nut (stick):
9600N·m{979.6kgf·m}
Piston nut (boom and bucket):
6200N·m{632.6kgf·m}
With the opening facing the
★ Insufficient tightening torque would piston
lead to internal leakage, nut Buffer on the rod chamber
looseness and thread damage. On side

the other hand, excessive

Fig. 8-242
tightening torque would lead to
buffer bearing expansion or the side
contacting the piston deformed.
★ Clean and degrease the threads of
the piston, nut and piston rod (with
banana oil or alike), and then
tighten the nut.

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12) Perform anti-looseness treatment to the

piston.
★ After tightening the piston nut (5),
install the ball (4), tighten the set Riveted
Punch pin

screw (3), and rivet it at two

positions on the periphery with a
punch pin.
Set screw (3):
66.9N·m{6.8kgf·m}

Fig. 8-243

5. Insert the piston rod into the cylinder tube. Tool

Nylon socket (split

1) Secure the cylinder tube vertically or type)
horizontally.
2) Insert the piston rod into the cylinder
(Alternate the gaps
tube. by 180 degrees)

★ If the cylinder tube is secured

vertically, the piston rod enters the
cylinder tube by means of its dead
weight.
★ When the piston enters the cylinder
tube, note that the slide ring shall
not fall off.

Fig. 8-244

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6. Cylinder head tightening

Refer to the cylinder head assembling figure,
and tighten the bolts in the order as shown in
the right figure.
Bolts: 267N·m {27.2kgf·m}
7. Install all necessary pipes/hoses.

Bolts tightening order

Fig. 8-245

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Removal and installation of work equipment assembly

Removal

Fully extend the arm and bucket, lower the work

equipment to the ground, and place the safety
lock control lever in Lock position.

Release the residual pressure from the

hydraulic circuit according to the section
“Release of residual pressure from hydraulic
circuit” in chapter “Test and adjustment” of this
manual (pages 4-28).

1. Disconnect the grease line (1).

2. Lift the boom cylinder assembly (2), and
remove the bolt (3).
3. Remove the plate (4) and then the pin roll (5).

★ Gaskets are installed. When removing

them, be sure to check their quantity and
thickness, and store them at a proper
place.
4. Start the engine and retract the piston rod.
★ Attach the piston rod with a cable to
prevent it from sliding out, and lower the
Fig. 8-246
hydraulic cylinder to the workbench or
place a support under the cylinder.
When placing a support underneath,
first remove the grease line joint at the
bottom of the cylinder.
★ Remove the other boom cylinder in the
same manner.

5. Remove the bucket cylinder hoses (6) and (7)

and arm cylinder hoses (8) and (9).
★ Plug the hoses to prevent oil from
escaping, and secure them to the valve
side.
6. Remove one work light connector (10).

8
Fig. 8-247

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7. Lift the work equipment, remove the plate (9),

remove the pin shaft (10) at the bottom, and
remove the trim plates (11) and (12).

★ Gaskets are installed. Remember to

check their quantity and record their
installation positions.

Fig. 8-248

8. Lift the work equipment assembly for

disassembling.

Work equipment assembly: 3451kg

Installation
● Perform the installation in reverse order of the
removal.

★ When the lock nut is being tightened, the

clearance a between the plate and nut
shall be maintained within 0.5-1.5mm.
Apply grease after installing the pin:
Grease (Molybdenum disulfide lithium base
grease)

When aligning with pin holes, never put

finger (s) into any pin hole.

Fig. 8-249

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★ Adjust gasket thickness, satisfying the

specified clearance a between the piston rod
head (12) and plate (4): 0.5＜a＜1mm.
★ Thickness of standard gasket: 1.0mm
and 2.0mm.

Apply grease after installing the pin:

Grease (Molybdenum disulfide lithium base
grease)

When aligning with pin holes, never put

finger (s) into any pin hole.
● Adding of hydraulic oil Fig. 8-250
Add hydraulic oil to the specified level, start
the engine to circulate the oil in the hydraulic
system, check the oil level again, and add
hydraulic oil if necessary.
● Bleed air
Bleed air from the travel motor according to
section “Bleeding air from each equipment” in
chapter “Test and adjustment” of this manual
(Pages 4-32).

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Removal and installation of HVAC assembly

Special tool
Symbo Part Necessit Quantit
Model
l name y y
Refrigera
Robinair
nt
34711-2 ● 1
charging
K
machine
S
Refrigera
nt Inoue
● 1
charging Qinghua
machine

Removal

First remove the cable from the negative

terminal of the battery.

1. Drain the cooling water.

Coolant: about 22.5 L

2. Use the tool S to collect refrigerant from the
HVAC.

Fig. 8-251

3. Remove the floor liner (1).

Fig. 8-252

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4. Open the rear left cover of the cab with the

ignition switch, and remove the air cleaner
element (12).

Fig. 8-253

5. Remove the fuse box (3) and glove box (4).

6. Remove the rear trim (5).
7. Remove the HVAC cover plate (6).

Fig. 8-254

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8. Remove the rear air duct (7).

9. Remove the left air duct (8).
10. Remove the retaining plate (9).
11. Remove the right air duct (10).

Fig. 8-255

12. Remove the cover (11).

13. Remove the cab center connector (12).
14. Remove the radio antenna (13).

Fig. 8-256

15. Remove the controller wire connector (14);

disconnect the safety relay connector (15);
disconnect 2 A/C relays (16); disconnect the
wiring (17) of the preheating relay; unplug the
relay (18), remove the set bolts (3 pieces)
under the relay, and remove the relay; remove
3 mounting bolts (19) and then the electrical
mounting plate.

Fig. 8-257

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16. Remove the A/C water pipes (20 and 21) from
the bottom plate, and remove the drain pipe
(22).

Fig. 8-258

17. Remove the HVAC unit (23).

★ When removing the HVAC unit,
remember to connect the 2 HVAC hoses
at the bottom.

Fig. 8-259

Installation
● Perform the installation in reverse order of the removal.
★ When installing the HVAC hoses, be careful not to allow dirt, dust and water to enter the hoses.
★ Check if the O-ring is installed in place before connecting each HVAC hose.
★ Check O-rings for damage or deformation.

★ Apply compressor oil (ND8#) to the threads of refrigeration pipe fittings, and tighten the pipe
using a double ended wrench.
Hose clamping screw: 8.83~ 14.7N·m {0.9~ 1.5 kgf·m}
Pressure plate bolts: 13.5±1.2N·m {1.38±0.12kgf·m} 8
● Charging with refrigerant
Use the equipment S to charge the HVAC circuit with refrigerant (HFC-134a).

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Removal and installation of counterweight assembly
Removal
1. Remove the cover (1) from the counterweight,
install the lifting bolts onto the counterweight,
and hang the counterweight.

Fig. 8-260

Wire rope

Fig. 8-261

2. Remove the 4 mounting bolts (2).

3. Use a wire rope or chain tackle to lift and
move the counterweight horizontally.
★ Be careful not to collide with the engine,
radiator and cooler.

Counterweight assembly: 3901kg

Fig. 8-262

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Installation

● Perform the installation in reverse order of the

removal.

Threads of counterweight mounting

bolts:
Thread locking adhesive (Tianshan 1277)
Counterweight mounting bolts:
1,180~1,470N·m{120~150kgf·m}

★ Installation and adjustment of

counterweight

1) Use a crane to lift the counterweight

to a proper place on the frame. Unit
Door
2) Move the counterweight, install the
mounting bolts, and satisfy the Counterwei
following dimensions through ght

adjustment.
● Clearance between the
counterweight and the
turntable:
10±5mm (left and right)
● Clearance between the Turntable
counterweight and the
machine door:
Fig. 8-263
10±5mm (left and right)
● The step difference between
the counterweight and the
turntable in the left and right
directions
b: Maximum 5mm
● The step difference between
the counterweight and the
machine door in the left and
right directions
a：10±4mm
● The step difference between
the counterweight and the roof
cover in the upward and
downward directions 8
c: Maximum 5mm

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Removal and installation of cab assembly

Removal

First remove the cable from the negative terminal

of the battery.
1. Remove the floor liner (1).

Fig. 8-264

2. Remove the cooler box (2) and glove box (3).

3. Remove the rear wall trim (4).
4. Remove the A/C upper cover plate (5).

Fig. 8-265

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5. Disconnect the left harness (6), display

harness connector (7) and windshield washer
harness (8).

Fig. 8-266

6. Remove the face blowing duct connector (9),

defroster duct connector (10) and back
blowing duct connector (11).

Fig. 8-267

7. Remove the fresh air filter element (12).

8
Fig. 8-268

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8. Remove the A/C air inlet duct (13).

Fig. 8-269

9. Please control the replenished part while

removing the electrical harness.

Fig. 8-270

10. Remove the wiper sprayer (15).

Fig. 8-271

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11. Remove the wiper spray pipe (16).

Fig. 8-272

12. Remove the 5 mounting bolts (17) and 4

mounting nuts (18) from the cab.

Fig. 8-273

13. Lift the cab assembly (19) for removal. Cab

assembly weight: 475KG

Installation
● Perform the installation in reverse order of the
removal. Fig. 8-274
8

Mounting bolts: 200N·m {20.4kgf·m}

Mounting nuts: 210N·m {21.4kgf·m}

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Removal and installation of cab windows

Fig. 8-275
(1) Right glass ★ The cab glasses (1), (5), (7), (8) and (9) are
(2) Front windshield glass held in place with adhesive.
(3) Front lower glass ★ When replacing the front windshield glass (2),
(4) Door window frame remove the front windshield assembly (12). (If
(5) Door glass the front windshield assembly is installed in
the cab, do not only replace the front
(6) Door sliding window glass
windshield glass). As the cab door glass and
(7) Left rear glass the sliding window glass are built-in sliding
(8) Rear windshield glass window assemblies, the glasses are required
(9) Sunroof glass to be replaced as a whole.
(10) Rubber weatherstrip ★ See “Removal and installation of front
(11) Front windshield lower weatherstrip windshield assembly” for replacement of the
(12) Front windshield assembly (front windshield front windshield assembly.
glass + front frame)

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Removal

When removing broken or cracked glasses,

avoid being hurt by sharp glass pieces. Secure
the broken or cracked glass using tapes or
alike before removal to avoid being hurt. Be
sure to remove the broken pieces. Protective
measures shall be taken before the
disassembly, and the glass shall be reinforced
with tape or the like to facilitate the safe
removal.
1. Removal of the glass (3). The glass is held in
place with weatherstrips. To remove it, slowly
pull the glass out from the bottom up.

Fig. 8-276

2. Removal of the glasses (4) and (6).

1) Remove the weatherstrips from the
window frames and door inner sides.
2) Gradually push the window frame from
the inside of the door to remove the
frame and glasses (4 and 6) as a whole.

Fig. 8-277

3) Remove the glasses (4 and 6) from the

window frame using a screwdriver.

Window
frame

Weatherstri
p

8
Fig. 8-278

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3. Removal of the glass (8).

1) Remove the stopper (rubber groove) with
a general screwdriver.
2) Insert a piece of bamboo stick into
Position A of the rubber strip, and pry the
rubber strip off.
3) Tap the glass with your palm from the
inside of the cab to remove the glass.
This operation needs to be completed by
two persons.

Fig. 8-279

4. Removal of the glasses (1, 2, 5, 7 and 9).

Fig. 8-280

1) Remove the resin plate, trim strips,

blocks, etc. around each glass.
Cab
2) Penetrate into the adhesive with an awl
Glass
(or knife) to make a hole.
Awl

Adhesive

Fig. 8-281

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3) Thread a piece of piano wire (or steel

wire) through the hole.

Piano wire (or

steel wire)

Fig. 8-282

4) Bind both ends of the piano wire on two

screwdrivers. Pull the piano wire back
and forth to cut the adhesive between Cab
(Outside of the cab)

the cab and the glass, and remove the

glass from the cab. This operation needs Glass
to be completed by 2~3 persons in
cooperation.
● Be sure to cut the middle position of
the adhesive between the glass and
the cab. When the piano wire
becomes hot, it is inclined to be
broken. Therefore, be sure to
change the contacting point of the
wire while cutting the adhesive. Adhesive

(Inside of the Cab)

Fig. 8-283

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Installation
1. Use a knife and spatula (5) to remove residual
adhesive and rubber seal from the cab metal
panel (surface sticked with glass).
★ Clean off the adhesive and rubber seal
until they would not affect the application
of new adhesive. Be careful not to
scratch the painted surface (or the
adhesion of adhesive would decrease).

Fig. 8-284

2. Use unleaded gasoline to remove oil, dust,

dirt, etc. from the surface of the cab (8) and
glass (9).
★ If the surface is not clean, the glass will
not be held in place with adhesive.
★ Clean the black part on the back of the
glass.
★ After cleaning the surface, leave the
glass for at least 5 min, allowing it to dry.

Fig. 8-285

Fig. 8-286

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3. Apply the primer (10).

★ The primer should be used within 4 months
starting from its manufacturing date. Do not use
the primer of which the storage time exceeds
this limit. Cab

★ After being unpacked, the primer should be used

up within 2 hours.
★ Even if the primer is re-packed immediately after
being unpacked, it should be used within 24
hours starting from the time when the primer is Trimmed edge of
unpacked. (After being unpacked for more than used adhesive on
cab side
24 hours, the primer should be discarded.）
1) Stir the primer (either applied to the cab or glass)
thoroughly before it is applied.
★ If the primer is kept in a refrigerator, leave
it under room temperature conditions for at Fig. 8-287
least half a day before stirring it.
★ (If the primer is unpacked just after being
taken out from a refrigerator, condensed
water forms in the primer. Therefore, it is
required to leave the primer under room
temperature conditions for a sufficient
period of time.)
2) The primer brush (11) should be cleaned in
unleaded gasoline prior to being reused.
★ After cleaning the brush, check for dirt
and foreign materials.
★ Prepare two brushes to apply the primer
to the cab and glass respectively.
3) Apply the corresponding primer to the adhesive
surface of rubber seal and the exterior adhesive
surface of the cab (8).
Primer on cab:
Sunrise MSI primer 24
★ The primer shall not exceed 2 coats.
(If the primer is applied more than two
times, its performance would decrease.)

Fig. 8-288
★ Application position: covering the full size
of (a).
● Application dimension (a): 25mm

Fig. 8-289

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★ Except for the above position, apply

the primer to the right side glass
and lower door glass.
● Application range on the right side
glass: (b)
● Application range on the lower door
glass: (c)
★ After applying the primer, leave it
for at least 5 min (within 8 hours),
allowing it to dry up.
★ Do not apply the wrong primer. If
the glass surface primer is wrongly
applied, use unleaded gasoline to
Fig. 8-290
remove it.

Fig. 8-291

4) Apply the glass surface primer to the

adhesive surface of glass (9).
Glass surface primer: Sunrise
MSI primer 35
★ The primer shall not exceed 2
coats.
(If the primer is applied more than
two times, its performance would
decrease.)

Fig. 8-292

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★ Application position: area around the

adhesive surface of the glass (9) (for the
installation of the rubber seal (6) and the
cab (8)).
★ Do not apply the primer to edges
approximately 5mm wide between the
black part and the transparent part of the
glass.
★ After applying the primer, leave it for at
least 5 min (within 8 hours), allowing it to
dry up.
★ Do not apply the wrong primer. If the
glass surface primer is wrongly applied, Fig. 8-293
use unleaded gasoline to remove it.

4. Install the rubber seal (6) along the inner edge

of glass adhesive (between adhesive strips).
★ Before installing the glass, do not
remove the separation strip for the
rubber seal on the glass.
★ When installing the rubber seal, avoid
touching the cleaned surface.
★ Do not allow the rubber seal on each
corner to rise.

Fig. 8-294

★ When installing the rubber seal (6) along

the frame periphery, do not overlap the
two ends. Instead, the clearance (e)
between the two ends of the rubber seal
shall be maintained as about 5mm.
1) Install the rubber seal (6) of the right side
glass to the position indicated in the right
figure.

Fig. 8-295
8

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★ Install an additional rubber seal (6a) to

the right side glass.
● The installation position of the additional
rubber seal (6a) :
（f）：50mm
（g）：90mm
（h）：250mm

Fig. 8-296

2) Install the rubber seal (6) of the left side

glass to the position indicated in the right
figure.

Fig. 8-297

3) Install the rubber seal (6) of the lower

door glass to the position indicated in the
right figure.

Fig. 8-298

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★ Install an additional rubber seal (6b) to

the lower door glass.
● The installation position of the additional
rubber seal (6b) :
（j）：110mm
（k）：90mm
（m）：200mm

Fig. 8-299

4) Install the rubber seal (6) of the front

windshield glass to the position indicated
in the right figure.

Fig. 8-300

★ Different from other rubber seals

(6), the rubber seal (6c) shall be
installed along the external edge of
the lower front windshield frame. (If
it is installed along the inner edge, it
will be seen through the transparent
glass from outside.)

8
Fig. 8-301

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5. Locate the newly installed glass

1) Check the upper, lower, left and right
clearance between the glass and the
cab, and then locate the glass, ensuring
even clearances.
2) Stick a piece of tape [6] to the connection
between the glass (9) and cab (8), and
draw a locating line (n).
★ To properly locate the right side
glass, rear left side glass and lower
door glass, stick the tape (6) at 3
points of the glass (left side, right
side and lower part).
3) Use a knife to cut the strip between the Fig. 8-302
glass (9) and cab (8), and remove the
glass.
★ Before installing the glass, do not
remove the strip on the left side of
the glass.

★ When locating the front windshield glass

(4), set its horizontal position to the frame
width;
The vertical position shall be so set that
the height difference (p) between the
frame top and the front windshield glass
is 3mm.

Fig. 8-303

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6. Apply adhesive.
★ The adhesive shall be stored in a dark
place where the temperature is lower
than 25℃.
★ Do not heat the adhesive to 30 ℃ or
above.
★ When reusing the adhesive, eliminate
the hardened adhesive on the nozzle.
1) Break the aluminum seal (13) at the
outlet of the adhesive bottle (12), and
install the nozzle.
Adhesive: Fig. 8-304

Sunrise MSI SR sealant U90 4463876

2) Cut the tip of adhesive nozzle to make

the cutting dimensions (q) and (r) shown
in the right figure.
● Dimension (q): 10mm
● Dimension (r): 5mm

Fig. 8-305

3) Set the adhesive bottle (12) on the

caulking gun [7].
★ Electronic caulking gun will be more
efficient.

Fig. 8-306
8

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4) Remove the separation strip for the

rubber seal on the glass.
5) Apply the adhesive (15) to the outer side
of the cab rubber seal (6).

Fig. 8-307

★ Apply the adhesive (15) to the

rubber seal (6) of cab (8) with the
dimensions (s and t).
● Dimension (s): 10mm
● Dimension (t): 15mm
★ The coat of adhesive (15) applied
shall be higher than the rubber seal
(6).
★ The adhesive should be applied
evenly, and the coat of adhesive
should be in the same level.
Fig. 8-308

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★ Apply the adhesive (15) to the additional

rubber seal (6a) and (6b) respectively of
right side glass and lower door glass.

Fig. 8-309

Fig. 8-310

7. Install the glass.

1) Install the glass (9), and align it with the
locating lines drawn in step 5.
★ It is not allowed to adjust or remove
the improperly installed glass.
Therefore, ensue that the glass is
successfully installed at one time.
★ Install the glass within 5 min after
the application of the adhesive.
2) After sticking the glass (9), press the
edge of the glass till it tightly sticks to the
rubber seal.
★ Press each corner of the glass with Fig. 8-311
8
force.

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★ After installing the front windshield glass,

fill the gap between the glass and the
center adjusting seal (16) within the
scope (s) with filler for the dimensions (t
and u). After applying the primer to the
glass (4) of Section A-A, apply the
adhesive.
● Caulking dimension (t): 2mm
● Caulking dimension (u): 5mm
★ When doing the caulking, use a rubber
spatula to cover the glass side and trim
the adhesive as shown in the figure.
★ Wipe off excessive adhesive.
Glass surface primer:
Sunrise MSI primer 35
Adhesive:
Sunrise MSI SR sealant U90 4463876

Fig. 8-312

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8. Secure the glass.

1) After installing the right side glass (1) to
the cab, insert the locating tape a (1~2
pieces) into the bottom of the glass to
secure the glass.

Fig. 8-313

2) Use styrofoam blocks [9] and rubber

bands [10] to secure the glass and the
rubber seal. This complete the
installation.
9. After the installation is completed, eliminate
excessive primer and adhesive on the cab and
glasses.
★ Before the adhesive dries up, use
unleaded gasoline to remove them.
★ During cleaning operation, do not apply
compact force to the glasses.
10. Protect the installed glasses.
1) Keep the locating tape, styrofoam blocks Fig. 8-314
and rubber bands in place for 10 hours.
(Under conditions: Temperature 20℃;
humidity 60%)
2) After removing the locating tape,
styrofoam blocks and rubber bands, wait
at least 14 hours before operating the
machine.

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Removal and installation of front window assembly

Lower the work equipment to the ground

and stop the engine.
★ To replace the front windshield glass, remove
the font windshield assembly from the cab.
Remove and install the front windshield
assembly (front windshield frame and front
windshield glass) according to the following
method.

Removal

1. Lift and level the front windshield assembly

with the sunroof, and secure it by the rear
locks (on both sides of the cab).
2. Remove the left gusset (1) and right gusset
(2).
★ The mounting bolt (4) and washer (3) of
the left gusset will be used to hang the
pull-up lever in step 6.
3. Unlock the front windshield, slide the front
windshield to the top till the upper rollers of
the front windshield run off the rail, and
remove the two upper rollers (each on the left
and right). (Fig. 8-271 and 8-272) Fig. 8-315

Fig. 8-316

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6. Remove the lower left pin (7).

★ After the lower left pin (7) is removed, the
plate (8) at the end of the pull-up lever
(9) is separated.
★ Hang the plate (8) on the mounting bolt
of the left gusset, and secure the plate in
place (with washer).

A load of 58.8N{6kg} is applied to the

rear of the cab. Therefore, be careful to
separate the pull-up lever (9) by
removing the lower left pin (7).
Fig. 8-317

Fig. 8-318

7. Remove the lower right pin 6. The connecting

plate 7 at the end of balancer cable 8 can be
removed by removing pin 6. Fully lower the
front windshield assembly

Fig. 8-319

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★ Avoid colliding with the monitor.

Fig. 8-320

9. 6. Remove the front windshield from the inside

of cab. Be careful not to make the front
windshield collide with the display and cab
interiors when it is moved out.
Perform the installation in reverse order of the
removal.

Fig. 8-321

Fig. 8-322

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Installation
● Perform the installation in reverse order of the
removal.

● Adjust the opening and closing of the front

window assembly as follows.
1. Open and close the front windshield
assembly, check if it interferes with the guide
rail, and check that the rollers do not get
caught.
2. If any problem is found, loosen the mounting
bolt of the roller adjusting bracket (13), adjust
the front windshield, and tighten the mounting
bolt again.
★ The support (13) shall be installed
properly. No angle is allowed.
Mounting bolts: 34.3N·m {3.5kgf·m} Fig. 8-323

3. Lift the front window assembly, and secure it

by the rear locks (on both sides of the cab).
★ Check that the rear locks in the cab are
fastened firmly.
4. Install the right-hand gusset (2).
★ After adjusting the “locked” position in
the following step 6, tighten the gusset
securely.
★ Install the right-hand gusset, ensuring
the clearance (a) between the guide rail
and the right-hand gusset (2) is within
0-2.0mm. Fig. 8-324
★ Install the right-hand gusset, ensuring
there is no level difference on the roller
surface (R).

Fig. 8-325

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5. Install the left-hand gusset (1).

★ After adjusting the “locked” position in
the following step 6, tighten the gusset
securely.
★ Install the left gusset, ensuring the
clearance (b) between the guide rail and
the left gusset (1) is within 0-2.0mm.
★ Install the left gusset, ensuring there is
no level difference on the roller surface
(R). (Refer to the figure above.)

Fig. 8-326

6. Adjust the “locked” position of the locks of

front windshield assembly as follows.
1) Tighten the left and right gussets (1 and
2) to the proper position, allowing the
front windshield glass (14) to rest against
the adjusting seal (19).

Fig. 8-327

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2) When opening and closing the front

windshield assembly, check that the left
and right locks (16 and 17) work
normally.
● If the left and right locks (16 and 17)
do not work normally.
3) Loosen the mounting bolt (18), move the
lock (16) forward, and tighten the bolt
again.
★ The adjustment operation of the
right lock is the same as the above.
4) After moving the lock, recheck the fit of
the front windshield glass (14) to the
adjusting seal (15) on the side of cab (the
Fig. 8-328
same as step 1).
● Repeat steps i) and ii) until the front
windshield fits the locks (16 and
17), and then tighten the mounting
bolts of the left and right gussets.
7. After performing the adjustment, pour water
on the front windshield glass, and check that
no water flows into the cab.

Fig. 8-329
8. Adjust the “locked” position of the locks of
front window assembly.
1) After adjusting the “locked” position of
the locks of front windshield assembly in
step 6 and step 7, lift and level the front
windshield assembly with the sunroof.
2) With the locks of front windshield
assembly on both rear sides of the cab at
“locked” position, check the following
items.
● Check that the left and right locks
(16 and 17) work normally (as
described above).
● The front windshield assembly must
contact the left and right rubber
stops (18), and push the stops back Fig. 8-330
by 1.5-3.0mm.
● The front windshield assembly must
8
push the limit switch back by
4-7mm.
★ The position of the limit switch (19)
shall not be adjusted. Therefore,
the “open” position of the front
windshield assembly is so
determined.

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★ The limit switch (19) is used to

prevent the front windshield wiper
from moving in case the front
windshield assembly is at “open”
position and the wiper switch is
wrongly turned on. If the front
windshield assembly is not at the
“closed” position (no windshield in
the front) and the wiper is activated,
the wiper will fall into the cab and
cause failure.
★ To check the function of the limit
switch (19), turn on the ignition
switch, and check that the wiper Fig. 8-331
does not move even it is activated
when the front windshield assembly
is at the “open” position.
3) Close the front windshield assembly (10).
4) Loosen the lock nuts (20) on the left and
right sides of the rubber stop (18), and
then pull back the two rubber stops (18),
ensuring they do not conflict with the
front windshield assembly which is at the
“open” position.
5) Loosen the lock nut (22), and adjust the
position of the striker bolt (21).
★ Striker bolt (21): M10; inner
Fig. 8-332
diameter of the plate (23): ø14.5mm
6) The front windshield assembly (10) shall
push back the limit switch by 4-7mm
(when at the “open” position).
7) The working condition of the lock (17).

Fig. 8-333

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8) Adjustment of left and right rubber stops

(18).
9) Allow the unlocked front windshield
assembly (10) to contact the left and
right rubber stops (18).
10) Close the front windshield assembly (10).

Fig. 8-334

11) Rotate the left and right rubber stops (18)

anticlockwise by one and a half turns.
★ Rotating the rubber stop (18)
anticlockwise by one turn
corresponds to squeezing the
rubber by approximately 1.5mm.
★ When the front windshield
assembly is at “open” position, it
shall push the left and right rubber
stops (18) by 1.5-3.0mm.
12) Tighten the lock nuts (20) on both sides
of the rubber stop (18).
Fig. 8-335

9. Adjust the stopper (24) of front window

assembly.
Adjust and lock the stopper (24), ensuring
that the surface (d) of stop (D) contacts the
surface (c) of stopper (24) when the front
windshield assembly (10) is lifted.

Fig. 8-336

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10. Check the function of front window assembly

After the operation of step 6 through step 9 is
completed, check that the locking forces of
left and right locks (16 and 17) are uniform.
★ Check the locking force at the “closed”
side (in front of the cab) and at the
“open” side (at the rear of the cab)
respectively.

Lower left pin:

27–34N·m{2.75–3.47kgf·m}
Fig. 8-337
Mounting bolt: Adhesive (LT-2)

Fig. 8-338

Fig. 8-339

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Removal and installation of display screen

Removal

First remove the cable from the negative

terminal of the battery.

1. Remove the 3 mounting bolts (4), and remove

the mounting plate and display components
from the support (3).
2. Loosen the set nut (1) and washer (2), and
remove the display (5) from the mounting
plate.

Fig. 8-340
Installation
● Perform the installation in reverse order of the
removal.

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Removal and installation of controller assembly

Removal

First remove the cable from the negative

terminal of the battery.
1. Remove the fuse box (1) and glove box (2).
2. Remove the rear trim (3).
3. Remove the HVAC cover plate (4).

Fig. 8-341

4. Remove the controller wire connectors A1(5)

and A2(6).
5. Remove the 4 mounting bolts and remove the
controller assembly (7).
Installation
● Perform the installation in reverse order of the
removal.

Fig. 8-342

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8-169
Removal and Refitting

Radio antenna
Black: Left channel output

Service Manual 12-2017

White: Left channel output
Black gray: Right channel output

Back panel
Gray: Right channel output

Power, ground and audio output

Black: Ground wire
Yellow: BATT power
Red: ACC ignition coil
SY215CAM3K Hydraulic Excavator

White: Right channel input

Audio input
Red: Left channel input
Main structure

Wiring
Fig. 8-343

Fig. 8-344
Structure
Radio

1)

2)
Removal and Refitting SY215CAM3K Hydraulic Excavator

Installation and removal

Removal
Armrest
1) Remove the cover of the armrest box. box cover

CAUTION
● Turn off the radio prior to the removal.

Radio

Fig. 8-345

2) Remove the radio connector CN-003F.

Connector CN-003F Cab harness

Fig. 8-346

3) Remove the four mounting bolts and washers,

and remove the radio and radio support from
the cover of the armrest box.
Armrest box
4) Remove the four set screws and washers, and
remove the radio from the support.
Installation
● Perform the installation in reverse order of the
removal. Washer Radio
Radio support

Screw

Fig. 8-347

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Connector model and wiring

Harness socket terminals

Radio wiring terminals Model: Deutsch DJ7072-3-21

Fig. 8-348
Battery
Structure

Fig. 8-349
1. Terminal 5. Tab 9. Plate pack
2. SOC hydrometer 6. Grid plate 10. Vapor–liquid separator
3. Cover 7. Paste 11. Central busbar 8
4. Polypropylene casing 8. “Envelope” partition

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Installation and removal

CAUTION
● Turn the ignition switch to OFF prior to the removal.
● Do not remove the SOC hydrometer. If it is loose, use a suitable tool to turn it clockwise.

1) Remove the battery ground wire.

Bolt Battery terminal Battery ground wire
● Open the waterproof cap, loosen the set bolt,
and remove the battery terminal.

CAUTION
● Battery gas can explode. Keep sparks
and flames away from the battery.
Battery

Fig. 8-350

2) Remove the battery cable and breaker.

Battery cable

Battery Breaker cable

Fig. 8-351

3) Remove the 4 mounting bolts and gaskets, Battery

remove the battery casing from the bottom

plate, and remove the battery.

Gasket Battery casing

Mounting bolts

Installation
● Perform the installation in reverse order of the Fig. 8-352
removal.

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Replacement
The machine is installed with two 12V batteries, with the negative terminal grounded. If one of them fails,
it is required to replace the battery with a new one of the same type. Different types of batteries may
have different charging rates. This difference may cause one of the batteries to lose its function due to
overload.

CAUTION
● The battery terminals should be painted with vaseline against corrosion.

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Ignition key switch

Structure

Fig. 8-353
1. Hosing 8. Cover 15. Spring cover 22. Contact SPR-A
2. Key 9. Cover pin 16. Reset spring 23. Contact B
3. Key ring 10. Cover spring 17. Ball 24. Terminal
4. Key knob 11. Disc 18. Ball spring 25. Bolt
5. Nut 12. Disc spring 19. Contact SPR-B 26. O-ring
6. Cylinder 13. Plug 20. Contact A 27. Harness assembly
7. End cap 14. Rotary body 21. Terminal block 28. Washer

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SY215CAM3K Hydraulic Excavator Removal and Refitting
Installation and removal

Removal
1) Remove the screw, and then remove the
cover of the armrest box.

Ignition key switch Armrest box cover Bolt

Fig. 8-354

2) Remove the two screws, and remove the Bolt Armrest box cover
mounting plate and ignition switch from the
cover of armrest box.

CAUTION
● Remove the key switch connector prior
to the removal.

Mounting plate Ignition key switch

Fig. 8-355

3) Remove the nut, and remove the ignition

switch from the mounting plate.

Ignition key switch Mounting plate Nut

8
Fig. 8-356

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Removal and Refitting SY215CAM3K Hydraulic Excavator
Key switch electrical schematic and wiring
Electrical schematic

Gear

On/OFF Battery Battery Accessories Glow plug Starter relay

relay (BR)

Fig. 8-357
Wiring

Harness plug terminals

Sheath model: Yazaki 7123-7464-30

Key switch wiring terminals

Sheath model: Yazaki 7222-7464-30

Fig. 8-358

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SY215CAM3K Hydraulic Excavator Removal and Refitting
Wiper
Main structure and principle
Constitution

Wiper blade

Rotating
mechanism

Wiper arm

Wiper motor

Connector

Support

Fig. 8-359

Service Manual 12-2017 8-177

Removal and Refitting SY215CAM3K Hydraulic Excavator
Electrical schematic

Green wire (low

speed)

Yellow wire (reset)

Blue wire (high

speed)

Red wire (power +)

Black wire (power -)

Fig. 8-360

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SY215CAM3K Hydraulic Excavator Removal and Refitting

Installation and removal

Removal
Interior trim
1) Remove the interior trim clip, and remove the
interior trim.

Interior trim

Fig. 8-361

2) Remove the actuating mechanism and motor

● Remove the bolts, and remove the wiper Bolt
motor and actuating mechanism from the cab.

Actuating
mechanism

Wiper motor

Bolt

Fig. 8-362

3) Remove the wiper arm and blade

● Loosen the set nut, and remove the wiper arm
and blade from the cab.
Arm holder

Protective
cover

Set nut

8
Cab
Installation
● Perform the installation in reverse order of the
Fig. 8-363
removal.

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Removal and Refitting SY215CAM3K Hydraulic Excavator
Adjustment of swing angle of wiper arms

● As soon as the blade reaches the mechanical

limit, the arm shall stop moving.
● If the arm continues to move when the blade
Mechanical
has reached the limit, or if the arm has limit
stopped moving while the blade does not
reach the limit, please adjust the moving angle
of the wiper to avoid being burnt out.
Blade
● The adjustment method is to loosen the lock
nut and adjust the moving angle of the wiper
arm according to specific conditions. The
objective of the adjustment is that the wiper
motor just stops as soon as the wiper blade Arm
reaches the mechanical limit.

Lock nut

Fig. 8-364

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SY215CAM3K Hydraulic Excavator Removal and Refitting

Relay
Engine relay

1) Inspection of starter relay

● Check the connectivity and function. If
any fault is found, replace the relay.

Fig. 8-365

2) Inspection of main power relay

● Check the connectivity and function. If
any fault is found, replace the relay.

Battery positive terminal

Fig. 8-366

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Removal and Refitting SY215CAM3K Hydraulic Excavator

Sensor
1) Inspection of coolant temperature sensor
● Place the sensor in a container filled with oil.
● Raise the oil temperature to the specified
value while stirring the oil. Body
● Measure the resistance between the terminal
1 and body.

50±0.2℃ 80±10Ω
60℃ 56.3Ω (reference)

Standard 80℃ 29.5Ω (reference)

value 100℃ 16.5Ω (reference)
Fig. 8-367
106±0.3℃ 14.3±1.0Ω
120℃ 10Ω (reference)

● If the measured value exceeds the standard

value, replace the sensor.

2) Inspection of engine speed sensor

● Measure the resistance between the terminal
1 and terminal 2.

Standard value (at 25

2.3±0.2kΩ
℃)

● If the measured value exceeds the standard

value, replace the sensor.

CAUTION
● If the tightening torque of engine speed
sensor is insufficient, the sensor may
Fig. 8-368
have no output signal. Tighten the
engine speed sensor to the specified
torque.

3) Inspection of pressure sensor

Pressure joint Main body Connector
● Input voltage: 4.75～5.25VDC
● Output voltage: 0.5～4.5V
● Pressure range: 0～50BAR

Terminal C Terminal B Terminal A

Fig. 8-369

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SY215CAM3K Hydraulic Excavator Removal and Refitting

4) Inspection of fuel level sensor

● Move the float upward and downward, and
Float
measure the rotating angle of the lever in
effective radius. The rotating angle of the line
between the float and the rotating point shall
be 105°.
Lever
● Move the float upward and downward, and
measure the vertical distance between the
highest point and lowest point where the float
can arrive, which shall be 500 mm.
● Move the float up to the top, and use a Terminal R
Shell
multimeter to measure the resistance between
the sensor terminal R and the ground. The
resistance Ru shall not be more than 9.6Ω. Connector

● Move the float down to the bottom, and use a

multimeter to measure the resistance between
the sensor terminal R and the ground. The
resistance Rd shall not be less than 86Ω.
Fig. 8-370

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Removal and Refitting SY215CAM3K Hydraulic Excavator

Terminal insertion and removal

Terminal insertion
1) Grasp the terminated wire at about 25 mm
behind the crimped terminal.

Fig. 8-371

2) Grasp the connector, with the back seal ring

facing you.

Fig. 8-372

3) Align the crimped terminal with one cavity in

the seal ring, and insert the terminal into the
cavity, completely and vertically. Verify proper
terminal seating by gently pull the wire back.

Fig. 8-373

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SY215CAM3K Hydraulic Excavator Removal and Refitting
Terminal removal

1) Grasp the connector, with its back facing you.

Select a removal tool which is suitable for the
wire, and use the removal tool to hold the wire
inside.

Fig. 8-374

2) Push the removal tool into the connector,

allowing the tool to disengage the terminal
lock and reach the terminal flange.

Fig. 8-375

3) Pull out the removal tool, removing the

terminal with the wire.

Fig. 8-376

Service Manual 12-2017 8-185

SY215CAM3K Hydraulic Excavator Hydraulic and Electrical Diagrams

Hydraulic lines diagram ........................................................................................................................... 9-3

Electrical diagram of HVAC ..................................................................................................................... 9-4
Electrical diagram of control switch display ............................................................................................ 9-5
Electrical diagram of cab ......................................................................................................................... 9-6
Electrical diagram of body ....................................................................................................................... 9-7

Service Manual 12-2017 9-1

Hydraulic and Electrical Diagrams SY215CAM3K Hydraulic Excavator

9-2 Service Manual 12-2017

SY215CAM3K Hydraulic Excavator Hydraulic and Electrical Diagrams
Hydraulic lines diagram

To As To Bs

To main valve XBtr

To main valve XAtr

To main valve XBtl

Adapter

To main valve PbL

Boom lowering
To main valve XBb1

To main valve XAtl

Bucket dumping
To main valve XBk

Safety lock To main valve XAb1

Boom lifting
To main valve XAb2

To main valve PCK

Pressurization

Bucket digging
To main valve XAk

Right traveling

Left travel

Swing priority

To main valve XAa1

Arm dumping
Traveling speed control
To main valve XAa2

To main valve XBs

Right swing

To main valve XBa1

Arm digging
To main valve XBa2

To main valve PaL

To main valve XAs

Left swing

99
ZX225-171205
Service Manual 12-2017 9-3
SY215CAM3K Hydraulic Excavator Hydraulic and Electrical Diagrams
Electrical diagram of HVAC
Control panel
ACM

10
6
7

11

17
18
19

21
22
23

26
27
28
29
30
31
32

35
36
1
2
3
4
5

8
9

12
13
14
15
16

20

24
25

33
34
CN-M30 CN-M29

11

10
10

12
13
14
15
16

6
7
1
2
3
4
5
6
7

11

17
18
19
1
2
3
4
5

8
9
8
9

12
13
14
15
16
0.5BrW

0.5BrY
0.5LgR

0.5WY

0.5GO
0.5WO

0.5OW

0.5GW

0.5RY

0.5VR
0.5RW

0.5WR
0.5LO
0.5BG
0.5BW

0.5VW

0.5BR
0.5BL

0.5BY

0.5PB
0.5YB
0.5PG

0.5Sb
0.5R

0.5B
8

0.5LgR

0.5BrW

0.5BrY
0.5BW
0.5WO

0.5OW
0.5GW

0.5WR
0.5VW

0.5WY
0.5RY

0.5GO
0.5BY

0.5RW

0.5LO
0.5BG

0.5YB
0.5PG

0.5VR

0.5BR
0.5PB
0.5BL

0.5Sb
0.5R

0.5B
SWP SWP SWP

1
2
3
4
5
6
7
8
9
10
11
12

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

6
7
CN-M33

1
2
3
4
5

8
CN-M28 CN-M27

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

6
7
1
2
3
4
5

8
1
2
3
4
5
6
7
8
9
10
11
12
7

0.5LgR

0.5BrW

0.5RW
0.5BW
0.5WO

0.5OW
0.5GW

0.5WR
0.5BrY

0.5WY
0.5BG

0.5GO
0.5VW
0.5RY
0.5BY

0.5LO

0.5YB
0.5PG

0.5BR
0.5VR
0.5PB
0.5BL

0.5Sb
0.5R

0.5B
Diffuser switching servo motor

MV 2
Inside temperature sensor

FACE(DEF)
THI

FOOT

GND

Vz
Pt
6

7
6
5
4
3
2
1
CN-M34

1
2

7
6
5
4
3
2
1
1
2
0.5GW

0.5OW

0.5BW
0.5GO
0.5BR

0.5BR
0.5Sb
050
CN-P15
2 2
1 1

S S 0.5WY
7 7
FACE Diffuser switching
0.5WR
0.5BrW
6 6 FOOT
Pt
servo motor
5 5 5
4 4
0.5BW Vz
3 3
2 2
0.5BR GND
1 1 MV I

CN-A30
2 2 0.5YB FRE
7 7
1 1 0.5VW REC
6 6
0.5WO
5 5
Pt Recirculation/ fresh
T HA M
4 0.5BW
4 4
Vz air switching servo
3 3
0.5BR
2 2
GND
motor
1 1

ECC
EC

CN-E06 S 0.5PB Mcool

1

7 7
CN-M26 0.5VR Mhot
6 6
1

12 12 0.5BG Pt
5 5
11 11 4 4
A/M servo motor
TO CN-M26-A TO CN-E06-1 0.85W 0.5BW Vz
10 10 3 3
3 9 9 2B 2 2
0.5BR GND
8 8 1 1 MA M
TO CN-M26-7 TO CN-P15-1 0.5BW
7 7
TO CN-M26-7 TO CN-A30-2 0.5RW
6 6
2Br
5 5 1.25R
20A 4 4
TO CN-M26-2 TO CN-P15-2 3 3 0.5RY 5A
2 2
TO CN-M26-1 TO CN-A30-1 0.5BR
1 1

24V 0.5BR
1 1
0.5PG
2 2 Low temperature sensor
THF
1.25RL 72C 40C 1.25G

1.25G
2
1.25RL

1.25RL
2G
2RL

0.5BL
2G

2B
0.5BrY
0.85W

0.5LO
0.5R
0.5R

2RL

0.5lgR
2RL
2Br

2Br

0.5BR
0.5BY
2G

0.5B
4

3
4

3
3
4
2
1

3
4
2
1

2
1

2
1

2
1
3
4
2
1

2
1
3
4
2
1

PROTECTION
FOR TEMP.

2
1

2
1
DRIVING TRANSACTION OF
CIRCUIT INPUT SIGNEL

RL RL VOLTAGE
CORRECTION

R LC C R LB M MB BLC SPH L THW

1
Compressor clutch relay Blower relay Blower motor High & low pressure switch Water temperature sensor

9
A B C D E F G H I J K L M N

Service Manual 12-2017 9-4

SY215CAM3K Hydraulic Excavator Hydraulic and Electrical Diagrams
Electrical diagram of control switch display

Starting switch
TERMINAL B BR ACC R1 R2 C
1 2 3
To control knob switch
HEAT
OFF 50 506 00
8
ON
336 1
START 337 2
22 13 00 3
11
506
4
CN-204M
50 5

60
6 To cab
7
11
7
8
harness
13
14
9 CN-204F
10
22
11
12

To the mode knob

6

1 2 3

00 506 50
60 14 13 13 336 337
5

F-311 F-310 F-312 F-314 F-313

F-315
2

4
0# 1
1
B 22 2
2 CN-209F
CAN+ 29 3
To body
3
CAN- B 4
4

harness
5
5
6
6
7
60
61
7 CN-209F
3
29 8
8
9 22
CAN+
10 0# A CN-7-112F
11
12 0#
CAN-
B To body
harness
2
CN-4-210M
CAN-

CAN+

CAN-
CAN+

29

60

61
0#
1
2
3
B

4
A

2
1

CN-206F CN-7-706
CN-7-709
Operation panel Sunlight sensor
Terminal resistor
A B C D E F G H I J K L M N

Service Manual 12-2017 9-5

SY215CAM3K Hydraulic Excavator Hydraulic and Electrical Diagrams
Electrical diagram of cab

To control switch harness CN-204M

To body harness Connector DT04-12P
Connector DT06-12S (black jacket)
Equipped with DEUTSCH bracket 1027-003-1200
Equipped with DEUTSCH bracket 1027-003-1200
Equipped with DEUTSCH bracket 1027-003-1200

To radio panel To HVAC

Horn button
Pilot switch Seven-wire socket jacket Yazaki 7123-1720 58- S 12PF
1
DJ7072-3-21

To cab left side harness CN-260M

To cigarette lighter
A B C D E F G H I J K L M N
9

Service Manual 12-2017 9-6

SY215CAM3K Hydraulic Excavator Hydraulic and Electrical Diagrams
Electrical diagram of body
RV3：Bucket digging RV4:Boom lifting pressure RV5：Right traveling To hydraulic oil
To diagnostic interface RV 7：Arm digging pressure sensor RV1：Boom lowering pressure RV2：Bucket unloading RV9：Swing pressure sensor YC:Compressor clutch To starter motor
RV8：Arm dumping pressure sensor pressure sensor sensor pressure sensor Front pump pressure sensor RV2:Rear main pressure sensor temperature sensor RV9:Fuel tank level To starter B terminal Alternator L/R terminal
sensor pressure sensor Connector 6189-6907 Oil pressure To body grounding Yazaki 7323-6214-40 Alternator E terminal
Connector 6189-6907 Connector 6189-6907 RV6：Left traveling pressure sensor Connector 6189-6907 Connector 6189-6907 Connector 6189-6907 Connector 6189-6907 Connector 6189-6907 Fuel filter element level alarm Connector X01FGY-M/C Socket
Connector 6189-6907 Connector 6189-6907
Connector 6189-6907 Furukawa Electric FW-C-2F

Kawasaki controller

To EDU
Yazaki 7323-7564-40

Series
Series Series

Yazaki 7323-7925-40

Series

To display screen harness CN-209F

To display CN - 210M Yazaki 7323-7563-40

To wiper harness CN-1-110M

Series

To CN-110F

Diode 6A10 282104 - 1

120Ω/1/4/W
Yazaki 7322-7925-40

Series

Diode 6A10 282104 - 1

120Ω/1/4/W

Kawasaki controller KC - MB - 2 - A2

Yazaki 7383-5059-40

Yazaki 7383-7665-50
To diagnostic interface

VA5:Secondary To boom work light harness

VA1:High speed traveling VA2:Swing priority VA3:Bucket VA6:Pilot pressure Y6:Arm digging To cab harness

9
VA4:Boom priority -2- Y6:Rear pump Y5:Front pump Y5:Arm dumping To cab harness CN-117M To left tail lamp To right tail lamp
solenoid valve converging pressurization solenoid valve To washer motor
proportional valve proportional valve
solenoid valve proportional solenoid proportional solenoid solenoid valve solenoid valve Connector DT06-12S (black jacket) Connector DT06-12S Connector DT06-4S Connector DT06-4S
Connector 174 352-2 Connector 174 352-2 proportional valve Connector 174 352-2 Connector 174 352-2 valve Connector 174 352-2 Connector 174 352-2
Connector 174 352-2 valve Horn Horn To KB To KB
Connector 174 352-2 Connector 174 352-2 Connector 174 352-2 H1:Turntable lamp

VA6:Pilot pressure solenoid valve

Socket

Service Manual 12-2017 9-7

ZX225-1709251